Lessons learned about hardware callouts and upgrades

[N204jh]

While working on the belly pulleys and cargo door, I made a significant discovery - not only have there been continuous improvements with the kit, the hardware (bolts, nuts, washers) is different between what's now included with the kit (from Aircraft Spruce) and what the various manuals call out. I've been following the text / image build files along with the older Bearhawk manual, both on the website.

How did I discover this? I was searching high and lo for a particular bolt and nut for the belly pulley, and no joy. I looked at the Aircraft Spruce order and they were not included. So then I fell back and looked at the various builder's log that are leading the way. But they had the traditional hardware.

I finally checked the Five Hardware Callout list downloaded from the website, and sure enough, the hardware was updated.

A recent significant kit upgrade - no more formers for the skylights, neither the . Square tubes have been welded to the posts for the 2 center legs and the rear, so the rear former is gone.

[FFTravism]

I noticed the skylight update too. I think that makes you required to do full skylights now. I decided to do fabric in the middle to cut down light a little.
Also be careful building from the plans if you have them. My kit is 4 years old and even back then the kits were different. I have had to order more aluminum because I was following the plans and didn't check if things changed. Big item that comes to mind is the cargo door aluminum skin has a call out for 3/8" overlap of bottom formers. That isn't enough when the gap between the door has been changed. You need 1/2" to 3/4".
Travis

[N204jh]

I also am only planning two side skylights with an aluminum center, although I might shift to fabric. Here’s what Virgil said:
”Essentially whatever you are going to attach to the top of the aircraft glass or aluminum will be screwed down to the top of these formers.
- When going through lexan, we use a 1/16x1/2 aluminum doubler strip on top of the glass. This helps to form a good seal and relieve stress on the Lexan.“

The detailed photos from McCardle’s plane shows the skylights in detail.

I have new extended hinges on the rear cargo door that provide plenty of space to have the rear door open completely. I was going to weld some extensions like other builders have done, including Virgil’s BH5 build. But the new hinges are really nice.