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Jared and Tabitha's Bearhawk Construction Log

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Category: Cabin and Cockpit

Work in the Cabin and Cockpit

Bending at the Brake

Posted on December 5, 2011August 23, 2012 by Jared Yates

This afternoon I stopped by Brad’s place and used his brake to bend the steel pieces for the aft window. Wasn’t it nice of him to let me do that? While I was there I also bent the aluminum pieces that will go on the windshield posts to help support the aft edge of the…

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Testing the D100

Posted on December 4, 2011August 23, 2012 by Jared Yates

In another stressful moment of truth, today I powered up the D100 for the first time. I started by verifying each pin in the wiring again. Here’s the unit that I found on eBay. It’s slightly used but in great shape: Here’s where the backup battery hatch is. I was surprised to see a battery…

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Cargo Door Gas Strut

Posted on December 1, 2011August 2, 2012 by Jared Yates

I cleaned up and primed the fuel line support that I welded on last time: Then I made one just like it and installed it on the right. While I had the primer out I sprayed a coat on the intake scoop to see how my fiberglass work was coming along. Sometimes it’s hard to…

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Fuel Line Tabs

Posted on November 27, 2011August 2, 2012 by Jared Yates

I came out for little while today to sand the last layer of filler and add another. AC 43.13 says that fuel lines should be supported every 16 inches. I can’t see how it’s possible to span the distance from the aft side of the front door to the clamp on the diagonal tube under…

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Adding Filler

Posted on November 21, 2011August 2, 2012 by Jared Yates

In replacing the engine mount bolts, I found that I needed a second washer to get the castle nut in the right place. I installed those washers on each one, but I didn’t put any cotter pins in yet. Odds are good that I’ll have to take the engine off again before we fly. I…

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Oil Cooler Continued

Posted on November 8, 2011August 2, 2012 by Jared Yates

I added the first layer of superfil on the windshield fairing, and another layer on the intake scoop. It will take several layers and lots of sanding to make them look reasonable. The oil cooler support will attach at the crankcase bolt just above the number 2 cylinder. I removed the original case bolt and…

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Still More Fiberglass

Posted on November 1, 2011August 2, 2012 by Jared Yates

This evening I worked on trimming the windshield fairing. I wanted to have an equal distance above and below the fold point, so I started by drawing a line along the the fold point. I used a square and a sharpie to mark a line along the fiberglass and used the belt sander to trim…

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More Fiberglass

Posted on October 31, 2011August 2, 2012 by Jared Yates

Today was a quick session. I added two more layers of fiberglass on the windshield and one more layer on the intake scoop.

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Fiberglass Windshield Fairing

Posted on October 21, 2011August 2, 2012 by Jared Yates

This morning I started on the fiberglass windshield fairing. First I applied contact paper to the windshield and boot cowl so that the epoxy wouldn’t stick to the expensive bits. Then I put a nice coat of automotive wax on the contact paper to make sure the epoxy didn’t stick to the inexpensive bits either….

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Oil Cooler Support

Posted on October 20, 2011August 2, 2012 by Jared Yates

This morning I started by finishing the rest of the lightening holes for the headrest parts. Next I made a few doublers for the oil cooler area on the back left baffle. I’m really guessing here with how much support I’ll need. I’ve studied a few other airplanes and copied what I have seen. I’ll…

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Smurf Extract

Posted on October 18, 2011July 8, 2012 by Jared Yates

The fiberglass from yesterday was cured well, so I used the belt sander to trim the outer edge further. To fix those problems I mixed up a batch of superfil, aka smurf extract. To spread the filler evenly in the corner, I used another hotel key. These have turned out to be quite handy and…

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Engine Intake Scoop

Posted on October 13, 2011June 30, 2012 by Jared Yates

Since the first headrest turned out well enough, I bent the parts for the other 3. I made some measurements for what type of support I’ll need to make for the oil cooler also. Since the intake scoop is going to need a fiberglass flange to attach to the cowl, I’m going to construct it…

