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Bearhawk 5 scratch build in Northern Idaho

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  • Bearhawk 5 scratch build in Northern Idaho

    Hi all,

    I just received Model 5 plans #5053 and hope to start on it as soon as I clear out my backlog of projects so as to open up room in my shop. Having the plans is giving me the incentive to redouble my efforts. Ha!

    A bit about me,
    I was raised on a small farm and from there worked in forestry, wildland firefighting, and became a welder-fabricator building wildland fire engines and water tenders before breaking my back in a motorcycle accident which prompted me to make a career change and get a degree in mechanical engineering. I currently work as a manufacturing engineer for an high-reliability electronics manufacturer and spend much of my time working on vehicles, riding motorcycles, and have been working on completing my pilots license in my PA28-140. I have a small family of three boys with ages varying between 1 month to 5 years old which is the primary reason why I was drawn to the Model 5. There simply are not many experimentals that have the capacity to haul a family of five with camping gear and still be able to land in remote areas let alone being able to get there quickly.

    The plans and support for scratch building were important to me, since with a family, I do not have much in the line of excess funds and I enjoy working with my hands and learning new skills anyhow. It may be a tall order, but ultimately my goal is to be able to have it completed in 5-7 years since I want to have it done in time for my boys to be able to enjoy it with me, having said that, they will be "helping" me in the shop so it may take a bit longer but they will be able to join me in the building process as well.

    A huge thank you to everyone that has taken the time to post tips, tricks, information, and videos on their builds. I have learned a lot from all of your experiences and look forward to being able to put it into application.

    Bill Duncan,

    Troy Idaho
    Last edited by Redneckmech; 11-22-2021, 03:02 PM.
    Bill Duncan
    Troy, Idaho
    Bearhawk Five Scratchbuild - Plans #5053
    N53BD - reserved
    Builders-Log

  • #2
    Welcome Bill! I was confused for a moment; I thought Bill Duncan was an old dude that used to own Alaska Bushwheel?

    The BH 5 is the plane I wanted to build and would have had I been able to get help scaling up the plans. My 3 kids were about the same age as yours when I started my build. We missed out on a lot of flying and there is a big part of me that wish I had taken a different route but I love my BH and think the 5 will be a great airplane for the mission you visualize.

    Do you keep your Piper at PUW? I finished my flight training there while attending engineering school at UofI.
    Scratch Built 4-place Bearhawk. Continental IO-360, 88" C203 McCauley prop.

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    • #3
      Welcome, Bill!

      I hope you will be posting your build status as you go. I will be ordering my plans for the Model 5 soon, so I'll likely be a few months behind you on the build.

      Good luck!

      Comment


      • #4
        Hi there Bill -

        Welcome to the forum. Northern Idaho is an awesome place. I too come from a wildland background, worked a few seasons for the Lone Peak Hotshots out of UT where I live. Too old and lazy for that now, which is good because it's more time to build. I'm scratch building a companion, about a year in and going strong. Two seater for me as I don't have kids.

        Post updates on your build! It's about the journey.

        Comment


        • #5
          Hey Bill - welcome to the North Idaho Bearhawk Scratch Builders Club!

          I am scratch building the Model B wings in Spirit Lake ID (north of Post Falls & Coeur d'Alene). Three years into the project, with some down time for other projects... so far I've completed all the ribs and fabricated the spars, which I am now riveting !

          Good luck!
          Karl
          Bearhawk Bravo #1508B - Scratch Build (wings)
          Northern Idaho

          Comment


          • #6
            Originally posted by whee View Post
            Welcome Bill! I was confused for a moment; I thought Bill Duncan was an old dude that used to own Alaska Bushwheel?

            The BH 5 is the plane I wanted to build and would have had I been able to get help scaling up the plans. My 3 kids were about the same age as yours when I started my build. We missed out on a lot of flying and there is a big part of me that wish I had taken a different route but I love my BH and think the 5 will be a great airplane for the mission you visualize.

            Do you keep your Piper at PUW? I finished my flight training there while attending engineering school at UofI.
            Hi Whee!
            Always nice to meet another Vandal!
            Yes, I fly out of PUW which has its advantages and disadvantages. They just improved the runway and taxiway the past couple of years and the slight change to runway heading only increased the crosswind component. If you have flown out of it I am sure you are familiar with the incessant crosswind :/ ... It can be dead calm at my house in Troy (on top of a hill in an open farm field) and a 15knot wind at the airport...
            I have read through a lot of your posts on your build and appreciate the information you have shared, I will likely be using your overhead trim crank idea since I am used to the overhead crank on my Cherokee. The build is certainly going to be an endeavor!
            Last edited by Redneckmech; 11-23-2021, 12:24 PM.
            Bill Duncan
            Troy, Idaho
            Bearhawk Five Scratchbuild - Plans #5053
            N53BD - reserved
            Builders-Log

            Comment


            • #7
              Originally posted by RobinDeMarco View Post
              Welcome, Bill!

              I hope you will be posting your build status as you go. I will be ordering my plans for the Model 5 soon, so I'll likely be a few months behind you on the build.

              Good luck!
              Thanks! I am likely going to need all of the luck I can get!
              I plan to post updates and keep a build log, I haven't decided to use Kitlog Pro or the EAA builders log as well as supplementing it in the forum here.

              With the projects I have to complete you may end up starting ahead of me. Ha!
              Bill Duncan
              Troy, Idaho
              Bearhawk Five Scratchbuild - Plans #5053
              N53BD - reserved
              Builders-Log

              Comment


              • #8
                Originally posted by kilohotel View Post
                Hey Bill - welcome to the North Idaho Bearhawk Scratch Builders Club!

                I am scratch building the Model B wings in Spirit Lake ID (north of Post Falls & Coeur d'Alene). Three years into the project, with some down time for other projects... so far I've completed all the ribs and fabricated the spars, which I am now riveting !

                Good luck!
                Hi Karl!
                Great to know there is another active builder in the area, let me know when/if you need an extra hand! Seeing built parts always helps increase motivation and solidifies the information in the drawing.!
                I saw there was another "B" builder in Hayden that has been posting on the EAA builders log. Perhaps we need to create a North Idaho Bearhawk Scratch Builders Club regional thread!

                Did you end up buying pre-formed spars? If not, who in the area did you have bend them? I am trying to get an idea of who has the capabilities semi-locally.

                Thanks,
                Bill Duncan
                Troy, Idaho
                Bearhawk Five Scratchbuild - Plans #5053
                N53BD - reserved
                Builders-Log

                Comment


                • #9
                  I scratch built all my ribs, so the pre-formed spars weren't an option (because they almost certainly wouldn't fit). I cut the spar blanks with a router in my garage and had a shop in Spokane bend all the flanges for me: Spokane Tin & Sheet Iron Works 509-534-0539. They did a great job! Cost was about $270.
                  Karl
                  Bearhawk Bravo #1508B - Scratch Build (wings)
                  Northern Idaho

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