Apr 27, 2024     Week 45 - (15 hours)       Category: Controls

This week began with reinstalling the yoke chain and tensioning it properly. The newly painted instrument panel was then installed, making further work on the yoke more difficult. Still we managed to get cotter pins installed on the turnbuckle clevis bolts. However, they still need to be safety wired. Further work had to be put on hold as the fuselage was loaded onto a trailer for transport to Laurel Avionics in Johnstown Pennsylvania. Arrangements have been made with them to install our transponder, radio, and two AV30c instruments along with some other electrical work. The same day our newly overhauled O-200 engine arrived from the shop. Things are moving along.

  Apr 13, 2024     Week 44 - (15 hours)       Category: Controls

This week we installed more trim pulleys and worked on the control yoke chain and related parts. Working aft, we installed the two pairs of trim pulleys that run just under the cabin floor. The parts manual calls for another pair at the aft end of the baggage compartment. The maintenance manual does not call for this set and there is no bracket for it. That, plus the fact that we only have 12 pulleys rather than the 14 shown in the parts manual, has led us to conclude the parts manual is wrong or might be referencing an earlier model. We looked at hooking up the new trim chain to the new cables, but it seems we may need a special tool to do that, so we set it aside for now. We then got into the complex control yoke chain and sprocket system. It needed cleaning and upon inspection by one of our A&Ps a couple of issues were found. The safety wires on both turnbuckles were the wrong size and two of the clevis bolts with castle nuts lacked cotter pins. So we ended up taking a lot of it apart and cleaning everything. Complete reassembly will happen next time.

  Apr 08, 2024     Week 43 - (20 hours)       Category: Controls

The trim system was the main focus this week. Four trim pulleys are mounted against the firewall and so need to go in before installing the rudder pedals. In order to install the pulleys we had to also install the new forward trim cables. We first employed one of our younger members to crawl into the rear fuselage. While he was in there we had him vacuum out some debris in the tail cone. His main mission, however, was to retrieve the forward trim cables that were under the floorboards. Once that was done we attached the end of each old cable to the forward end of each new cable and then threaded them through. Next, one of our members crawled under the panel to install the sets of pulleys with their respective cables. Not an easy task. The next job will be to complete the installation by installing the sets of pulleys that bring the new forward cables under the floorboards back to where they will eventually be connected to the two rear trim cables.

  Apr 02, 2024     Week 42 - (20 hours)       Category: Controls

Figuring out puzzles continued this week. More work was done cleaning and laying out the complex rudder pedal assembly. Robert continued sorting out wires and connectors, some of which lack a clear indication of what they do. Work also continued on things on or near the interior firewall that need to go in before the rudder pedals can be installed. The parking brake was reconnected. Because four trim pulleys need to be mounted against the firewall, we started figuring out the trim system and its cables. We will be installing new cables.

  Mar 23, 2024     Week 41 - (30 hours)       Category: Landing Gear

The Rans is nearly finished, so attention returned to the Cessna this week. A recently discovered AD on the ignition switch resulted in its removal. A new one is on order. The large upper snap rings were installed on the main gear legs. The new Cleveland brakes and wheels were installed and fluid was temporarily added to the nose gear strut to keep it from bottoming out. Then the plane was lowered onto its gear with a cushioned sawhorse supporting the tail. That done, we could once again get into the interior to continue work there. We recruited one of our younger members to crawl under the panel to install the brake master cylinders and hoses. The rudder pedals will soon go in, so a few members began the process of figuring out that puzzle.

  Mar 09, 2024     Week 40 - (30 hours)       Category: Tail Feathers

While the Rans continued to demand attention, some signifiant progress has nonetheless been made on the Cessna in the last couple of weeks. The wings, tail feathers, and some other parts were sent to the paint shop in Pennsylvania. We also started installing insulation between the panel and the firewall. We are using 3M 4014 Sound Dampening panels. They are self adhesive and go under the glare shield and along the sides of the boot cowl area. More will go inside the wing root area and inside the doors. Another on-going project is the electrical system. New solenoids were installed on the firewall and battery box. After much trial and error, the new STC gascolator was also finally secured in place. Finally, this weekend the process of getting the Cessna back on its gear was begun. With some effort, the main gear legs are mostly installed. The large snap rings on the upper legs are awaiting a different tool to install. Meanwhile, the nose gear was bolted in place and work was begun on installing the new Cleveland brakes. She should be finally sitting on her own gear soon.

  Feb 17, 2024     Week 39 - (15 hours)       Category: Tail Feathers

Work continues on the Rans S-12XL, but we still made some progress on the Cessna. Our A&P/IA returned with the right rivets and completed installation of the bracket on the horizontal stabilizer. The brake master cylinders were also cleaned and overhauled with new O-rings and seals. They're ready to reinstall. The process of installing new insulation has also begun but I didn't get any photos of that. On Monday 2/19 the plan is to send the wings and some other parts to Pennsylvania for paint.