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Headrest Structure

Posted on October 4, 2011June 30, 2012 by Jared Yates

Yesterday I located the oil cooler on the left rear baffle. Today I cut out some aluminum tubes to use as the supports that will keep the flanges from bending together when I tighten the bolts. Unfortunately, I ordered the wrong size of tube! It’s too small and the bolts won’t fit through. I finished…

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Locating the Oil Cooler

Posted on October 3, 2011May 6, 2014 by Jared Yates

While I was thinking about the aileron control cables, I realized that my previous location for headset jacks wasn’t going to work. I cut the old bracket off and this is what was left: I used the die grinder and files to clean off the weld bead. It’s always frustrating when I end up making…

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Landing Light Bracket

Posted on September 30, 2011June 30, 2012 by Jared Yates

This morning I sprayed the last coat of polyspray on the flaps, ailerons, and rudder. I came back to the hangar after lunch to debur the left door skin and start making the landing light bracket. For a while I wasn’t sure if I was even going to install a landing light. It certainly isn’t…

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Window Planning

Posted on September 26, 2011June 30, 2012 by Jared Yates

Tabitha came out to the hangar today, so I took a break from the stinky covering. We worked together to create a cardboard template for the new left rear window. We also marked and cut the left lower front door skin, which we’ll replace with something transparent. Tabitha wants bigger windows, and having windows does…

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Covering Spray

Posted on September 16, 2011June 30, 2012 by Jared Yates

Our seats are at the upholsterer, so I need to hurry up and finish the headrests. I cut out some 8×8 .032 aluminum squares to use as the face and top. I used the bench grinder to remove some of the larger bits of the weld bead from the exhaust pipe. Since the temperature has…

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Back Seat Seatbelt Tabs

Posted on August 27, 2011June 29, 2012 by Jared Yates

With the lower cowl in place I started preparing the outer fiberglass scoop that will cover the FAB and direct the intake air to the inlet. I found an RV builder who had a scrap scoop, which was quite affordable. I only needed a very small piece of the original, so any defects or mistakes…

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Initial Prop Install

Posted on July 5, 2011June 26, 2012 by Jared Yates

Today I connected the blue LED that will become the parking brake annunciator. Since the parking brake valve is just a check valve, it could be especially troublesome to land with it in the closed position. The brakes would apply normally, but they wouldn’t release! I’m planning to make this blue light come on any…

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Parking Brake Switch Wiring

Posted on June 29, 2011June 26, 2012 by Jared Yates

This morning I made my first attempt at a parking brake indication switch. It didn’t turn out very well. I’d like to be able to adjust it so that it accurately indicates the valve status. It may take a bit more head scratching.

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Parking Brake Control Bracket

Posted on June 28, 2011June 26, 2012 by Jared Yates

I needed to make a new bracket to support the control cable in the new configuration. I removed the old brake lines, and while I was in the area, I replaced the remaining firewall tab clecos with bolts.

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Reversing the Matco Parking Brake

Posted on June 27, 2011June 26, 2012 by Jared Yates

Our spinner came with it’s original white paint, which matched the Husky that it came off of. I knew that we were going to have to repaint it one way or another, but we’ve both always preferred to have a polished spinner. I figured that I didn’t have anything to lose by stripping off the…

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Antenna Mounting

Posted on June 21, 2011June 25, 2012 by Jared Yates

6/21 1015 ground shields, drill left com antenna, add tab to tail post 1235 2.4 hours This morning I connected the rest of the audio shields to each other. I didn’t have any of the one-ended crimp-on terminals so I just used one half of a yellow crimp-on splice. I found a good spot for…

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Window Re-design

Posted on June 20, 2011June 25, 2012 by Jared Yates

This evening Tabitha came out and we worked more on the left rear window design. We are making a cardboard template that will be the same size as the final lexan piece. This will give me something around which to fabricate a steel structure. The new window will be much larger than the original, on…

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Troubleshooting the Audio Amp.

Posted on June 16, 2011June 25, 2012 by Jared Yates

After some email help from Bob Nuckolls I was able to get the audio amplifier circuit working. I tested it by listening to music on the audio input. I’ll have to wait until everything is up and running before I can fine tune the volume resistors.

