Minimum List To Get Started

[robert7467]

Received plans for the Bearhawk lat week. So far I have built 2 EAA tables and I have around 3 more to go.
I have order the builders manual.

What is the minimum equipment/materials to get started? I need something cheap and easy that will keep me busy for a while.

Should I start with Rib Stiffeners? If so, what are the tools and materials required to get those started?

Thank you for your thoughts! I am just looking at the cheap and easy way to get started.

[marcusofcotton]

Welcome Robert!
If you start with ribs, etc., the stiffeners can be made from "free" material from fall off and perhaps an oops or two.

Trust you're referring to Eric's build manual. Also get Russ Erb's CD and back issues of the newsletters. Continue your studies first and start to formulate the answers of progression that will make the most sense for your situation.

Where are you located? A visit to a nearby builder can be good.
Mark J

[robert7467]

I am located in Mississippi 10 minutes from Memphis. I saw a materials list posted online for the wings, but with that list it will cost a few thousand. I was hoping to start the build and progress to more materials and tools.

One other question: Will a table mount drill press work, or should I get a floor one?

Right now I have 2 EAA tables complete and I am about to start tooling up.

As I am tooling up, I would like to start somewhere on this.

Right now I have a Mooney so I am in no big hurry.

[X'N]

2 sheets of 4x12 .025 and a sheet of .032 will keep you busy for months if you working on your ribs. You'll need a sheet of 3/4 MDF, nice deadblow hammer, a few sharpies, tin snips, router and flush trim bit (A drill press on max speed also works) Fly hole cutter, some files...

table mount drill press will work for the wings. I'd spend more $ on a quality one VS size. Cheaper drill presses tend to have a ton of run-out. Don't overlook craigslist I got a 1950's drill press that needed some cleaning and new bearings. I think I have $65 total in it. My friend said its nicer than his $400 drill press he just got.

[robert7467]

Will the 2 sheets be sufficient for working on the 4 place bearhawk?

Thank you Dan..... This is exactly the information I was looking for. This way I can get started and tool up as I go. The way I was looking at it, was about $2700 for sheet metal plus a ton of $$ in tools as well.

[X'N]

I forgot the 4-place has a bunch more nose ribs & uses .025 for the aileron and Flap nose ribs. Better stick with the Layouts that mswain posted. So 3 4x12 .025 and 1 4x8 .032.

[mswain]

As Dan mentioned, 3 4x12 sheets of .025 2024 T3 and a 4x8 sheet of .032 2024 T3 will keep you busy for a while with minimal tools. Here is a nice layout another member did.

[marcusofcotton]

Re: Drill press
About ten years ago I had a similar choice to make, balancing budget and drill press needs. After considerable research I ended up with a new bench drill press by Delta. It had longer travel than most similar ones and no perceivable runout. Table was easily adjustable for position while maintaining true level. the belt speed change is quick and easy but in loading it frequently slips too easily. Don't know if a new one would compare as well or not. FWIW, I just brought home a fifty year old floor model that just needs a little tlc, even though I'm tight for space.

Mark J
NE MN

[robert7467]

I would prefer a bench due to cost, but I am keeping an eye out for a nice floor model on craigslist.

[robert7467]

I know a quality drill press is highly important. As as the router goes, should I get a middle of the road router/table combo or just a router? Sorry for asking so many questions.

[bestbearhawk1231]

I used a ryobi router and table. I think I payed 100 bucks or so on sale. Didn't want to risk damaging my Bosch not knowing what was going to happen on metal. A higher hp model will allow you to cut more ribs at once without bogging down. Get the larger diameter chuck if possible, it will greatly reduce the amount of bit chattering. Also, 3 cutting edges on the bit will give you a nicer finish, I kept getting a lot of chatter marks on the aluminum with the 2 cutting edge bits. If I remember right, I had the best luck with the 3 edge freud diablo bits from home depot if you want I can get a pic of a new one in the package yet when I get to the shop next. Keep your follower bearing well lubricated, I used 5-20 mobile one synthetic since I had a half empty bottle in the garage at the time.

[John Massaro]

The way I'm seeing things, there's plenty to do with setting up a proper work area and making the master rib template and forming blocks before ordering any sheet metal.

Just my 2¢.

[robert7467]

Sheet metal ordered. Has anyone used the Harbor Freight Drill Press or are those junk?

[X'N]

Quality control there can be hit or miss. I was lucky enough to get one that only had .030 of runout...

[Chris In Milwaukee]

I've got a HF drill press. It's not bad. My chuck was concentric, but I've heard from others that theirs were not. I burned up the power switch in about a year. Replaced it with a standard 15A light switch. The motor on mine occasionally stalls on startup depending on the gear ratio used, but a quick spin with the hand gets it going.

The saying goes, "What do you get when you pay $169 for a drill press? A $169 drill press." :-)

But aside from its minor faults, it does what I need it to do. And it's a floor model.

~Chris

[robert7467]

I read up on them, and from what I am seeing is that they are great except for the fact that they have faulty switches. I am trying to find a good quality used one but I am not having any luck. I guess I have about a week to get my shop situated to hopefully find a decent one.

[bestbearhawk1231]

I have had good luck with my Ridgid floor model from Home Depot that I bought on clearance around 3 years ago. I didn't pay much more than you are looking at paying for the HF one. If I remember correctly I paid around 200 for it, still in the box. It will pass clean through a 4x4 and haven't found a bit size yet that will slow it down as long as the pulleys are remotely close to where they should be speed wise. 300-3000 rpm.