  Feb 10, 2024     Week 38 - (20 hours)       Category: Wings

Once again the Rans S-12XL took some of our attention, but that project is nearing completion and will soon be ready for our A&P/IA to complete the condition inspection. Meanwhile, some progress was made on the horizontal stabilizer bracket. Our A&P returned with a stronger rivet gun and did a few rivets, but found that some of the holes required bigger rivets than we had on hand. He'll be back. Tires and tubes were also mounted on the new Cleveland wheels. And the overhauled nose gear was mostly assembled. Robert also continues to look at various systems to see what we need in terms of electrical stuff.

  Feb 03, 2024     Week 37 - (20 hours)       Category: Wings

A very busy week. At one point on Saturday we had three projects going at once in the hangar. The Rans S-12XL continues to demand some of our attention, but we still managed to accomplish some important things on the Cessna. Our A&P/IA came to look at our stabilizer bracket issue. He determined that the problem was our rivet gun wasn't powerful enough. He will return with a different rivet gun to finish the job at some point. In the meantime, we continued to work toward getting the plane on its gear and getting wings ready for paint. A part on the nose gear was lightly machined to make it round to fit and the gear was mostly assembled with all new O-rings and hardware. We decided to replace the old gascolator assembly with a new and better “Steves Gascolator” STC. We ran into a problem in that the bracket that adapts the new gascolator to the Cessna's firewall fitting doesn't fit. We've been in communication with the manufacturer, but they've been little help. Stay tuned on that one. In order to send the wings up to get painted, we decided it would be best to fit and drill the new Horner wingtips in advance so that we don't scratch new paint later. We also got new tips for all of the tail surfaces so some of them were fitted as well.

  Jan 20, 2024     Week 36 - (15 hours)       Category: Tail Feathers

Not too much has been done on the Cessna the last couple of weeks. That's because we needed to bring in the donated Rans S-12XL to begin changing out hoses in preparation for its condition inspection. But a few things got done. Parts were gathered and inventoried for the nose gear rebuild and installation. On the firewall, the auxiliary power plug and fuse set were installed. The task of re-riveting the attach bracket on the rear spar of the horizontal stabilizer was begun. This is part of complying with AD80-11-04, Service bulletin SE79-49. Bucking the rivets proved difficult and hard on the arms. More to be done on that.

  Jan 06, 2024     Week 35 - (20 hours)       Category: Tail Feathers

The first order of business this week was to complete installation of Service Kit SK152-24 to comply with AD 2009-10-09 R2. This involved installing the bumpers on the rudder horn. The parts were prepped last week. The new bumpers are riveted on, but the instructions also require sealing the installation with Pro-seal to help prevent corrosion. Pro-seal is thoroughly nasty stuff and tends to get on everything, but our guys did a nice job with it. It was used to not only seal the bumper to the horn but was also applied to each individual rivet. The rivets were then squeezed by hand and each rivet checked with a gauge. The next project was installation of the new (to us) windshield. The first step was application of adhesive felt around the edges of the glass. The windshield was then fitted in place. The retaining strip that runs along the bottom edge was originally riveted in. We decided, with our A&P/IA's approval, to use stainless steel screws and fiber lock nuts instead. We can do this since we now have easy access to the interior side for installing nuts and washers. A small amount of clear silicone sealant was applied to each hole and a small white nylon washer went under each screw head. In other news, the AV-30s and tail surface tips have arrived. And the propeller passed inspection and was able to be overhauled.

  Dec 30, 2023     Week 34 - (20 hours)       Category: Tail Feathers

The main focus this week was work to comply with the rudder horn AD (AD 2009-10-09 R2). This AD requires the installation of a kit to replace the rudder stop bolts and bumpers with larger versions so that the rudder cannot be accidentally moved past its normal limits. Without the installation of the kit the airplane would have to be placarded against doing spins. The old stop bolts and bumpers were removed. New stop bolts and a new backing plate were installed, all according to Cessna Service Letter SEL-27-02 and Service Kit SK152-24. The rudder horn and new larger bumper were prepped for installation. The nuts for the engine mount bolts installed last week were also torqued according to maintenance manual specifications and torque seal applied. While we were looking at tail surfaces, we inspected all of the tips and found cracks in all of them. The decision was made to replace them all.

