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Hi Allen, I had the exact same problem you described when I started. When dimpling the rivet holes in the "arms" of the K1000 nutplates, the female side of my dimple die was crashing into the center (threaded) portion of the nutplate, causing the arm to bend. This was a particular problem on the...

@jaredyates it is working like a champ! Thanks for all you do to support the Bearhawk community.

Finished fuselage fuel lines except for one connection that will be done just before interior fabric. Started fitting floor boards.

I'm struggling with placement and orientation of the AN804-6D bulkhead tee where the fuel lines come together at the front doorposts (Station B-P). It seems that if I just drill the former and install the T as shown in the Bearhawk Book (image attached here), I will end up with a localized low...

Time to reawaken this thread! I've hit a major milestone on my 4-place "A" model QB, having completed the majority of the "stuff" related to tailfeathers and things aft of the cabin that needs doing before covering. Control cables made up, elevator balances cast, VHF nav antenna mounted in...

Got the elevator balances cast and trimmed for weight.

The bearings used in my 4A match the 4th picture you posted - MS21152-2 (RE4H6 or REP4H6) rod end bearings which slide into the bearing mount tube and are cross-drilled and then riveted in place. The ones that came with my kit were unserviceable and I couldn't find replacements on the open...

Hi all, I'm seeing interference between the AN115-21 shackle and the flange at the top of the elevator horn, when the elevator is deflected down below the neutral position. At the "full down" elevator position, the shackle is about 35 degrees off line from the cable: ​ The previous builder...

In the "how to add months to your build" category, I've at long last found a method for making wingtip lenses to cover the bays where I will mount my FlyLEDs RV-10 "The Works" lighting system. Much of the time was spent kluging together a vacuum forming system, as my local lead on vacuum...

On my BH4 I ended up making a little bracket to position the fitting the way I wanted it.

First attempt at the adapter. Formed with hammer and vise and oxy-acetylene welded the washers in place. This one became a practice piece early in the process since I didn’t get the part positioned correctly when making the fold and ended up with a small crack in the part. The bending of the...

Working through first builder’s rudder rigging. The rudder pedals seem to have been mounted too far aft (5” behind centerline of firewall station). With this condition it’s impossible to depress the brake pedal with the rudder pedal at its forward-most travel. Unbolting the pedal assembly and...

Hi all, In July 2003, an OPTIONAL engineering change modified the length of the 4-place rudder horn from 3-1/4" "center to hole" distance to 2-1/4": http://bearhawksafety.com/4-place/changejul03.html In October 2007, a subsequent engineering change was released to change the design back to the...

Working my way through the main gear on my 20-year old kit. Disassembled struts and replaced the o-rings with fresh ones (purchased directly from Bob). Previous builder had run hard line from the gear leg directly to the caliper via the shortest possible path, leaving no extra loop to absorb...

Awww what a headache! IIRC the fuel tank cover is a structural part as it carries some of the load of the monocoque design. So getting the screws and screw holes right matters... IMHO it sounds like making a new cover is probably required. Are the nut plates already installed in the wing? If...

I drilled a #40 hole in the inboard and outboard flap "Bearing" tubes. For the inboard tube I also drilled a 1/2" hole in the bottom skin for access to the little hole in the tube, which I will close out with a plastic hole plug. ​ ​

I used these in a couple of tight corners. ​

At long last, I have both wings all closed up and ready to move to storage. That'll make room for the fuselage in the garage. I'll be starting by surveying the work done by the previous builder. It's on the gear with doors on and flight controls partially rigged, firewall in place and what looks...

For drilling aluminum I use low cost cobalt bits from Amazon, and treat them as consumable. I’ve been happy with this brand. Yardstore has a great reference table for bit sizes, which I refer to daily. I’ve used a #27 bit as a clearance hole for a #6 screw when installing nut plates. It’s a...

Here's what I finally came up with for aileron bellcrank travel stops. I used MS27405-6 "Type A" clamps (these are readily available) and 1/2” x 1/8” steel bar, gas welded.​ There's a bit of clear shrink tube over the tabs to provide some cushioning.