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Powering Up the GPS

Posted on June 15, 2011June 25, 2012 by Jared Yates

Today I brought out the Garmin 430 unit so that I could test my wiring. This is a bit of a stressful moment, since the unit is very expensive and I ran all of the wires by hand. I powered the circuit with fuses and used my meter to re-verify every single pin to be…

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Intercom Testing

Posted on June 14, 2011June 25, 2012 by Jared Yates

It has been a couple of weeks since I’ve been able to get back to work. I installed the rear audio jacks and created the d-sub connection that I wrote about last month. Since the three non-pilot jacks all share a common audio source, I had to find a way to connect several small wires…

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HS34 Installation

Posted on May 31, 2011June 25, 2012 by Jared Yates

Today was a long productive day in the hangar. I started by installing the HS34 to make sure that the bracket was in a good spot. Here’s how the instrument panel looks as of today: I finished the audio wiring for the front two jacks, and went home to escape the mid-day heat. Our windshield…

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Parking Brake Adjustments

Posted on May 17, 2011June 25, 2012 by Jared Yates

Today I made a bracket for the parking brake valve. This will support the end of the cable. I installed a cable control and found that I had a bit of a problem- it was backwards. I definitely want for the cable to be pushed forward when the parking brake is released, but in my…

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Wiring the GNS430

Posted on April 14, 2011January 21, 2012 by Jared Yates

Here’s the rudder. All of the taping is done and it’s ready to smooth. I connected several more wires to the 430 today. It has a bunch of them, and it would have been many more if I were using a remote annunciator and indicator. The connectors on the back are divided into the three…

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Rudder Lacing and Taping

Posted on April 13, 2011January 21, 2012 by Jared Yates

These nice weather days have provided an excellent opportunity to spend some time in the hangar. Here’s the rudder after the first coat of polybrush: I finished the rudder rib stitching in about an hour and a half. This is one of those skills that gets faster with experience. I marked the areas for taping…

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Covering and Wiring

Posted on April 12, 2011January 21, 2012 by Jared Yates

Today I shrank the fabric on the rudder and applied the first coat of polybrush. While I was waiting for one side to dry I returned to the wiring. My 430 rack was a second-hand find, and the previous owner chopped off the wires right behind the connectors. I took all of those little stubs…

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Wing Wiring

Posted on April 7, 2011January 21, 2012 by Jared Yates

Today I finished wiring the D100. The last step was to splice together the DSAB wires, which are the wires that allow the three Dynon units to communicate with one another. I also started working on the wires that run through the wing conduit. I realized that I need to order more cable for the…

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Dynon Wiring

Posted on April 6, 2011January 21, 2012 by Jared Yates

I started out today by drilling a hole in the firewall for the EMS wires. The thermocouple wires for the EGT and CHT sensors are fairly large, so the hole is about 1/2″ in diameter. I added a serial plug for the HS34, since I learned that it also needs to be able to receive…

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Aileron Balance and Wiring

Posted on April 5, 2011December 25, 2011 by Jared Yates

Today I had a visit from fellow Bearhawk Builder John Rheney. It was great to have him stop by, since most of my visitors are not Bearhawk builders. We were able to talk about several of the special challenges and hard decisions in the building process. My Aircraft Spruce order from Sun-n-Fun arrived, and I…

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Installing the Alternator

Posted on March 22, 2011December 25, 2011 by Jared Yates

In the last installment you might remember that I damaged the ebus alternator by shorting it to the airframe ground. The good news is that I was able to find a replacement for just the diode, and thus reuse the circuit board and mounting hardware that I got from Bob at aeroelectric.com. I clipped the…

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Making Smoke

Posted on March 16, 2011December 25, 2011 by Jared Yates

After a few trips around town to find the right length of grade 5 bolts, I was able to install the last bolt for the alternator bracket. I finished the main wiring for the electrical system, so I figured I’d turn on the master and see if it works. Since there aren’t any circuits connected…

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Prop Governor Studs

Posted on March 7, 2011December 25, 2011 by Jared Yates

Lately I’ve been fiddling with a Hartzell prop governnor that I got from another builder. The flange is designed so that the studs have to be just the right length, and my existing studs are too long. I spent a little while fiddling with it today before I finally decided to give up on the…