  Dec 23, 2023     Week 33 - (30 hours)       Category: Fuselage

In spite of the holidays we had a good turn out this week and got a lot done. One major project was the installation of the new kevlar steering rod boots. The new frames and boots had to be match drilled to match the holes in the airframe. Sealant was then applied to the assembly and stainless screws and fiber lock nuts were used to secure everything together. Our new fiberglass wingtips arrived and Gerry supervised a test fitting and cut the holes for the tip light for the left wing. He also inspected the tinnerman nut plates on the wingtip and found several that were no good. He suggested replacing them with rivnuts and using machine screws instead of sheet metal screws to secure the tips. Since we are doing away with the vacuum system and installing some new instruments, it was decided to further disassemble the instrument panel. The yokes were removed, the panel taken out, and the individual instruments removed and cleaned. Most of them will be taken to the instrument shop in Lock Haven for inspection and, if needed, overhaul. The final task of the week was the installation of the engine mount. This proved to be not as simple as it looked. But with a little persuasion from a plastic mallet and various contortions, it finally fell into place. The only thing left is to properly torque the nuts. (All hardware used was new hardware per the parts manual.) In the middle of all this we were interrupted on Thursday by Erick Webb who came by with AOPA's Cessna 170B Sweepstakes airplane. We got a nice up-close look at this beautiful restoration that will soon be given away to some lucky pilot.

  Dec 18, 2023     Week 32 - (20 hours)       Category: Firewall

The replacement insulating firewall blanket from Airtex arrived, so much of this session was devoted to installing it. Many things attach to and through the blanket, so this was not an easy job. The old blanket was used as a rough template. Holes were cut and the blanket was trimmed to fit around various things on the firewall. Installing it required a lot of time crawling up under the panels and matching screw holes through the blanket and the firewall. In the end it fit perfectly and looks great – a great improvement over the old one. Meanwhile, a new limit switch was installed on the flap motor. We also had our business meeting which set a record for length. There was much to discuss and decisions to be made. We raised our projected budget and decided to do away with the vacuum system. A pair of UAvionics AV-30s will replace the AI and DG which were removed. A trip was also made this week to East Coast Propellers in Lititz PA. We took the Cessna's prop there in hopes of having it overhauled. We got a tour of the facility which was very impressive. During the tour the shop manager described the conditions that can cause a prop to fail inspection and be condemned. A lot of what he said sounded like our airplane, so we're hoping we don't have to buy a new prop. We also brought a wing into the hangar, planning to install bell cranks etc. But after some discussion decided to wait and install them after the wings are painted.

  Dec 09, 2023     Week 31 - (15 hours)       Category: Controls

The main focus this week was on preparing parts that go inside the wings. This includes all of the bell cranks and the flap motor. We obtained all new hardware, lubed the bearings, and assembled everything ready to be installed. Meanwhile, the new (to us) windshield and back window were test fitted. Mark has been working on polishing out scratches in the windshield using a kit for that purpose. He decided, after looking at it in the light of the workshop, that it needs more polishing so he took it back home. We also brought in our A&P/IA to answer some questions. We were concerned about the condition of wiring. He said it looked okay to him and was not worth replacing. He strongly recommended getting rid of the vacuum system and going with electric instruments such as the Avionics AV-30. The problem there is the cost. We will discuss this more at our next business meeting.

  Dec 02, 2023     Week 30 - (20 hours)       Category: Fuselage

Work resumed this week on the Cessna. We decided that the insulating blanket on the interior of the firewall was in too bad a shape to save. Removing it involved removing the many things that secure it to the firewall. It took awhile, but in the end we managed to remove it mostly intact so we can use it as a template for the new one which is on order. While we were digging around up under the panel we also reinstalled the handles and removed the old encoder. Meanwhile, prep work was being done for the wings. The plan is to bring in each wing, do some more cleaning, and then install all of the bell cranks and the flap motor. This is in preparation for sending the wings to the paint shop. The bell cranks were located and primed. Everything to install them was identified and inventoried. Some new hardware will be ordered. As a side project, Tim has been working on the cowling which is in rough shape. He just finished essentially remaking a major section of the nose bowl.

  Nov 24, 2023     Week 29 - (3 hours)       Category: Fuselage

On Friday, exactly one year since we first acquired the Cessna, the fuselage returned from the paint shop looking like a brand new airplane. We carefully unloaded it from the trailer and moved it into the chapter hangar. Lots of work ahead yet, but seeing how good she looks with the new paint job gives us incentive to keep going.

  Jul 17, 2023     Week 28 - (6 hours)       Category: Fuselage

Another project, an RV-12, demanded more attention than the Cessna this week, but one major step was accomplished. In earlier sessions we worked to get the fuselage ready for stripping at the paint shop. With those tasks completed, this week the Cessna headed out the door and onto a trailer for its trip to the paint shop in Pennsylvania. We're told that as soon as the shop gets another plane in for stripping, they will do both planes at once. The shop is busy, so we expect that to be sooner rather than later.

  Jul 08, 2023     Week 27 - (8 hours)       Category: Tail Feathers

Work on the Cessna has suffered a lot of interruptions lately, including the chapter hosting the Ford Tri-Motor. But a few things are moving along. We have a strange hole through the horizontal stabilizer that some time in the past was improperly repaired with something like Bondo. In consultation with one of our A&P/IAs we discussed the possibility of doing proper patches or maybe having that part re-skinned. In order to get a cost estimate for re-skinning, we thoroughly cleaned the stabilizer and took photos to send to Royal Aircraft in Hagerstown. Depending on the cost, we'll decide what to do. Meanwhile, the fuselage has been prepped for transport to the paint shop in Pennsylvania for stripping. That may happen as soon as this coming week.

