Long Distance Build

[Gunpilot]

I just purchased 4 place plans #1082 from the previous owner and am really excited to get started. Problem is I'm active duty Army (Apache helicopter instructor pilot) and currently deployed to Afghanistan. What I'm hoping to do for the next couple months is get started on acquiring some of the tools and equipment that I'm going to need, which leads me to my second problem; I had the plans shipped to my wife in Kansas because I was afraid of them getting lost on the transatlantic flight.
If any one could please help with a required tool list that would be amazing i.e.

Rivet Gun Type/Style/Size?
Welder MIG gas/MIG stick/TIG/ARC? (grew up on a farm with ARC and I can use a MIG, never used a TIG)
Drill Press Size?
Hydraulic Press?
Sheet Metal Brake?
Wood Router Suggestions?
Band Saw?
Disc or Belt Sander for the Rib Forms?
Hand Tools Hammers/Snips/Drill bits/Saw blades?
Work Table Size, What's minimum and what would be too big?
Getting started hardware, rivets/materials/aluminum/steel? (I'll probably start with the wing forms and then wings, easier to store once complete)

Also since these plans will be slightly older how do I make sure I'm up to date? I've already downloaded the assistance manuals from Avipro.

Any help would be greatly appreciated, I'm hoping that I might be able to get some good deals with a full two and a half months to shop around. As I said before I'm very excited about the project, I've been looking at kits and plans for about two years now and I love the utility of the Bearhawk, I've been an aviator for about twelve years now but never been able to take my family up with me (only two seats and the Army locks the keys up to their 23 million dollar helicopters at night).

-Greg

[Flynguy521]

Greg- Welcome to the Bearhawk club, and thanks for protecting our freedom! As far as tools go check eBay. I have found really excellent deals on there. You can get an updated set of plans from Bob for $30. These will contain any changes made. Eric Newton's build manuals are invaluable as well as Russ Erbs cd. You can download Eric's. Russ' is only available via download. Check out my website andysairplanefactory.blogspot.com under the resources page for links to good workbenches. There was a thread a while back on here on optimum height that you can search for. I made mine following the plans to the letter and I find it perfect. I'm 6'2". As far as required tools you can do a lot with a little, but let's face it. We like our tools. Buy the nicer stuff. Better it hurt now with the price vs hurting later with it giving you mediocre performance or damaging your work piece. That being said, you don't have to have the most expensive version of everything. For example, I have heard horror AND praise stories of people with Harbor Freight drill presses. To each their own. I didn't buy one. I stuck with Craftsman for most of my tools. I don't have a band saw yet, but Nortgern Tool has one I have been eyeballing. There were plans on here for sheet metal brakes that several people posted. That is the route I plan on going. However, you can find one in your town probably. The fuselage is oxy/acetylene welded. Tinmantech is the place to go for your welding tools. For a complete list look up the tool kits from Brown tool company, Aircraft Tool Supply, or Avery Tools and search for their Mustang or RV tool kits. Peruse the list if what's included. You will be using just about every tool listed. Get the general stuff first, like the drills, squeezers, deburring tools, fluting pliers, drill stops, microstops, and so on. You can fill in the specifics later. Rivet guns are a touchy subject. 3x "seems" to be the happy medium for what we will be doing so that is what I went with. I bought American. Also, be sure to get the Tony Bingeles book series for home building. I hope that helps a little. Also, sorry if this reads as one long paragraph. Tapatalk app isn't posting breaks for some reason. -Andy

[alaskabearhawk]

What Andy said. Plus, if you haven't already contact Bob Barrows and tell him you have that serial numbered plan set. He likes keeping track of who has the plans. You can order a set of replacement plans for around $30 or so and they come with all the current revisions. This may help as well as far as plans usage goes: http://www.youtube.com/watch?v=6TqgxL8kn3k

Good luck!

[ellsworb]

Greg,

I'm currently at KAF if you ever want to talk Bearhawks and Patrols. PM me if you're here.

Brandon

[Flynguy521]

Alaskabearhawk reminded me of the most important tool. That Itoya art portfolio for storing the plans! That way the are kept in tip top shape. Easy to access and organized.

[wingnut13]

Hehe, I'll be sitting in the sand in a few months as well thinking of what I should be doing back home. I was thinking about pounding out some ribs while I'm there but it wouldn't make for happy bunk mates. I don't think I'll be at KAF though (unless I get deported. . . ..again).

[Gunpilot]

The plans just got to my wife today, looks like the next step is e-mailing Mr. Barrows.

[alaskabearhawk]

Better put a stamp on that email. He doesn't have an email address...old school.

[mikeno]

If you'll PM me your e-mail address I'll send you the tool list I pulled off the old Bearhawk forum with some of my comments re: what you really need to get started. I don't know how much time you've got left in the sandbox but I'd concentrate on reading, reading and re-reading the plans and the CDs. Unless the guys in the sheet metal shop are willing to part with some 2024-T3 shipping aluminum sheets will cost you dearly. First step usually is to make the 200+ rib stiffeners and attach angles which requires a sheet metal shear, a brake and bench grinder with 3M conditioning wheel(s) plus various hand tools. I started last January and I'm just now ready to build my spars due to various interruptions. I've spent some time in the sandbox (BAF) early and think your time is best spent reading. Thanks for your service - be safe! Mike BearHawk #1250 KLXT