Back in the Game

[PropMan]

Since my last post, finished fuel system (just need to flow test), finished brake system including parking brake, layed out controls on panel, painted and installed panel, installed controls and made firewall pass thru. Next is engine baffles, wire up engine monitor, keep putting on parts for the last time ?

 

[PropMan]

Working on small details, throttle bracket, left windows sill, installed left rear window and closure piece.

 

[PropMan]

A friend once told me " The enemy of completion is perfection " so true Mark!
As i am doing final assembly of the LSA i find things I can do better, that will improve comfort without increasing weight but by grams. This is one. Upper window closure. But of course I had finished the window. Oh well, its almost done now. Lol

 

[PropMan]

Couple shots of the top window closure

 

[PropMan]

Sorting out window latch and catch, along with interior panel.

 

[Bcone1381]

I copied Bob's Patrol on the left window, which is a blade that rotates down into a slot cut into the window sill. I put a very slight angle on the slot so the window latch tends to stay closed....rather than vibrate open. The blade is close to the round window frame stock and makes for a neat clean snag free install.

 

[PropMan]

Back at it after Osh!
Mission shift?
I've decided to go bare bones. No Alternator, so no Adsb required. Pulled the GRT EFIS, Trig TY22 Transponder/ADSB out/in.
So, about a 12 pound reduction and 10k worth of stuff!
The calculations on hourly electric consumption is around 1 amp. I have a small solar panel with controller that produces 20watts/hr going in the skylight.
panel will consist of AV30e, Trig TY91, GRT 4000 eis, magnetic compass, 2.25" airspeed indicator, Ipad Mini 6, and my cellphone.
Working on wiring now!

 

[TJLEMAY]

What engine?

 

[SpruceForest]

I would perhaps consider keeping any provisions for ADS-B (while avoiding the actual installation of alternator, boxes, etc.)... would be very surprised if the UAS/AAM industries - fairly deep pockets there - do not continue to press for universal ADS-B equipage to address their need to cost-share their separation assurance/anti-collision problem with other NAS users. ACAS-xu is already baked in terms of standards work, and the universal ADS-B equipage 'safety/security' argument is plausible cover for further rule making activity. Just saying.

 

[PropMan]

I would perhaps consider keeping any provisions for ADS-B (while avoiding the actual installation of alternator, boxes, etc.)... would be very surprised if the UAS/AAM industries - fairly deep pockets there - do not continue to press for universal ADS-B equipage to address their need to cost-share their separation assurance/anti-collision problem with other NAS users. ACAS-xu is already baked in terms of standards work, and the universal ADS-B equipage 'safety/security' argument is plausible cover for further rule making activity. Just saying.

The thing is, I can add all these items later, but if I start with them, I can't remove them and currently operate under class b & c . Most of my flying, 99 percent, is outside the mandated adsb airspace anyhow.

 

[SpruceForest]

Exactly what I am saying... you have apparently already done some of the work figuring out how to get ADS-B in the plane, so if the provisions (bracket tabs, antenna mount, etc.) that are the hard part of retrofit are already done, you get the benefit of exemption from the rule with reduced time and/or cost to compliance if the regulatory environment changes. Sanity may prevail and ADS-B continues to be an airspace rule with exemptions and onus on UAV/AAM to stay clear of piloted aircraft. If not, a change in policy to move to portable units for non-electric aircraft would be my pref, but you'll be good either way.

 

[PropMan]

Installed comm antenna, wiring up Trig TY91

 

[PropMan]

Lots of small details this week, pushing to have a flyin aircraft in 6 weeks ? ??

 

[interstate al]

I almost wish I would have kept my original simple panel, but have never flown with glass so decided to jump in and give it a try. I'm a couple weeks away from my DAR inspection so no turning back now.

 

[PropMan]

I almost wish I would have kept my original simple panel, but have never flown with glass so decided to jump in and give it a try. I'm a couple weeks away from my DAR inspection so no turning back now.

Last year I owned a Aeronca 65TC, flew it to Osh and back then sold it. That's when I started thinking, I flew all that way with basic instruments an my Foreflight. It was a great trip. Took me a few months to make the decision to revamp the panel. Happy I did.

 

[interstate al]

Did you sell your 10" GRT Sport?

 

[PropMan]

Did you sell your 10" GRT Sport?