  Jun 10, 2023     Week 26 - (25 hours)       Category: Fuselage

A lot of different tasks were completed this week on the Cessna. The main project was removal of the steering rod boots and frames. It turns out the frames were riveted in with hard cherry max pulled rivets. They proved to be very difficult to drill out. It took a long time and lots of effort for Bob to finally get them free. Meanwhile, the frames that hold in the front and rear windows were cleaned and more pulleys were located and removed from under the floor of the fuselage. One set of small pulleys for the trim system were discovered to be far back in the tail cone. Luckily we always try to involve youth in our chapter projects. Our eleven year old member got in there and made short work of removing those pulleys. Since the doors will also need to go to the paint shop as part of the fuselage, we brought in the doors and inspected them. It was found that the window opening mechanism on both doors was worn to the point of not working. So Tim set to work fabricating a plate that will renew the track for the arm that holds the window open. The doors from the wrecked Cessna were also brought in and disassembled in order to scavenge parts that might be useful to restoring our doors.

  Jun 03, 2023     Week 25 - (15 hours)       Category: Fuselage

This week a lot of our time was taken with another club aircraft. But when we finally got back to the Cessna good progress was made. Remaining rivet pieces were drilled out of the rear window channel and that was cleaned up somewhat. Meanwhile, the front windscreen was taken out which, like the rear window, required removal of a couple of stubborn screws and drilling out lots of rivets. The fuselage is now closer to being ready for painting. The last major task will be removal of the steering rod boots and their frames.

  May 28, 2023     Week 24 - (12 hours)       Category: Fuselage

At our last business meeting it was decided to go ahead and have the Cessna painted even though it will stretch (break?) our budget somewhat. Since it is all apart, it is clearly the best time to do it if we're ever going to. Toward that end a number of things need to be done to prepare the fuselage before sending it to the paint shop. More antennas were removed. All the rivets holding the rear window were drilled out and screws removed, one of which was firmly rusted in place and had to be drilled out. Once all that was done the rear window came out revealing years of accumulated dust and dirt under the strips that hold the window. The rear window is going to be replaced. Yet to be removed are the front windshield and steering rod boots.

  May 13, 2023     Week 23 - (20 hours)       Category: Fuselage

A number of things saw progress on the Cessna this week. The remaining push-pull cables were installed. Some of the tiny screws that attach the cowl chafe seal were also located and installed. We still need to get metal lock nuts to permanently install them. The lower cowling was brought in for cleaning and inspection. There is quite a bit of fiberglass work that needs to be done at the front of the cowling where it forms a ring around the landing light. This is a weak area and has evidently been repaired before. In order to repair the fiberglass, a metal reinforcing plate and the metal mount for the light had to be drilled out. They proved to be difficult to get out, but were successfully removed in the end. Meanwhile, years of accumulated dirt and oily grime were cleaned from the cowl's interior. The old Loran antenna was removed. We need to figure out how to best cover the hole. Apparently, there is a plate made for this purpose, but it seems to only be sold in Europe. One of our members remembered that he had a complete set of wingtip position and strobe lights that he had taken out of his aircraft when he installed ADSB. He brought the set in and they appear to be perfect for the Cessna. That is one less expense for the project. The ongoing struggle to locate hardware also continued. The parts manual is very clear and detailed, but many part numbers for hardware are outdated and have been superseded by new numbers that are not always easy to track down.

  Apr 30, 2023     Week 22 - (15 hours)       Category: Fuselage

This week was basically a continuation of last week's projects. The forward cabin floor just aft of the firewall was black with a sticky thick layer of dirt and grime. It is not surprising given that this area is almost totally inaccessible when the rudder pedal assembly is in there. So probably we're dealing with an accumulation of dirt, hydraulic fluid, and whatnot since 1977. It took awhile, but with the help of our newly graduated A&P student we got it pretty well cleaned up. In the photos you can see a before and after view of the co-pilot's side floor. Meanwhile, work was supposed to continue on riveting the cowl chafe seal (deck guard) around the edge of the firewall. Unfortunately, the problem that came up earlier reoccured. The soft material of the seal compresses as the rivet is squeezed causing the rivet to deform or otherwise fail to set properly. When this seal was located in a salvage yard, it was attached to the wreck with screws instead of rivets. So now we are in the process of experimenting with attaching using tiny screws instead of rivets. Stay tuned.

  Apr 22, 2023     Week 21 - (15 hours)       Category: Fuselage

Not a lot was done on the Cessna this week. The main gear wheels were cleaned and inspected. They both had tiny cracks where the bolts go through, so they were declared unusable. Wheels from the wreck were also inspected and found to have too much corrosion. So it looks like we're going to need new wheels and brakes. There has been much discussion of having the Cessna painted. If we go that route, that will change our plans regarding the order in which we do things. Painting is a lot cheaper with the airplane disassembled. The process of riveting in the cowl chafe seal around the firewall was begun. More cleaning of the floor just behind the firewall was also done. More yet to do. We had to stop work to begin setting up for the chapter picnic.

