BearHawk 5 school of construction

[Sir Newton]

General cheerleading! All wing spars have been fit up & are being deburred right now. As well builting a Alodine holding trough out of 6" sc40 PVC pipe. To clean & treat all the spar parts in. It took me basically 200+/- hours to fit out all 4 wing spars.
​​​​I very happy to be moving forward.

[way_up_north]

Great progress ...thanks for posting detailed photos ... can really zoom in on the parts.. brings the plans to life

[Sir Newton]

Corrosion protection & Paint Preparation of wing spars. I used 6" sc40 PVC pipe cut in half. One tank for alodine, one tank for cleaner and to wash water tanks. Over all it work ok, the end result was very good, and the procedure to work with the chemicals was safe. However alot of work to complete.

[NCLSA183]

All the different and unique ideas that we see from builders are amazing and entertaining.

[Sir Newton]

Bearhawk 5 model B wing spar photos after being cleaned & alodine treatment applied.

[geraldmorrissey]

Looking good Sir Newton. Love the photos. Keep them coming.
Gerry
Patrol #30

[Sir Newton]

You know the saying "Paint that Gold" Right hand rear spar is back on the jig & completely reassemble ready to install RIVETS!

[Sir Newton]

Good day BearHawkers, Just some more cheerleading going on here. Uploaded a few pictures of my spars in various stages of riveting. I am trucking right along with the project. Ordered up all the tubing for the fuselage. Hit that like button so I know someone is actually looking at these posts! or don't.

[way_up_north]

Sir Newton... great progress...!!

[rv8bldr]

Those look awesome. And I am incredibly envious of both the amount of space you have to work in and the real-man tools I see in the background :-)

[Sir Newton]

Thank-you for the supporting comments you guys.

[Sir Newton]

Greetings to my fellow builders. Just general project cheerleading here, Attached are pictures of RH main rib with all the stiffeners ready of riveting. It took roughly 30 mins per rib to fabricate, drill holes, prepare with anodyne & install the stiffeners. Slow & steady progress every week is the goal. LH ribs next week & maybe receive my rivet order from Hanson. Cheers All

[Sir Newton]

I have something to admit, I am addicted to building BearHawks. Picked up Patrol plans. Project #2

[Bcone1381]

Sir Newton;

The progress you are making is astonishing to me. It took me a year to fabricate a set of ribs. Would you share some details with the group how you can go from a rib blank to a rib with ready to install while spending 30 minutes each on them?

BTW, I often think to myself "using today tools and technology, can we standardize and declare "Industry Best Practices"?" Meaning what is the best way to do a job with the least effort, having the best result in order that we can improve our (meaning Builders of Bearhawks) completion rate, and get a completed airframe out the door in less than 10 years. It looks to me like your spar and rib production is achieving that goal.

[Bcone1381]

Best Practice.....There are several folk who have written material. Russ Erb, Eric Newton, The Patrol Book, probably a score and a half of Beartracks articles. Is the Bob Stick the best practice for flanging a rib lightening hole, or wood dies in a press or a female wood die and a rubber press?

Those of you with a career of fabrication experience....you are fabricating about 2000 hours a year....20 years is 40,000 hours of experience....are I think are very well suited to guide the "Bearhawk plans built Best Practice of Fabrication" Also, as we move ahead into the digital age, the Best Practices will change. CNC routing, and 3d printing using Solid Works data will change "Best Practices" in the future I think. If we can convince Bob that his design will remain Copy Write Protected is might happen faster.

Its all about improvement of the completion rate.

[Sir Newton]

Over the past months I have thought more about this post. Being a green BH builder I have started to noticed many ! things about the construction of every other plane I set my eyes on now. All of the designs have been borrowed from someone's past design & in some cases improved upon. It is not rocket science. I get upset when I see out right greedy people set up financial barriers to entry into aviation. The industry is rip for disruption imho. There is so much good stuff for younger ones to learn by getting involved in our hobby.

[NCLSA183]

I can only imagine the time savings of always having the right tool for the job just a few steps away... Color me "envious". I've collected a few good tools over the years but have never been able to collect "that" much working space!! :)

[Sir Newton]

Hello BearHawkers, Just some general cheerleading here. SO, Riveting on LH main & rear spars are complete. The spars came out straight as an arrow they are prefect! May I highly recommend using a jig similar to the one I built. I do not want to over step here, however the jig works like a hot dam. The electrical strut I used to celeco the spar to are at the Stations A, B, D, & E. Now we are working on bucking all the RH spar rivets. If any one has any questions. Just ask. I really like chatting about BearHawk anything. cheers !

[Sir Newton]

This is what the RH main spar looks like up on the jig after I stuffed proper length rivets into every single hole ! before I start bucking rivets. There is a celeco every tenth hole. The masking tape is needed to hold rivets in place while you start to buck rivets. LH main took 12 hrs to buck all the rivets RH should be quicker with some experience under our belts. Cheer enjoy your week end.

[Bcone1381]

Looks Good!! All those individual pieces of tape look time consuming to install. Are you familiar with Rivet Tape? Put One long piece over all the rivets. https://www.yardstore.com/rivet-tape-1

[Sir Newton]

Bcone1381, lol, Yes I am. I even bought 2 rolls of 3/4. I am just to cheap to use it.
I watching Mike Patey bending spars on his UT channel. Mike looks like a ton of fun!
After his video I have decided to model up my wings in Solid Works to run an FEA

[Sir Newton]

We have passed a major milestone. The wing spars have been completed. If I had to guess it took in and around 300 hours to complete all 4 wing spars. I have kept a detailed log so if anyone cares about the exact time. I could figure it out. Build on Bearhawkers! BUILD ON!

[geraldmorrissey]

Curious, what primer did you use? Looks gold, like alodine in the photo. Great job.
Gerry
Patrol #30

[Sir Newton]

It is alodine, I had a chat with our local inspector today about priming before his pre-cover inspection, He did not care one way or the other. So I will use Endura EPC2 sealing primer when the day comes to prime the wings. I am pleased with how the spars came out. I am fabricating a jig to help assemble the wings ribs to the spars.
Cheers Gerry your comments are really appreciated thank-you

[geraldmorrissey]

My fwd spars are going together now. Am very interested in your approach to rib to spar tooling. Will follow with interest. Keep the pictures coming.
Gerry
Patrol #30