Not yet, was on vacation when I got a few inquiries

 

[PropMan]

More items off the "short list". Less parts laying around the hangar!

 

[PropMan]

Wingtips trimmed an trailing edge bonded

 

[interstate al]

I may be interested in up sizing my 7" after I've flown it a while. Drop me a message when you decide to sell. Thx

 

[PropMan]

Boot cowl going on, windscreen an trim are done, just need to install. Engine baffles an small details next week! Hopefully first Engine start mid month.

 

[PropMan]

Boot cowl complete! Windscreen on,now to paint the bottom Windscreen fairing.

 

[PropMan]

Carb heat-done, cowl going on so engine baffles can be fabbed an fit.

 

[PropMan]

One would think with all these tools out, aluminum shavings and chips, more would be done. Oh well, one piece at a time!

 

[PropMan]

Progress is sometimes measured in mm of posterboard. Lol. Tomorrow i convert these to aluminum!

 

[Bcone1381]

We could use a good "Creativity with Poster Board" thread in the Tips/tricks section.

 

[PropMan]

Lots to building baffles from scratch, almost done tho

 

[rodsmith]

I admire the talent it takes to make baffling from scratch. I'm so glad I bought the Van's baffling kit.

 

[PropMan]

I admire the talent it takes to make baffling from scratch. I'm so glad I bought the Van's baffling kit.

Thanks, wish I could have bought some. Just couldn't find anything suitable for the O200 and LSA cowl.

 

[PropMan]

Third attempt at the carb cowl. I really don't like the square shape on a curved cowl. Just me i guess

 

[jaredyates]

It is definitely a tricky spot! On our first plane I used the Vans FAB. I got the scoop from an RV builder and made new composite material to interface that with the aluminum of the cowl. If you want more curves, an option is to make up what you want by carving foam, then laying up composite material on your carved foam. This is a way to build whole cowls, just think of how much easier it will be to just make an intake scoop!

 

[PropMan]

It is definitely a tricky spot! On our first plane I used the Vans FAB. I got the scoop from an RV builder and made new composite material to interface that with the aluminum of the cowl. If you want more curves, an option is to make up what you want by carving foam, then laying up composite material on your carved foam. This is a way to build whole cowls, just think of how much easier it will be to just make an intake scoop!

I hope to fab one from aluminum, a few curves, but main goals are weight reduction and maintenance friendly, want to be able to remove the scoop from lower cowl for oil changes. With the O200 I don't see how the RV fab would be a good solution. So, off I go. ?

 

[PropMan]

Well, I scrapped last night's efforts this morning. ? Compromise is a necessity whe completion is priority!
It has curves, very subtle tho. Will hopefully finish up tomorrow.
Goals were met, its fairly light and will be attached with screws to allow easy access to lower inner cowl for oil change.

 

[Bcone1381]

Boy, I like how that turned out. Very Nice. I see you fabricated several peices. I often do the same. Its so much easier to rivet two parts together than to fabricate one part with multiple bends positioned in exactly the right places.

 

[PropMan]

Today I installed the rubber seal on baffles, so calling that part .

Now, confession time. Two weeks ago while finishing up the cowl i realized there wasn't enough space for a spinner back plate ?.....
Crap, what to do? I took some measurements, needed .40" more to clear the backplate. Called Sam at Saber mfg. Ordered extended drive lugs, upsized bolts to 7/16", got a .40" engine to prop spacer, while at it increased the face diameter to 6" for better clamping pressure. Had to fabricate a press to get the old lugs out, it never ends ?

All that done.
Short list gettin shorter!!!

 

[PropMan]

Calling the firewall forward done! Hope to run the engine next week. Just have to paint a few things, set timing, fuel flow test. If that goes well. AW inspection will be scheduled. Yee Haw! ?

 

[Sierra Skydog]

very nice install job Frank!

 

[PropMan]

Thanks Skydog!

 

[PropMan]

Windscreen fairings done !

 

[PropMan]

Cowl parts painted , all but nose bowl installed. Should be able to do that tomorrow. Then prop goes on. Yee Haw

 

[PropMan]

Props On!
I'll cut the spinner later, after AW cert is done.
covering ailerons and painting them now.

 

[PropMan]

Almost there!

 

[rodsmith]

Looking very good!

 

[PropMan]

Door paint complete!
covering the ailerons, then paint later this week if all goes well. Short list is shorter?