  Apr 16, 2023     Week 20 - (15 hours)       Category: Fuselage

Crawling down into the rudder area behind the firewall yielded two sets of pulleys for the trim system. They will need to be cleaned and inspected. Like everything in that area, they are very dirty. The new cable for the cabin air was permanently attached to the little door on the side of the fuselage. It actually works now. Meanwhile, cleaning continued. The parts washer was put to use cleaning main gear wheels. The new windshield that was purchased from a salvage yard was also carefully cleaned and inspected. It came out very nice and will replace our existing windshield.

  Apr 08, 2023     Week 19 - (20 hours)       Category: Fuselage

This week the rudder bar assembly finally came out. It was necessary to remove a central cover plate and attached springs before the bars could be removed. Then came the right master brake cylinder. The cylinder is held in by a single pin and cotter pin. The space for removing the cotter pin is very small and difficult to get to. It took awhile, but it finally came out. Both master cylinders will be inspected and overhauled. The landing gear parts and engine mount returned from the paint shop. Our nose wheel was cleaned and inspected by our A&P/IA. Unfortunately, it failed. We will need to get a replacement. Riveting the cowl chafe seal (AKA deck guard) turned out to be more of a project than expected. New aluminum backing strips were made to make a more flush and sturdy grip for the rivets. The battery box was mostly riveted back to the firewall. We need a few cherry max rivets to finish the job. The battery box cover was also refurbished. A new cable for the cabin air control was installed. Connecting it to the little door on the side of the fuselage proved to be something of a puzzle. Our experienced A&P/IA assisted in solving that. All of the pass-through openings in the firewall were identified and the new mixture control cable was installed.

  Apr 01, 2023     Week 18 - (25 hours)       Category: Fuselage

It was decided this week that the rudder assembly needed to come out. The second master brake cylinder is hard to get to otherwise and the area around the pedals is in great need of cleaning. Removing the pedals themselves proved not too difficult. But the connecting bars are another matter. They are held in by four sets of plastic bearings, each of which is held together with two bolts. The nuts are nearly impossible to get to with a wrench, so a little tool was fabricated out of sheet aluminum to hold the nut while the bolt was turned. Still, it wasn't easy. Although loose, the bars are still connected to other things that will need to be dealt with before they can be removed and cleaned. Meanwhile, lots of cleaning of parts continued. We were joined by some new members who eagerly attacked the grease and dirt. Some new parts also arrived this week. A fuse assembly that goes on the firewall was located in a salvage yard. It was tested and appears to be in better condition than our original one. Front and rear windshields were also obtained from the same salvage yard. They need to be cleaned and carefully inspected before we decide whether to replace out existing glass, which is not great, but is serviceable.

  Mar 25, 2023     Week 17 - (24 hours)       Category: Fuselage

Progress continued on the Cessna this week. Landing gear parts were delivered to the paint shop in Pennsylvania. We painted the firewall. Since the firewall is galvanized steel, it was necessary to prime it with an acrylic bonding primer. It was then top-coated with high temperature silver paint. Before painting, the ten rubber cowl fasteners were removed and found to be in pretty rough shape. Many, if not all of them will be replaced. The process of installing the new cowl chafe seal was begun. The seal is riveted between the forward fuselage edge and narrow aluminum strips. The assembly was clamped and clecoed in place. Next step will be to match drill the strips and then rivet. The nose wheel and its parts were cleaned using a parts washer. It all needs further inspection. It was decided that the master brake cylinders should probably be removed, inspected, and overhauled as necessary. This proved to be a fairly major task since the attaching hardware is deep behind the rudder pedal assembly. After some considerable effort, the left cylinder was removed. More work was also done sorting out and evaluating electrical components.

  Mar 18, 2023     Week 16 - (20 hours)       Category: Fuselage

As usual, cleaning continued this week. Once again, John did a great job, this time on the break assemblies. They were particularly dirty. Both appear to be serviceable. Floor pans were also cleaned. Stubborn glue residue along with dirt had to be removed from them. Small parts were also given attention, especially the many pulleys for the control system. (The photo shows a pulley before cleaning on the left and a cleaned pulley on the right.) Once cleaned, all the pulleys will need to be inspected by our A&P/IA. All of the hardware for the engine mount and landing gear came in. Our next step is to paint the firewall. A paint shop was found that agreed to paint the engine mount and landing gear parts. The parts will go to the shop next Wednesday. Kevin found himself in Dallas this week and went to a salvage yard. He managed to find the elusive cowl chafe seal we've been searching for. Meanwhile, Robert has taken charge of sorting out and testing the airplane's electrical components. It appears many will have to be replaced.

