Tell us what you did today on your Bearhawk Project

[geraldmorrissey]

Nearly finished my rudder fixture, just needs paint, layout and locators. Horizontal stab fixture just needs a few locator blocks. Elevator fixture in work. Also built a mandrel for bending tubing. Made from some mahogany cutoffs from a neighbors home remodel. Will make one for 3/8", 1/2" and 7/8". Hope it works.
Gerry
Patrol #30

[geraldmorrissey]

I tried to account for springback by doing just what you did, but it's a guess.

[alaskabearhawk]

I noticed you put triangular gussets on the LE tube blocks. I'm going to make an assumption that you are going to get the LE tube close, then force it into place at the end of the bending procedure. .When you bend your tube the goal is to have the piece drop in without any pressure one way or the other, in other words no induced stresses. I had more of a hard time of bending the tube in a horizontal plane, keeping it flat on the table. FWIW, here's how I did mine:

http://www.mykitlog.com/users/display_log.php?user=yeeeha&project=527&category=7248&log=144020&row=159

http://www.mykitlog.com/users/display_log.php?user=yeeeha&project=527&category=7248&log=144058&row=158

[geraldmorrissey]

Thank you for your comments. The right angle locators are dual purpose, 1. Lift the leading edge tube up off the fixture surface 1.5" so the contoured ribs clear the top of the tool and 2 . Provide a location surface for the leading edge tube. I will make sure that the tube is flat and it's
final contour fits the tool with no preload. If it takes ruining a tube to get it right, I'll have some extra welding practice material.

[spinningwrench]

Slinging the O-360 onto the Patrol today. These numbers seem brutal.

[Utah-Jay]

265 sounds about right for a O-360. My angle valve weights 287

[rodsmith]

Haha, that's light. I weighed my IO-540 before hanging it, 414#, but that was with every engine accessory, 12 quarts of preservative oil, and the engine mount.

[Sir Newton]

That is eye opening.

[Bcone1381]

Re-made fuel sight gages. Electrical has come to stop for now....just ordered the COMM, Xpndr, Intercom wiring harnesses. I like my Panel....Love it!! You can make these things without subcontracting everything out.

I took a Sport Air Workshop Fiberglass for RV's class and learned how I should have made my windshield fairing. Haha! Bob's method works fine and its sturdy so I'm sticking with it. But other fairings will be better!! Way Better!!

I'm still messing with my Gear Strut Fairings. The time I've spent on them is ridiculous and I'm still not quite there. EDUCATIONAL!! is the key word. Now I'm fabricating an end cap that will attach to the strut using a tube clamp....it will be sturdy and simple. I also experiemented with pour foam last night. A world of possibilities exist with this stuff!!

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[spinningwrench]

Your segmented panel will be handy for access if you need it. Fiberglass fairings look familiar. That was a good course.

[Bcone1381]

Gear strut end caps are going to work out! A hose clap will secure the fairing to the shock strut.
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[Dpearson]

Trying to wake this thread up... Today I finished up the nutplates for the right main tank. Lotta nutplates! Moving on to the right aux tank now...
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[Bcone1381]

The electrical system is by and large done. I have PTT switches that still need to be installed and the EMS will be wired in connection with Firewall Forward tasks.

I designed the system using Bob Nuckolls' book Aeroelectric Connection. I used his Z101 wiring Diagram, and B&C products throughout. I wired it all myself with the exception of avionics wiring harnesses for the COMM and Transponder. I contracted out to Aviation Electrical Services in Palmer, AK for those items. The Instrument panel has three sub-panels, each face is removable and service loops allow it to pull away at least 10".

To prevent EMI issues I put all the possible noisy wiring on the right and firewall areas, and the the sensitive wiring like Intercom and avionics and future EMS wiring on the left and panel area of the boot cowl.

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[Bdflies]

That’s looking great Brooks!

[Bcone1381]

I met Bill at OSH in 2016 at the Bearhawk Picnic. He helped give me confidence to build. Thanks Bill!

[NSLaw]

Scratch built companion update: the ailerons and flaps are done for now. Will need to had the piece to the back of the training ribs once they’re hung to insure proper alignment with the trailing edge of the wing. Sharing a couple quick photos.

Next up, wings!

[Chewie]

Congrats. I see you riveted the angles to the ribs first instead of the spars. I wonder if that makes those corner rivets easier to get at. That was a tricky spot for me.

[NSLaw]

Yes, riveted the angels to the trailing ribs before final assembly. Couldn’t see any reason not to, and it makes for four very easy rivets. Chewie

[LukeFrog]

Dry-fit the tailfeathers for the first time. Angle of incidence of the horizontal stab was perfect as per the plans, and after unsticking a stuck hinge gummed up with paint on the rudder, all parts move freely. Almost like it was made for it!

[Darqfaux]

Dry-fit the tailfeathers for the first time. Angle of incidence of the horizontal stab was perfect as per the plans, and after unsticking a stuck hinge gummed up with paint on the rudder, all parts move freely. Almost like it was made for it!

Looking awesome! Which model are you building?

[LukeFrog]

Looking awesome! Which model are you building?

Model B 4-place

[Bcone1381]

I like the design of your tail rotissory. Simple & elegant!

[LukeFrog]

I absolutely can't take any credit for that! It was a very generous gift from Graham Johnson, who recently finished his Patrol. I did him a favor a while back and he offered me his rotisserie when he no longer needed it! I'm very grateful for his help, and aim to pay it forward when I'm done

[spinningwrench]

Cowling coming together. Made simple jig to allow hinges to be mounted so skins are all flush.

[DBeaulieu]

Got the wings in the slings and the metal crates (to be repurposed) in another hangar. Everything big is on wheels and easy to move about.

[alaskabearhawk]

Milestone day today. Except for a few trim pieces yet to be made, I shot the last of the paint this afternoon. Have to wait 24hrs to peel all the tape off. Now I can disassemble the paint booth and finally get it out of the shop! The rest of the bits are done.

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[spinningwrench]

Nice looking paint. Looking forward to see your entire scheme.

[alaskabearhawk]

Here ya go: https://bearhawkforums.com/forum/bea...hawk#post71711

[Sir Newton]

Outstanding color choices

[spinningwrench]

Installing Vetterman crossover exhaust. Really tremendous quality part and fit from this vendor.

[rodsmith]

Clint is great to work with. In my case I needed a custom exhaust for my IO-540 because of my cold air induction. Later I sent my heat muffs back because I needed the intlet and outlet offset. Such good service and quality!