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P-leads and Wiring

Posted on March 3, 2011December 25, 2011 by Jared Yates

I finished up the p-leads today for the Bendix mags. These mags require a special terminal, and I was able to find a used set of terminals in good shape. I used a single-conductor shielded cable, which was especially troublesome to strip and separate. The weave of the shield is very tight and it took…

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Architecture Wiring

Posted on March 1, 2011December 18, 2011 by Jared Yates

I sold a motorcycle and was able to buy some much-needed parts. The first is this Plane Power AL12-E160/C Alternator. This is the case mount unit since our engine doesn’t have the mounting boss. The parts look great! The other big part of my order was the probe package for the Dynon D180. This is…

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Battery Bus & P-Leads

Posted on February 16, 2011November 14, 2011 by Jared Yates

Today I continued with more wiring. I finished the SD-8 ammeter wiring that I started yesterday, and made a cable for the starter: I found a covered fuse block to use for the battery bus. Since it is on the engine side of the firewall I was worried about an uncovered block getting dirty. The…

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SD-8 Wiring

Posted on February 15, 2011November 13, 2011 by Jared Yates

Today I continued with wiring the SD-8 and it’s components. I have a copy of the Z-13/8 drawing in the hangar, and I’ve been drawing lines on the diagram to note wires that are complete. First, I made a hole in the firewall for the alternator output wires. Then I ran the wires to the…

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Electrical Distribution Panel

Posted on February 10, 2011November 13, 2011 by Jared Yates

I deburred the lightening holes in the electrical panel, and removed all of the sharpie ink from layout planning. Next it was time to get to work populating that panel. I started with the diode bridge for the SD8 circuit. First up is the resistor: Here’s the resistor for the capacitor: Here are most of…

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Wire Routing

Posted on February 4, 2011September 24, 2011 by Jared Yates

I started out today by putting the control sticks back in. I drilled a hole in the bottom of the left stick that will allow the push-to-talk switch to fit through. Next I attacked the 0.025″ aluminum panel that I’ve spent the last few days making. I didn’t weigh it before and after, but hopefully…

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Window Planning

Posted on February 3, 2011September 24, 2011 by Jared Yates

Tabitha came out today and we did some planning for the windows. With the top of the fuselage uncovered it was hard to realize how dark the back seat area would be with small windows. So we used a few blankets and such that we had around to serve the role of the covering material….

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More Electrical Infrastructure

Posted on February 2, 2011January 30, 2014 by Jared Yates

Today I picked up where I left off yesterday, adding a few more parts to the power distribution panel. Next I started making a few parts to mount the audio amp and the low voltage warning. The next challenge was to cut a hole with the odd shape of the d-sub. The crowbar overvoltage module…

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Power Distribution Panel

Posted on February 1, 2011August 6, 2011 by Jared Yates

Today a few more parts came in: Alan stopped by and made some airplane noises: Since it was handy, I took a picture of my load analysis: I spent quite a bit of time with Bob N’s Z13/8 drawing and a handful of parts, trying to figure out how it all needed to go together….

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Cabin Heat Valve

Posted on January 18, 2011April 3, 2011 by Jared Yates

Today I stopped by to visit my new friend Alan Waters. I asked him to weld some flanges onto my adapted cabin heat box, but instead he offered for me to come over and do it myself. This was an awesome opportunity that I didn’t want to miss! This box needed an additional hole and…

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Governor and Carburetor

Posted on January 14, 2011March 10, 2011 by Jared Yates

Today was a good day for staying close to the propane heater. With the topic of the governor installation on hold, I turned my attention to the carburetor. With all of that done, I was ready to figure out where to route the engine controls through the firewall. I wanted to keep the throttle cable…

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Baffles and Avionics Support

Posted on January 2, 2011March 10, 2011 by Jared Yates

The new engine baffle piece that I ordered from Vans came in today, along with a plate for supporting the mixture and throttle cables. In the picture below you can see the difference between the new and old baffles. The old piece on top also has bends where I tried to make it line up…