  Mar 11, 2023     Week 15 - (30 hours)       Category: Fuselage

Cleaning continued this week. John did a remarkable job of cleaning the flap motor assembly which appears to be in good working condition. (It worked to lower the flaps when we first recovered the airplane.) The two shimmy dampeners were disassembled and inspected. One is from our airplane and the other is from the wreck that we bought. Which parts will end up being used is still to be determined. Work on the area behind the panel also continued. All of the major push-pull controls were removed and inspected. Unfortunately, it looks like almost all of them will need to be replaced for one reason or another. The cabin vent air door and cable were frozen in the open position. It took considerable time and effort to remove the cable and free up the door. We contacted a paint shop about getting the engine mount and landing gear parts painted, but haven't heard back yet. We also inventoried the new hardware needed to put the engine mount and gear back together and on the airplane. An order for that hardware will go out this week. Congratulations to Kevin and his wife on the arrival of their newly purchased 1974 Citabria. Work on our projects paused to admire the new addition.

  Mar 05, 2023     Week 14 - (30 hours)       Category: Fuselage

As usual, more cleaning continued this week. Floor pans were cleaned as well as the cabin spar carry-through tunnels where the wings attach. The tunnels will need to be inspected by our A&P/AI. More pulleys in the forward cabin were removed. The nose gear strut and torque link assembly got a lot of attention. They were cleaned and parts blasted with either fine glass or walnut shells. The strut was then primed. The main gear legs and engine mount were also blasted clean, but still need to be primed. The gascolator was again disassembled and inspected. A service letter (SEL-28-10) requires inspection of the bowl to determine if it is stamped with specific numbers. Any bowl with any of those numbers would need to be replaced. Our bowl had no numbers on it at all, so we believe our bowl is good. However, we will verify this with our A&P/AI. An overhaul kit was obtained for the gascolator and a couple of replacement parts for it will be ordered. Work also continued on the firewall area. Robert focused on sorting out and identifying all of the electrical wires that come through the firewall. Many of the parts, including the voltage regulator, some of the wiring, and maybe solenoids may need to be replaced. Meanwhile, on the other side of the firewall, Bob worked on removing the avionics trays in order to better get at cables behind the instrument panel. This turned out to be something of a project since many of the screws holding the trays in place were both frozen and hard to access. After much struggle, he got them out. With the trays removed, we got a clearer picture of what lies behind the panel and we were able to begin removing cables that go through the firewall.

  Feb 26, 2023     Week 13 - (30 hours)       Category: Fuselage

Continued steady progress this week, with most efforts focused on tasks necessary for getting the Cessna back on its gear. Toward that end the firewall got a lot of attention. The battery box was removed, which required drilling out a bunch of rivets. Cleaning the firewall required lots of time and elbow grease. Work also continued on cleaning the landing gear legs. We got an overhaul kit for the nose gear shock strut, but that hasn't been done yet. The avionics stack was removed, and more pulleys were extracted from the cabin area. All pulleys are being cleaned and inspected. Any found questionable will be replaced. We ordered all new cables. Our A&P/IA came by again on Saturday to inspect things and give advice. We have small holes on both sides of the horizontal stabilizer that we're not sure what to do with. The previous owner apparently fixed it with something like Bondo. Our A&P/IA inspected it and said he would research the proper repair for it.

  Feb 18, 2023     Week 12 - (40 hours)       Category: Fuselage

Steady progress on the Cessna continued this week. The process of cleaning the main landing gear legs was begun, which involves gently sanding off layers of dirt and built up residue to get them down to bare metal for inspection. In spite of all the Croil, the engine mount and nose gear leg still won't separate. Our A&P/IA, who visited again today, advised heat in the form of a welding torch may be the only way to free them. We were able to at least remove the inner nose gear assembly. Again, our A&P/IA helped with that and advised us to get a rebuild kit for the shock strut. Meanwhile, more cleaning and inspection continued. Landing gear fairings were cleaned. Some parts of them may need to be repaired or replaced. The gascolator and its related parts was disassembled and inspected. It turns out the gascolator from the wrecked 150 is a newer McFarlane model and is in better shape than our original, so we will replace our's with the salvaged McFarlane. We obtained a new rivet removal tool which was used to remove the small rivets along the upper firewall edge that hold in the cowl baffle seal. The seal is old and badly deteriorated and needs to be replaced. The fuselage skin where the wings attach had a lot of old tape residue which was cleaned off. The bare skin was then coated with Cortec primer for protection. The interior also got more cleaning and some inspection by our A&P/IA. A member's grandkids also came by to inspect our work and to try out the Cessna's controls.

