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Bearhawk Plans # 1217 started its construction journey 11 years, 8 moves, and 4 kids ago and finally took to the sky today under the identity N27AZ. The details: - Basic fuselage was started from a VR3 kit (TIG welded, not by me). The rest of it was gas welded by me. - Wings are scratch built...

All, I've been absent for 6 months on another project, but time to start turning wrenches on the Bearhawk again. Lots of new topics for me to catch up on, but I need some schooling on magnetos. I'm using toggle switches for the mags, and Aeroelectric Connections has a clever trick for ensuring...

Hello all, I can't seem to find documentation on installing the magneto harnesses, which probably means its very simple and these are silly questions, but here we go. For reference, I have the Slick 6393 and 6350 on my O-540. 1) does it matter which mag is connected to the top or bottom spark...

Given the number of variations on accessory cases and the fact that many accessories have ports on them, we need a thread dedicated to identifying those which are not clearly indicated in the various Lycoming manuals. (There is a single thread in existence but is titled Oil Cooler Lines). I...

What have folks done for drain holes in fabric? I haven't found a thread on this yet. Specifically: 1) just one at the bottom of the rudder? I don't actually remember seeing drain holes on rudders before 2) on both sides of aileron/flap ribs or just on the downhill side? Any other relevant...

I brought my engine and prop into the same room for the first time today and noticed one of the prop hub bolt faces didn't seem to have an indent for the crank flanges like the rest did (bottom right bolt in the bottom pic). The crank, for its part, has four protruding bolt flanges and two that...

I've had a hard time determining the style of alternator mount on my O-540, and I havent found a single forum online that thoroughly and pictorally describes the difference. It would be nice to have a few pictures of each style so future shoppers would know whether to select boss mount or case...

My oldest kids and I just had our first plamping experience at Noble County Airport (I10) east of Columbus. Wolf Run State Park is your typical, loud, crowded campground on a lake. But across the lake is a nice runway with a wide path to a primitive, shaded, and very private camping area near...

My Bearhawk project has a roommate! My brother is keeping his PA-32-260 in the hangar until Bob overhauls his engine, which means I've been flying it more than building recently. I decided to post this question here since the topic is applicable to the Bearhawk wing, and the community here is...

Ok, so this isn't quite Bearhawk related (except that the airplane in question is temporarily sharing my hangar with some Bearhawk parts) but I would be grateful for some advice here. My brother just bought a Cherokee Six and is keeping it in my hangar until the engine gets pulled for a Bob...

I bought this from ACS years ago and am just now getting around to using it. I immediately noticed the holes were slightly misaligned so that when you insert a nicopress sleeve it's not quite straight. Thus when it's clamped, the end result is a bit crooked. Then if I loosen the tool, rotate the...

Any kit or scratch builder is susceptible to making the mistake I just made, so a public confession wouldn't hurt. While riveting a wing skin to the nose ribs (poor access to the shop head) I apparently slipped the bucking bar off the rivet and caused a little dent in the skin. I removed the...

It's quite nice when someone volunteers to help in the shop, especially when it comes time to dimple and deburr the wing assembly. Little did I know how the many ways that could go very wrong. In a few places on the rear spar, the yoke of the squeezer caught on a protruding rivet or...

Good day all, My main tank's aft hole is out of round thanks to a drop on the floor. Any ideas on the best fix? All I can think of is buy a 3/8" NPT tap and run it through, but I don't like the idea of aluminum shavings in the tank. Thanks in advance. - Nic, #1217

Good day all, we talk a lot about corrosion on here and I figured it wouldn't hurt to have a thread dedicated to PICTURES of different types of corrosion, materials, and areas where it's been noticed so that those of us who aren't as metallurgically inclined can benefit from it. It can also be a...

I'm considering using stainless steel shipping strap material for my fuel tank straps. McMaster carries a 302 stainless material that is 0.75"x0.025" as specified. Based on it's estimated breaking strength, it looks to have the properties that you see around the web for 302 stainless. It would...

There are plenty of places on these aircraft that use machine screws. I'm embarassed to ask such an elementary question, but I couldn't find a definitive answer through Google. What drill bit size is considered "best practice" when drilling for these screws (#4's, #6's, and #8's)? I can find...

I have my spars and ribs assembled and cleco'd together and was pondering continuing with the skinning process before riveting the ribs to the spars. I would appreciate any opinions you all have. Pros: -It allows me disassemble anything that I need to, just in case. -It makes the...

What size bearings are used in the control stick pushrod? In the 4-place, there is a little pushrod that connects the control stick assembly to the bellcrank which is connected by cables to the elevator. I measured the shaft diameter on the bearings in my plans and they look to be somewhere in...

I did some searching, and it doesn't appear that a definitive conversation has taken place on rear float fittings. It looks like there are four options: Buy weld-on fittings from Avipro (I cant find a picture of what they look like on the fuselage) Copy the main gear fittings (more work and...