Nashville, TN - Bearhawk 5 Plans Builder

markpatrick717

New member
Hello everyone,

My name is Mark and I am a 30 yo Mechanical Engineer in the Nashville, TN area. I have always been passionate for aviation having spent my teenage years building and flying homemade R/C aircraft & drones. In fact, I like to image that I was one of the "pioneers" for the modern day drone craze as back then I was building them from scrap wood, CD cases, and old Wii remotes (to rob the accelerometers from them). Somewhere along the way I got away from all that and became a Mechanical Engineer, got married, started a machine shop side business, and now here I am. I actually don’t have my pilot’s license yet, and it’s been about 15 years since I’ve flown in a GA aircraft. I’ve also never flown in a taildragger. All things I'd like to fix soon enough.

I purchased plans to start a Bearhawk 5 build in May 2026 and I have spent the last few weeks working on converting the plans into CAD. I am extremely skilled in Solidworks as that is what I primarily use in my day to day job. I find it very helpful to visualize how the parts assemble and I plan to use it to design fixtures/jigs/etc from the model.

Why plans instead of a quick build?
1. I am looking for a dragon to slay, so to speak. I have a strong desire to accomplish a few monumentally difficult things with my time and this is one of them. I've been telling my wife I will build a plane one day for about 10 years and its finally time to get started.
2. Quick build kits are currently out of my price range. Building a plane is very expensive yes, but with a plan's build I don't need it all at once and with the current price of quick build kits...yikes!
3. I recently found out my late grandfather built a plane back in the late 70's/early 80's and this feels like a small way to connect with him in some way. I actually didn't know about this until after I bought my plans. Somehow nobody ever told me this and unfortunately I don't have any more information on what he built. My grandmother simply says he built and flew a plane and that's all I have to go off of.


Goals & Build Log
I'd like to have this plane flying by the time I'm 40 and have my PPL w/ taildragger endorsement by then as well. That's a ~10 year build goal and I believe I can do it. During the process I hope to make some friends, learn a lot, help others with their builds, and enjoy the process.

I have started my EAA build log, which can be found at this link: https://eaabuilderslog.org?s=BearhawkFive

At the time of writing the only entries are for acquiring my plans and building a 4'x20' workbench in my shop. I will do my best to keep the build log current moving forward.



If there's anyone in the area who'd like to connect please let me know. I am also going to join one of my local EAA chapters, likely #863.
 
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@markpatrick717 I'm awaiting my BH5 plans and am planning on doing the CAD thing, too. One thing I haven't figured out is the best route for the ribs. I don't think they can be modeled using the standard sheet metal tools given that they require deformation of the metal. I see on your build log you've already done them. Mind sharing the process you used? And do you think you're going to CNC the blanks or will you hand cut?

Also, your pallet racking workbench is genius! I have some extra and I might just have to steal borrow your idea.

P.S. Is 717 a reference to a Pennsylvania area code? I live in 717 right now...
 
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