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Making Electronics

Posted on January 1, 2011March 9, 2011 by Jared Yates

Our Bearhawk is going to need two little circuits that I’m going to try and make. The first is a low-voltage warning module. They Dynon EMS has a built-in warning for low voltage, but this little circuit will be a stand-alone warning for a system that is fairly important. I used the Bob Nuckolls designed…

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More Panel Holes

Posted on December 22, 2010March 9, 2011 by Jared Yates

I was able to get home for a day or so amidst lots of training. I thought about how to best fix the left rear engine baffle that I cut incorrectly last month, but decided just to order a new one from Vans instead. It was only a few dollars and will save a day’s…

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Cutting out the Windows

Posted on November 25, 2010March 9, 2011 by Jared Yates

Tabitha has wanted to change the window layout ever since she saw an airplane with bigger back windows. Today she cut out the existing frames on the left side. While I was at Matt’s hangar he sent me with a length of spring to use for the rudder return springs. While Tabitha was working on…

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Installing the Starter

Posted on November 18, 2010March 9, 2011 by Jared Yates

After seeing the amount of stress that the Garmin racks would place on the panel, I started thinking about how I can add some bracing to the back. I spent a few minutes today checking to see if that support could be as easy as a piece of aluminum angle across the two diagonal tubes,…

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Instrument Panel

Posted on November 17, 2010March 9, 2011 by Jared Yates

Today I finished enlarging the center hole in the instrument panel and attached the two Garmin racks. I added the Dynon trays, but did not yet cut the left flange off of the right tray. I’m planning to wait until I get the HS34 and its mounting hardware. Next I enlarged the holes for the…

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Instrument Panel

Posted on November 16, 2010March 8, 2011 by Jared Yates

I started off today by getting some silver polyspray onto the patches. Don brought up the instrument panel, so I started with the deburring process while I waited for the polyspray to cure. I added the ELT controller to the left side, since it is something that is low on the ambidexterity priority list. I…

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Seat Foam and Silver

Posted on October 18, 2010March 8, 2011 by Jared Yates

Tabitha came out today and we glued the foam together for the back seat cushion. I had planned on a 3″ thick bottom cushion for the back seat, but with a little bit of testing we realized that the headroom would be limited with a full 3″ cushion. Instead, Tabitha carved out much of the…

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More Position Lights

Posted on October 4, 2010March 8, 2011 by Jared Yates

I stopped by Laney’s fly-in towards the end of the event, but there were still a few airplanes left, including a new Maule. I liked the step on the landing gear, and perhaps it’s worth investigating. In the hangar, Tabitha worked on getting the seats while I started roughing in the position light mounts. The…

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Positioning Position Lights

Posted on September 27, 2010March 8, 2011 by Jared Yates

Here’s the antenna block that I was working on in the last session. I couldn’t figure out how to clamp it for drilling, and even if I did, I don’t think I’d have enough room between the elements to get in there and install the nuts and terminals. Meanwhile, I did make some progress on…

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Stainless Firewall Shields

Posted on September 26, 2010March 8, 2011 by Jared Yates

Today I tried a Tony Bingelis technique for making shields for firewall pass-through parts like engine controls and wires. The idea is to provide an equal level of fire protection for areas that use rubber grommets. I started by choosing a “die” from my die collection, also known as a socket set. I’ve found sockets…

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Copper Strips, Parking Brake

Posted on September 25, 2010February 22, 2011 by Jared Yates

In the week since I last worked, the JB weld on the ANL mount cured nicely. I filed it flush with the back of the mount and then realized that it hadn’t occurred to me to find out if JB weld was electrically conductive. It turns out that it isn’t, which I was glad to…

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Brake Lines

Posted on September 15, 2010February 22, 2011 by Jared Yates

I spent an hour today installing the brake lines. I think that they’ll work fine with a little bit more support.

