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I have an IO-540 and purchased my exhaust from Vetterman. I'm working on the cowling and finding that the exhausts from cylinders #1 and #6 do not clear the bottom cowl. Has anyone else experienced this issue? If so, any suggestion for how to address it? Thanks.

I'm not coming up with a good way to secure the flap pulley cable guards. I recall there was mention that securing them was recommended but not a must since they have bearings and you can torque down on the bearing which should lock the guard in place. Just curious what others may have done. Thanks.

I'm wondering what others have done to seal where the fuel tank filler necks protrude through wing skin, if anything. I had originally thought I would use a small bead of ProSeal, but wondered if there is too much movement up and down that would quickly break the seal. Also, any thoughts on how...

Looking for some input on the pros/cons of using AN fitting connections for fuel lines at the wing root to fuselage versus flexible rubber fuel hose to make those connections. Having had a C182, I know that Cessna uses the flexible hose to make the connections. I've also experienced the flexible...

Just wondering if anyone has mounted a Garmin roll servo in the wing at the bell crank and might have some pictures. I'd rather not mount it under the seat and the travel requirement is beyond the limits unless you weld a tab higher up on the stick, which presents a whole bunch of other issues.

I am in the process of roughing in my aileron and balance cables. I recall reading (cannot find the post now) that tensions are typically set at approx 30 lbs but that less on the aileron cables (25 -26lbs) makes for lighter stick pressures in roll. However, when I set my aileron cables to 26...

Has anyone purchased a Cummins polished aluminum spinner? They are out of Australia. For a 13" for Hartzel prop, it's about $400 including shipping. Still need to purchase Van's backplate and backplate doubler. My brother is building an RV8 and has received his. I've only seen pics but looks nice.

I was just informed by the DAR I will be using for my Bearhawk that it is not on the 51% amateur built list. He says that I will now have to complete the FAA Assembly Checklist (2011) where I indicate have to indicate percentages of fabrication or assembly for each area of construction. My...

I was reading the article "The Silence That Stuns" in the June 2016 issue of Sport Aviation (pages 24-26.) The author states for engines 390 cubic inches and above you should run 1/2" I.D. fuel line. I'm pretty sure I read somewhere in Bearhawk documentation that 3/8" was adequate. I have...

Hi, all. I just started the fabric for my horizontal stabs. Got as far as attaching to trailing edge and then had one of those 2:00 a.m. "wake-up calls"... How am I attaching the fairings? I was wondering how folks are going about creating attach points. (I have the wood airfoils installed...

I am in the process of mounting Garmin a/p servos. Pitch was fairly straightforward. However, It seems like there is more left-right travel than the roll servo will allow. With the optional longer crank arm, the servo is limited to about 2.9 inches. When I measure the travel at the bottom of the...

I made a small relief notch, bent them up slightly and added a small u-shaped "clip" out of aluminum that enclosed the ends.

Has anyone used Polyfiber's Mark II paint for metal? There's not a whole lot of information out there. Would like to know more about durability, etc. It IS a two-part catalyzed paint but does not contain the isocyanates and therefore does not require the fresh-air respirator. I've been told it...

Maybe the answer is obvious, but physics was not my strong suit... should the plane be in level flight attitude when you balance the elevators? Or does it matter?

I just melted down a bunch of tire weights to first get rid of the clips and debris and I created a two 3lb slugs. I will get the final weight by balancing and remelt them for pouring. But can someone tell me when 5 to 5.5 pounds is mentioned, is that total or per side? I though it was total...

Just wondering if anyone has a particular heater box they would recommend for the BH with an IO-540. Thanks.

I've been doing some research online on propellers. If you go to Hartzell's site and look at there recommendations for the Bearhawk they call out a CS 2-blade 84" for the O-540 (250hp / 2575rpm) but a CS 3-blade 84" for the IO-540 (260h / 2700rpm). I am installing a 260hp IO-540 DA45. Does that...