DavzLSA progress

[marcusofcotton]

Various scenarios: prelanding brake checks, brake line failure at takeoff on longer flight with loss of fluid, while landing realize no brake but still using rudder for directional control (possibly continuing landing or a go around), etcetera. Common? No. But when fabricating pedals, why not make it so cam over can't happen? Seems wiser than wishful thinking that "a brake failure could never happen and if it did, oh if only I still had my normal rudder control available...oh darn it anyway."

Not really interested in arguing it. When designing and fabricating, do it trying to think of failure modes and ways to eliminate them or reduce their consequences.

[Archer39J]

Ok, to builders out there who have located their pedals as per the plans: Do they still over-cam?

[Archer39J]

Various scenarios: prelanding brake checks, brake line failure at takeoff on longer flight with loss of fluid, while landing realize no brake but still using rudder for directional control (possibly continuing landing or a go around), etcetera. Common? No. But when fabricating pedals, why not make it so cam over can't happen? Seems wiser than wishful thinking that "a brake failure could never happen and if it did, oh if only I still had my normal rudder control available...oh darn it anyway."

Not really interested in arguing it. When designing and fabricating, do it trying to think of failure modes and ways to eliminate them or reduce their consequences.

https://bearhawkforums.com/forum/bearhawk-4-place-plans-build/1100-rudder-pedal-placement

Oh, I see you actually commented on the thread where folks determined that:

A: The pedals will still over-cam even when located properly.

and

B: It's a non-issue.

Sorry, had to check where I had read all that before.

[stinger]

In all the demonstration I have observed, the complete systems are not serviced or connected. #1. the brakes are Not serviced . #2 the rudder cables are Not connected. #3 the Rudder stops controlling the travel are Not employed. #4 the break manual has Not been taken in consideration concerning the geometry providing the break pressure required. If you are using Matco brakes check the book. #5 where are the return springs? One must look at the overall system not a part of it. Yes, I could make my peddle pop over center if the system was not complete. Stinger

[davzLSA]

Thanks for the info Stinger, it is my intention to check everything once the whole system is installed and serviced. I think the video is what opened the can of worms here. But as I have said the dialog here is good for me and makes me think about things I would not otherwise consider. Thanks for your and everyone else input.

[davzLSA]

HI Guys, I think there will be a davzLSA 2.0 in the near future. Im not giving up on my LSA but I have had to do some major soul searching about my welding. This is my first attempt at such a massive welding project and to be honest Im not very good at it. Im a telephone man for a living not a welder. To me the safety of my family and myself is more important than my pride in my ability to make aviation grade welds on my airplane. I have a friend who is an expert aviation welder and I trust his opinion. At this point I am weighing my options. I might be able to salvage the fuselage I have but the jury is still out on that. I can buy a fuselage or I may just buy another tubing kit and try it again. One thing is for sure I now have plenty of practice and I believe I could do a better job the second time around. I have not made a decision yet, I want to haul the fuselage down to Florida and get my friend to evaluate it and see if it can be salvaged. Ill keep you guys up to date on what Im going to do if anyone is interested. Thanks for all the support all you guy have offered.

[sbmurphey]

Keep us posted. I enjoy watching your progress. As builders we can all relate to making decisions every day that we can live with. Looking forward to version 2.0 or even 1.1

[davzLSA]

Thanks for the encouragement Stephen, Im leaving in the morning for Jacksonville where my friend lived. I have the fuse strapped to my Ranger pickup truck, it really looks stupid I just hope it stays on the truck. I guess I can think of it as its first test flight????

[Bdflies]

Pictures please!

[davzLSA]

Ask and ye shall receive sir, it was a fun trip, the wind was blowing like crazy so I really had a huge sail on the top of my truck so I was not able to drive over about 60 miles an hour, it took about 10 hours to get down there. See I told you it looked stupid???? The fuse is being evaluated now, I hope to know something about it in a week or 2. Ill keep you guy up to date.