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Priming and Wingtips

Posted on September 14, 2010February 19, 2011 by Jared Yates

After spending a few minutes making holes in my aluminum welding practice pieces, I got back to productive work. I cleaned up the skylight parts and sprayed them with some temporary primer. I also trimmed the little grounding bus off of one of my fuse blocks, since I’m going to be using the brass forest…

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Seats and Populating the Firewall

Posted on September 13, 2010February 19, 2011 by Jared Yates

Today I spent time adding more stuff to the firewall. While I was doing that, Tabitha was working hard on shaping the seat foam. I added the nutplates for the battery buss, which is going to provide power to things that will be powered even with the master switch off. I finished installing the shunt…

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Nutplates for Firewall

Posted on September 7, 2010January 12, 2011 by Jared Yates

I don’t have any pictures for today, but it was still a productive session. I installed the last gusset for the seatbelt tab, and installed several nutplates for the firewall-mounted electrical accessories including the battery and starter contactors. Today George Carter stopped by to visit too. I met George at the hardware store a while…

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Seatbelt Tabs, Skylight Tabs

Posted on September 4, 2010January 12, 2011 by Jared Yates

Here are the tabs that will support the shoulder harnesses for the front seat passengers: Most of the time today went to working on the flap handle and the seat foam, but I didn’t take any pictures. Tabitha is getting pretty good with the electric knife!

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Welding Skylight Tabs

Posted on September 3, 2010January 12, 2011 by Jared Yates

Since I used round tube for the skylight structure, I’m welding little tabs onto the tubes. These tabs will get nutplates and will hold together the aluminum-acrylic-steel sandwich. I originally sized the tabs so that they would fit a standard nutplate, but then I realized that I really don’t need to install nutplates on the…

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Populating the Firewall

Posted on August 31, 2010January 12, 2011 by Jared Yates

Today I started planning to add a few more items to the firewall. I’d like to make sure that I don’t try and put two things in the same spot, and also make sure that I can have maintenance access to items that need it. Tabitha also came out for a little while and cut…

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Seat Foam and Brakes

Posted on August 26, 2010January 12, 2011 by Jared Yates

Tabitha came out today and started working on the seat foam while I made some of the rigid brake lines. While she was working with the electric knife, I installed some nutplates in the firewall. For such a big sheet, the blind dimple die is really useful. It’s very important to stay focussed with this…

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Brass Grounding Tabs

Posted on August 25, 2010January 4, 2011 by Jared Yates

Today I started making the brass grounding blocks. My orders from Stein and All Electrics came in- great fun! The brass terminal strips were available from Stein for $1 each, so a few minutes of soldering and a $3 piece of brass from the hobby shop saved me $50 or so from B&C. The flux…

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Fuel Lines, Flap Handle

Posted on August 18, 2010January 4, 2011 by Jared Yates

I finished making the wing fuel lines today and started on the fuel quanity gauges. I used files and emory cloth to debur the holes that Wade punched into the battery box yesterday, and used the band saw to rough cut the aluminum flap handle piece to shape. I used files and emory cloth to…

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Battery Box and Avionics

Posted on August 12, 2010January 4, 2011 by Jared Yates

Today I finished the last fuel line that I can make without putting the wings back on. While I was at the hangar I also counted the pins on the Garmin racks so that I could make a shopping list for the d-sub parts. I think if I order 50 male and 50 female pins,…

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Elevator Trim Pushrods

Posted on August 10, 2010November 28, 2010 by Jared Yates

Today the river of airplane parts is flowing again with the arrival of my Oshkosh Aircraft Spruce order. I added the dimpled nutplates to the little boot cowl piece, and used my new fuel lube to install several NPT thread fittings that were on hold pending its arrival. Since my repaired elevator trim pushrods didn’t…

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Reinventing the Window

Posted on August 2, 2010November 28, 2010 by Jared Yates

Another suitable title for this post would be “Defenestrating the Stock Window Design.” Tabitha and I have been discussing windows ever since our cookout and during our visit to Oshkosh. She says that the existing stock windows aft of the front doors are too small and too few, while I contend that they are completed…

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Fuel Selector Installation

Posted on July 21, 2010November 28, 2010 by Jared Yates

Today my goals were to install the fuel selector and gascolator, and to run as many fuel lines as time and supplies would permit. As I mentioned last time, locating the fuel selector has been tricky. The best location interfered with the little trapezoid-shaped tab that came from the factory. That tab is made out…

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Starting Fuel Lines

Posted on July 20, 2010November 28, 2010 by Jared Yates

Since I’ll be on the way to Oshkosh shortly, I wanted to spend some time figuring out the fuel and brake systems again. This will allow me to buy the few remaining parts that I don’t have. I have had some 3/8″ .035 5052-0 line for a while, but I figured I should try bending…