  Feb 12, 2023     Week 11 - (40 hours)       Category: Fuselage

A lot was accomplished on the Cessna this week. Last week our A&P/AI told us we needed to remove the engine mount, nose gear, and main landing gear. This is necessary so that all of those components can be cleaned and thoroughly inspected, including the firewall itself. We began by removing accessories attached to the firewall. Meanwhile, Mark Gosselin used cardboard to make a template for constructing a cradle for the fuselage. Fairings for the main gear were then removed which involved the removal of many stubborn rusty screws. Brake lines were also drained. The brake fluid looked remarkably good, which gives us some hope the master cylinders are still in good shape. On Saturday, when we had more people to help, the main gear was carefully removed according to the directions in the maintenance manual. This was soon followed by removal of the engine mount and nose gear. The fuselage was then lowered onto the cradle. Wheels and brakes were removed from the landing gear legs and attempts were made to separate the engine mount from the nose gear. The roll pin connecting the two at the upper end was removed without too much trouble, but apparently time and rust seem to have welded them together. It was decided that patience and repeated applications of Croil will eventually convince them to part ways.

  Feb 04, 2023     Week 10 - (30 hours)       Category: Fuselage

Cleaning and some disassembly of the fuselage continued this week. Both the cabin area and the tail cone got a lot of attention. Lots of accumulated grime was removed revealing structure that is in good overall condition. So far, the major issues with the plane, aside from a lack of logbooks, are dirt and rusty hardware. With some difficulty, the four block-bearings were removed from the cabin spar carry-throughs. This will enable better access for cleaning and inspection. Some work was also begun on and under the instrument panel. A homemade wood plate along the top edge of the panel was removed, revealing structure and the rearview mirror. Wheels, tires, and brakes recovered from the wrecked Cessna were disassembled and inspected. They will be compared to those on our plane and the best parts used. We got two visits from chapter A&P/IAs. We were able to ask lots of questions and get their approval for what we've done so far and what we intend to do going forward. One major topic that was discussed with them was how to get the airplane in good graces with the FAA since we don't have log books. It was decided that next week we will get in touch with the local FSDO office to find out what steps we need to take beyond what we're already doing. We paused work on the Cessna to greet Steve Gross who stopped by with his newly completed and painted RV-10. Congratulations Steve!

  Jan 28, 2023     Week 9 - (40 hours)       Category: Wings

The main focus Thursday was to get the engine disconnected from the firewall so that the engine can be removed on Saturday. Meanwhile a lot was accomplished on the interior. The seats were removed and the interior vacuumed out. All of the interior plastic panels were also taken out. On Saturday the engine was removed. It will soon go to an engine shop in Virginia to be overhauled. Work also continued on the interior. The portable intercom and a Loran receiver were taken out. Inspection plates and access panels were removed, and a lot of cleaning was done. There was some discussion about how to best deal with the entire area between the instrument panel and the firewall. Access in this area is difficult, but we would like to be able to properly inspect, clean, and renew as necessary the many parts there. There was also more review and discussion of ADs. There is one concerning the seat rails that will need to be addressed. We agreed that at this point we need to consult with our supervising A&Ps.

  Jan 22, 2023     Day 8 - (30 hours)       Category: Wings

Cleaning of parts continued on Thursday including the aileron that needs to be re-skinned. A review of ADs has also begun. One involves the possibility of cracked plate nuts on a bracket that attaches the vertical stabilizer. As part of complying with the AD we removed the bracket and drilled out the plate nuts. The plate nuts will be replaced with regular lock nuts. Our work intersected with the Zenith 750 Veterans Build project when a wrecked Cessna 150H was delivered to the chapter house. The plane has been purchased by the Veterans Build in order to recover a good Continental O-200 engine for the Zenith. We helped wrestle the aircraft into a hangar on Thursday. On Saturday, we inspected the wreck and recovered any parts that we might be able to use on the Cessna project. The best find was a seat belt and shoulder harness set that appears to be better than what is in our plane. In the afternoon we brought our Cessna fuselage up to the chapter workshop so that we can begin work on it next week.

  Jan 14, 2023     Day 7 - (35 hours)       Category: Wings

Work on the Cessna's wings continued this week. The outboard section of the left aileron is bent and needs to be re-skinned. We're going to have a professional shop install new skins, but we needed to drill out all the rivets to remove the old skins. This took a couple of days and a number of drill bits. Pulleys and bell cranks were removed from the left wing. The bell cranks were then cleaned and inspected. The stall warning device was also removed from the wing and cleaned. On Saturday Tom Crone arrived to deal with the final two broken screws embedded in the right wing fuel tank frame. His expertise saved the day and both screws were finally removed. Meanwhile more cleaning took place, especially on the leading edge of the left flap which is oddly rough. Some time was taken Saturday to put the wings on a stand and get them out of the way for a couple of chapter events taking place next week.