[davzLSA]

HI Guys,

You may be wondering why in the world would anyone go to such an extreme to get some welds checked? I take aviation safety seriously and I really do love aviation but I'm not prepared to die for it or my ego or pride or even think about putting anyone else in jeopardy I know my welds are strong (my expert told me as much but they were not aviation quality) and the fuse could be flown but I have access to a couple of guys who between them have about 80 years of experience specifically in aviation welding and were willing to look at my fuse. I could not pass up the chance to get their experienced opinion. All of this is the result of my soul searching about my ability to weld and the consequences of my not having aviation quality welds. My goal is to share this and my building experience on the forum and I hope it makes other people think about their welds. This is my contribution to everyone in this community that have given me so much in the way of good information and encouragement. Im not saying who these experts are unless I have their permission to do so. However if anyone is interested in consulting with them about their welds I would be happy to get you connected with them. Sorry bdfles but I have no pictures for this post but im sure if my welds were to fail inflight the NTSB and FAA would have pics of my mangled wrecked airplane and Im sure someone would blame it on the Corvair engine Im going to put in the plane. I hope all you guys stay safe in building and flying.

David

[Peter Bishton]

David your posts are very Informative - keep them up. Btw what is the status of the corvair engine.. Could you maybe update us. Also love the pic of the pick up truck and fuse. Peter

[Chewie]

What aspect of your welds makes you unsure of their quality?

[davzLSA]

Hi Mark and Peter, My Corvair engine has been test run and is in good shape it is sitting in a box in my spare bed room ready to be hung on the front of my plane, As for my welds there were several of them that had inclusions and to many impurities in them. The concern was that corrosion could set in and it would not be detectable. They were not clean welds. There were several major clusters that were suspect. The fuse is with my friend now. He and the other expert are going to see if it can be fixed at a reasonable cost but it could be beyond repair, I wont know for a week or two. BTW my friend is not charging me for this evaluation, he is not it to make money he is also very concerned with aviation safety.

[JimParker256]

Dave, after taking the welding class at OSH (it was a blast!), the instructor told me "Yeah, those welds are good enough to fly..." Then I went to the Bearhawk booth, and saw the difference between my crappy welds and the ones the Bearhawk factory does... Oh, my! What a difference! My welds look like a dog pooped in the joint, and it solidified. The factory welds look like a stack of coins somehow magically melted together in the joint... After seeing what a professional job looked like, I could not (in good conscience) pass on the opportunity to have that work done by the pros. And judging by how slow my welding goes, the "upcharge" to have a tubing kit welded for you at the factory is amazingly cost-effective!

[Chewie]

Show us some factory welds Jim! Give us mortals something to aim for. Gas welds, I assume.
I know looks aren't everything but consistency in appearance implies consistency in quality.

[JimParker256]

I'll do that tomorrow, when the light will be better. But it will probably be in the PM, since I've got my flight review scheduled in the AM...

[davzLSA]

HI Jim, I look at this project as a journey not a destination, an opportunity to learn new things and become proficient in skills I do not yet posses (welding). I believe in the EAA ethos Learn, Build and Fly. I fully intend to learn to make aviation quality welds and to do it with a gas torch. So I'm not just trying to build an airplane I'm also trying to improve Dave. My expert buddy told me to just go buy a factory fuse. But if I did that I would just be selling out myself and my beliefs. As of now the jury is still out on my fuse but if it is unrecoverable it will be scrapped and I will weld another one. I'm not going to weld it though until I have acquired the skill to do it. I did make some good welds on my fuse so I know I am capable of welding it I just need more practice. I intend to practice and convince my welding expert friend that I have the skills to do it. Then when I'm done I will get him to evaluate it again. I really will get him to check it as I go so he can check me if I'm messing up. So I have a plan with the goal of Improving Dave and learning new skills and of course building a kick ass airplane. And Jim please get Mark some weld porn!!!