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Instrument Panel Layout

Posted on July 19, 2010September 30, 2010 by Jared Yates

While we were on vacation with Tabitha’s parents, Tabitha’s dad and I spent some time working on the instrument panel layout. He’s going to try to cut it on one of his CNC routers, so we were measuring and researching the hole dimensions. If it works, this will save some time of cutting and filing…

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Welding and Priming

Posted on July 1, 2010September 30, 2010 by Jared Yates

The only parts that didn’t survive the move when we purchased the project were the tail struts. I haven’t been able to find them anywhere, and neither has Richard. This is unfortunate, since they are fairly expensive. I was able to buy another set from Mark, though he cautioned that they may need a length…

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Test Fitting the Tail Pieces

Posted on June 30, 2010September 30, 2010 by Jared Yates

Before I proceed with any of the covering steps, I want to be sure that I understand exactly how the tail goes together. To check all of this out, i tried a test fit. I repositioned the engine lift over to the downhill side of the airplane so that I could level it left-right. Our…

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Rudder Pedal Springs

Posted on June 29, 2010September 30, 2010 by Jared Yates

Sometimes building an airplane involves taking three steps forward, sometimes it means taking a couple of steps back. Today I spent a little while adapting some springs for the rudder pedals, but I don’t really like them. I also spent a while making the third version of the boot cowl panel, and also made it…

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Rudder Pedal Geometry

Posted on June 24, 2010September 30, 2010 by Jared Yates

In our last episode, I was moving the rudder pedals forward to address the potential over-center problem that Mark at Avipro brought to our attention. Back when Richard was building, the consensus was to locate the rudder pedals for ergonomics. Subsequent experience led to a new recommendation to locate the rudder pedals exactly as depicted…

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Cable Guard Nutplates

Posted on June 23, 2010September 30, 2010 by Jared Yates

Today Tabitha came to help. She installed nutplates in the floorboards for the rudder cable guards while I took care of a few loose ends. I was recently reading through the Beartracks newsletters and came up with a few things to check on. The first was the flat plate of steel that joins the two…

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Elevator Patch and Cable Guards

Posted on June 10, 2010September 30, 2010 by Jared Yates

Today’s efforts include a morning session of fabric work and an evening session of sheet metal work. Richard had started the taping process on the tail pieces, but some are still in the works. Since one side still had exposed rib laces, I figured that I would check to be sure that they were spaced…

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Drill, Debur, Dimple, Nutplates

Posted on June 4, 2010August 21, 2010 by Jared Yates

Today was a day with lots of hours and not a lot of pictures. I finished the work on the left air intake, which included dimpling the boot cowl and cutting countersinks into the plastic vent. I also dimpled all of the holes in the boot cowl skins that will get rivets, except for the…

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Engine Mounts and NACA Scoops

Posted on June 3, 2010November 28, 2010 by Jared Yates

I’ve been watching the price of the engine mount rubbers for the past few months, and the trend seems alarming. In the 2008 Vans Accessory catalog, they were $40 per lug (for a total of $160). Today Vans sells them for $125 per lug, or $500 plus shipping! Yikes! I was surprised to see the…

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Headset Jacks and Door Sill

Posted on May 28, 2010May 20, 2011 by Jared Yates

I started out today by finishing something from last week. While I had the torch out, I also added a few more parts to the skylight area. First up were some plates for the headset jacks. This plate goes on the spanwise mini-bulkhead that I’m creating at the aft side of the skylight. This is…

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Repositioning Door Area Flange

Posted on May 20, 2010June 28, 2010 by Jared Yates

Today was a two-part day. In the first session, I used a dremel tool to remove the weld on the vertical portion of the door threshold at the forward end. This was to allow for repositioning that piece so that it would attach properly to the aluminum piece that goes there. This also involved cutting…

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Seats and Engine Mount

Posted on May 15, 2010June 28, 2010 by Jared Yates

Today Tabitha came out again to finish squeezing some more wingtip rivets. We also tested the glue on the foams to make sure that it wasn’t going to dissolve them. The glue checked out OK, so we glued one of the bottom cushion combinations. Tabitha marked it for cutting and spent some time thinking about…

