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  • #31
    Really making big progress now. Spars are going to be assembled very quickly on this jig. I could not find any measurable deficiencies with is jig. The jig worked out really well. Very pleased with myself. :cool: enjoy the pictures pound up the likes. ​​
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    • #32
      Great pictures...appreciate you posting them

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      • #33
        Good evening nothing out of the normal Just general cheerleading. Figured I would show you where I'm at on my right hand for rear spar & I moved to lightning holes that were conflicting with the pocket rib stations. Basically the two holes at either end of the aileron were moved. Inbroad holes 1.75 & outbroad 1.5
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        • way_up_north
          way_up_north commented
          Editing a comment
          since you are one of the 1st to scratch build the bravo wings....any commentary is appreciated..


          just curious why you moved the holes, did you have them marked in the wrong place or is there anything on the plans to look out for that is tricky?

          ... I like what you did...doing the stations 1st and holes 2nd means you cant put the holes in the wrong spot...and is a great logical way to it

          Thanks
          Last edited by way_up_north; 02-17-2021, 09:13 AM.

        • Sir Newton
          Sir Newton commented
          Editing a comment
          I double checked my interpretation / calculations of the dimensions from the drawing. I am correct. However there's interference on either end of the aileron with the aileron skin 0.020 pocket rib stations on the rear spar.
          Resulting in my decision to relocate to the lightening holes.
          Last edited by Sir Newton; 02-17-2021, 11:56 AM.

      • #34
        When you first posted your jig, i didn't understand what you were doing. Now seeing the spar on it, it makes perfect sense. Very cool.

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        • #35
          General cheerleading! RH main spar fit out!
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          • #36
            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.
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            • #37
              Great progress ...thanks for posting detailed photos ... can really zoom in on the parts.. brings the plans to life

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              • #38
                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.
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                • #39
                  Bearhawk 5 model B wing spar photos after being cleaned & alodine treatment applied.
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                  • #40
                    Looking good Sir Newton. Love the photos. Keep them coming.
                    Gerry
                    Patrol #30

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                    • #41
                      You know the saying "Paint that Gold" Right hand rear spar is back on the jig & completely reassemble ready to install RIVETS!
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                      • #42
                        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.
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                        • way_up_north
                          way_up_north commented
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                          Sir Newton... great progress...!!

                        • rv8bldr
                          rv8bldr commented
                          Editing a comment
                          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
                          Sir Newton commented
                          Editing a comment
                          Thank-you for the supporting comments you guys.

                      • #43
                        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
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                        • #44
                          I have something to admit, I am addicted to building BearHawks. Picked up Patrol plans. Project #2
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                          • #45
                            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.
                            Brooks Cone
                            Southeast Michigan
                            Patrol #303, Kit build

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                            • Sir Newton
                              Sir Newton commented
                              Editing a comment
                              Senor Bcone1381
                              The 30 min time frame I refer to in post# 43 is not from a raw rib blank. It took me 30 minutes per rib was to fabricate & anodyne the 0.025 stiffeners & install them on each rib. All parts sanded & deburred. No short cuts taken. Today I finished off 1-14 LH main rib stiffeners. I should tell you that I am a journeyman welder & steamfitter with 25+yrs in the trade of metal fabrication. 1st time working with this light gage aluminum though. I agree with you about standardizing "Industry Best Practices"
                              I thought someone had wrote a book/ instruction manual on how to build BearHawks & was selling it to everyone already? To date I have spent 719 hrs on this project proper. That would include making material list, ordering material, & fabrication. I am not sure if you could call that fast.
                              Last edited by Sir Newton; 04-22-2021, 09:53 PM.

                            • Bcone1381
                              Bcone1381 commented
                              Editing a comment
                              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.
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