 

[PropMan]

Paint going on aileron #1, should have them painted and installed before Christmas!
waiting to see what day the DAR can come out after new year. Hope to be flying by end of January!
short list is real short!!!!!

 

[PropMan]

First start! Yee Haw Had to shut down, not showing oil pressure. Turned out to be instrument problem.
Oil temp and tach are working !
#3 valve cover gasket leaking.
All in all, a good day.
More to come!

 

[Cguy]

That's a pretty good Christmas present, good timing!

 

[PropMan]

That's a pretty good Christmas present, good timing!

Thanks, hope to have Airworthiness Inspection done in a couple weeks!

 

[PropMan]

I replaced the oil pressure gauge with a mechanical one, old school, and it works! Had to pull right baffle off to see what's leaking on the 3 valve cover. Was a torn gasket, thats 2 of 4, ugg. Sure wish they'd been more careful assembling, cost me an hour of work! Ran engine to verify gauge operation and check for leaks. All good now! Yee Haw. More to come

 

[PropMan]

All done that needs to be done for inspection! Hurry up and wait for a couple weeks. Time to get documentation together!

 

[PropMan]

Working on the spinner and adjusting the prop while waiting for Airworthiness inspection

 

[PropMan]

Working on the spinner and adjusting the prop while waiting for Airworthiness inspection

Static run gave me 2150rpm, target is 2300rpm.

 

[PropMan]

Spinner cut is done, tomorrow is fasteners and fillits. Hopefully the DAR will call this week and get the airworthiness cert done too!

 

[PropMan]

Props adjusted, painted and installed. Spinner done other than paint. Airworthiness Inspection next week! Yee Haw!! More to come.

 

[PropMan]

N964BW is officially an aircraft!
more to come!!!!

 

[PropMan]

First picture of the most recent Certified Bearhawk LSA

 

[Perry Kuznar]

Awesome! Looking forward to your future flight reports.

 

[Bcone1381]

There are not many LSA's flying in the USA. I suspect performance will be spectacular!!

For those who don't know, Propman is a retired professional Prop Fabricator. Your Prop looks longer than most to me (I could be mistaken, often am.) I'm curious what performance aspect you designed the prop to achieve. I also am curious to hear about your engine & how the package performs.

 

[Sierra Skydog]

Congratulations! Hope to see your flight data soon

 

[rodsmith]

Excellant! Always thought the LSA would be a really fun airplane. Would love to have one to go along with my 4-place if I could afford to.

 

[PropMan]

There are not many LSA's flying in the USA. I suspect performance will be spectacular!!

For those who don't know, Propman is a retired professional Prop Fabricator. Your Prop looks longer than most to me (I could be mistaken, often am.) I'm curious what performance aspect you designed the prop to achieve. I also am curious to hear about your engine & how the package performs.

Several years ago I sent a prop to Bob and he tested it on his LSA. With that data I designed this one for cruise performance, im sure it'll do well in climb also. It's 76" diameter with 44" of pitch. My calculations say I should see 1200-1500 fpm climb at gross with a WOT around 125-130 mph @ 2700 RPM. The engine is from Bob built by Mike. Hopefully over the next month I can do the Task Based flight testing and share results with everyone.

 

[Bcone1381]

Awesome! That design needs desperately more completions to boost its image. It may be the best kept secret in the utility EAB arena.

 

[PropMan]

I agree, low cost of operation, good useful load 1500lbs designedgross wt, and fantastic short field capabilities.

 

[OhioLSA]

Congratulations! Like the others, I'm looking forward to hearing about your flights.

 

[PropMan]

Me and the LSA have around 40 quality hours burning up gas and time! Enjoying it more each flight. Took it down for a few maintenance and finish items the past weeks.
Had to rework the fuel sight gauges due to cracking around the fittings. Not sure the cause, I was very careful in tapping the tubes and to not stress during assembly. There weren't any when I began flying.

Rearranged the panel, again

Painted the spinner, finally

Added a heat shield on one exhaust pipe, it was heating up a small spot on cowl.

Replaced the GRT EIS4000 with an WAPSI aero. I'll report on this later after some flight time.

Getting the wingtips prepped for paint. Next week's job is painting them.

Sure hope to make Byrds in September.

Oh, adjusted and repainted the prop to get a bit more rpm for climb performance. Now seeing 2350 at 6000ft DA and 1000fpm at gross