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Tailwheel Spring and Wingtip

Posted on May 9, 2010June 28, 2010 by Jared Yates

Tabitha came out today too and we made some good progress. I was at a stopping point with the tailwheel spring because I didn’t have a drill that would handle larger bits. It had a temporary bolt in place of the AN-7 that is supposed to go in there. With the new drill I was…

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Seat Foam Ergonomics

Posted on May 8, 2010June 28, 2010 by Jared Yates

Today Tabitha came out to help. With the seat pans finished, it was time to start thinking about cutting the foam for them. But first, the flooring supplies came in, both the foam padding and the top layer. The plan for the seats is to use one inch of firm tempur foam on the bottom,…

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Welding Skylight Tubes

Posted on April 25, 2010June 28, 2010 by Jared Yates

I started cutting and adding in some of the new skylight tubes today. I cut a notch into the tube to make it match the mounting area. Mysterious note from the future! I learned in retrospect that the following picture shows a tube that is ground a little too much. It should have been a…

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Skylight Modifications

Posted on April 24, 2010June 28, 2010 by Jared Yates

Today I finished the back seat covering. Now it’s ready for some airplane noises. After I finished the back seat I took a little lunch break. Fellow EAA 731 member Kevin Ball stopped by and we spent an hour or so talking about the airplane, then I went over to Bart’s to take a look…

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Welding, Casting, Covering

Posted on April 23, 2010June 27, 2010 by Jared Yates

asting complete on 1, elt brscket on, control sticks done, cast 2, cover front seat bottoms and backs 1800 lunch? With one aileron balance tube done, the second was easy. I’ll elaborate more on the process this time. I used tire weights that were really dirty. I would tilt the pan, and direct the torch…

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Back from Sun-N-Fun

Posted on April 22, 2010June 27, 2010 by Jared Yates

It’s been a while since the last building entry, but I’ve been out of town more than usual. I just got back from Sun-N-Fun with a new list of ideas and a few new parts. One of my SNF finds was these LED position lights. If I didn’t already have the aeroflash lights, I would…

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ELT Antenna Bracket

Posted on April 2, 2010June 29, 2012 by Jared Yates

Today I was in the mood for some welding. First, I noticed back when I primed the headrests that I had missed a problem with one of them. I had started to cut one of the horizontal tubes, then realized that I was cutting in the wrong place. This left a scored line around the…

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Bending Cable Guards Again

Posted on April 1, 2010June 7, 2010 by Jared Yates

I needed to bend the new aft cable guards again, so this time I took some pictures of the process that I described earlier. Thanks again to Brad and Joel for letting me use their machinery! The weather was nice, so I put the blanks into the car that Dad was driving down to the…

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Cable Guards and More Parts

Posted on March 31, 2010June 7, 2010 by Jared Yates

Today I spent some time going through a big order of parts and hardware. This order included lots of stuff, including the rest of the screws for the wing inspection panels. Dad was in town, so he cut out some new strips of aluminum for the aft section of the rudder cable guards. I also…

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Cable Guard vs Baggage Door

Posted on March 20, 2010 by Jared Yates

This was my first attempt at making a transition for the rudder cable guard. Since this piece was too short (see the left side of the picture) I figured it was expendable. I think that the best solution is going to be a combination of a piece like this one (but longer) and a door…

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Rudder Cable Guards

Posted on March 15, 2010 by Jared Yates

Today I drilled and clecoed the rudder cable guards in place. The aft guards are too short. I tried to make them 24″ long each so that they would come out of a 48″ piece of stock. Since the aft bulkhead forms an obtuse angle with the floorboard, the cable guard needs to be longer…

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Burn Testing Nautolux Decco Dot

Posted on February 26, 2010June 6, 2010 by Jared Yates

I have been looking for some good material to use as a floor covering. Bob uses bare aluminum, and that method certainly has some merits. It is light, simple, and durable. Tabitha would rather have something that looks a bit more finished, but also something that dampens vibration a little bit better. She says that…

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