  Jan 07, 2023     Day 6 - (55 hours)       Category: Wings

On Thursday work resumed on the Cessna following the holidays. Cleaning of the right wing and its parts continued as more attempts were made to remove screws that had broken off inside the nut plates for the fuel tank cover. In this, we were mostly unsuccessful. A small crack was found on the web of the wingtip rib. Tim fabricated a patch to fix it. At the chapter meeting we consulted with Gerry Blake about the broken screws. He recommended that we contact Tom Young who is an expert on dealing with Cessnas and their issues. On Saturday we had a great turnout and a lot more was accomplished. Tom arrived and used various techniques to remove most of the stubborn broken screws. Two remain to be dealt with. He also helped remove the fuel tank cover from the left wing. The fuel tank was then removed from the left wing along with the aileron, flap, and wingtip. Rusted screws and nuts were also removed from the mounting bracket for the vertical stabilizer. And, of course, lots and lots of cleaning took place.

  Dec 18, 2022     Day 5 - (20 hours)       Category: Wings

Today began with our Frederick Sport Flyers business meeting. Much of the discussion was devoted to the Cessna project. As a result we now have five members financially invested in the project as well as some plans and a tentative budget moving forward. Work then resumed on the wing. We removed the aileron without difficulty, but then found that the push rod bolt was somehow frozen inside the rod end. Multiple methods were tried to remove it without success until one member hit it with a rivet gun. Sometimes brute force is the answer. Meanwhile, the continuing task of cleaning everything continued. The interior of the wing was vacuumed once again, while soap and elbow grease continued to remove more dirt. The day concluded with a discussion of next steps and an initial order list of parts and supplies.

  Dec 11, 2022     Day 4 - (30 hours)       Category: Wings

Thursday began with a close inspection by Jerry Blake of the Cessna's parts located in the chapter hangar. He reported that for the most part everything looked good and he pronounced it a worthwhile project. He recommended that we spray interiors with Corrosion X as soon as possible. Jim took on the task of extricating the trim actuator from the horizontal stabilizer. As expected, that proved to be a difficult job, which required most of the day and help from almost everyone. But in the end he got it and its related parts out. The actuator will need serviced or replaced. Meanwhile, the same process was taking place with the flap motor and its related parts. Once that was removed, we were able to remove the flap as well. On Saturday we continued with work on the wing, removing the aileron bell crank and all the remaining pulleys.

  Dec 06, 2022     Day 3 - (16 hours)       Category: Wings

The main focus of these sessions was the right wing. We brought the wing into the chapter house with the intention of removing the fuel tank and inspecting the wing more closely. It proved more difficult than we imagined. The screws that secure the panel over the fuel tank had, over the course of many years, virtually welded themselves in place. We tried just about everything we could think of to loosen their death grip on the nut plates. Penetrating oil, an impact screw driver, drilling and easy-out screw extractors, a heat gun, and a Dremel tool were all employed. After considerable effort and time, the panel finally surrendered and we were able to remove the fuel tank. The tank itself looks good although parts around the filler neck will need to be renewed. With the tank out and the wingtip removed an inspection of the internal wing structure revealed it to be in remarkably good condition with very few signs of corrosion. Meanwhile, the fuselage was moved from temporary storage in hangar 11 to hangar B-10 where it will share space with the Cub for the time being.

  Nov 29, 2022     Day 2 Cleaning - (6 hours)       Category: Inspection

Removing years of dirt from the Cessna was today's objective. The bulk of it was just accumulated dust from sitting in a dirt floor shelter. For the most part the dirt came off easily revealing fairly decent paint underneath. Aside from some touch-up, we may not need to have her repainted. A lot of parts and miscellaneous stuff in the cabin was removed and sorted out. The seats appear to be in fair condition. The upper cowling was removed to get a first look at the engine. The engine compartment appears complete. Since it has 3,000 hours on it and has been sitting for so long, the engine will obviously need to be overhauled. The condition of mags and other accessories is still unknown. At this point several important things remain to be done. Decisions need to be made regarding financial support for the project and a thorough inspection by an IA needs to be completed. Meanwhile, the fuselage will soon be moved to hangar B10 and the engine pulled. The fuel tanks will also be removed so they may be cleaned and the wing structure more easily inspected.

  Nov 25, 2022     Day 1 Recovery - (12 hours)       Category: Inspection

Mark Gosselin discovered this abandoned and lonely Cessna 150 sitting in an open sided shelter in Shirleysburg Pennsylvania. After a little detective work he was able to locate the owner and arranged to purchase the plane as a restoration project for the chapter. Early on the morning of Friday November 25th a group of chapter members headed to Pennsylvania to rescue N105ES, a 1977 Cessna 150M with about 3,000 hours on it. It has been sitting neglected in the shelter for many years and was covered with a thick layer of dirt and grime. But we found the airframe complete and undamaged aside from some minor hangar rash. After a brief inspection, disassembly was begun. The tires were inflated and held air. When external power was connected the panel lit up and the flaps operated! It took most of the day to remove the tail surfaces and wings. Everything was then loaded onto trailers and brought back to Frederick, arriving around 6pm. Temporarily, we put the little Cessna in hangar 11. The immediate plan is to clean and inspect it further and then move the fuselage into hangar B10, sharing space with the Cub.