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Old 11-03-2017, 01:39 PM   #26
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It didnít take too much force to align the tail post and rudder before, but cutting out the NAV light allowed it to relax right into place. After I welded in the new section of tube, it lined up almost perfectly.


B5FEE00E-4576-489D-8627-A0F9547F8E97.jpg   DC8305EE-2075-49AB-B57A-1ED7091B584D.jpg  
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Old 11-03-2017, 01:47 PM   #27
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The home builder special tailwheel horn from ACS took some lathe work to get the shaft round and a couple hours of sanding to clean up the casting. I forgot to take a before picture though. It still needs a little more work but only for aesthetics.

I also had to add a small gusset to the rudder after cutting out the old steering horn. Seems stout enough now.


0C41542E-7FFC-49DC-9DF1-89377CDC8A88.jpg   47251233-32A2-49CA-89B8-16C5E05E10B2.jpg  
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Old 11-03-2017, 02:38 PM   #28
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I thought the fabricated one looked pretty good, your rebuild looks good too.
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Old 11-04-2017, 02:53 AM   #29
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They didnít break a lip on the fabricated one on the original build. Even with the doubler, it was still flexible. There was also a crack started on the bottom.
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Old 11-04-2017, 03:02 PM   #30
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Originally Posted by bneub View Post
The trend is to have multiple levels of redundancy in the electrical system and avionics. Iíve seen planes with two sets of screens, dual alternators, backup batteries, an iPad, and a stratus like box all jammed into one little plane
Sounds like an RV...
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Old 11-04-2017, 07:20 PM   #31
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Ref to saving weight, I don't think cutting the cooling fins is such a good idea.
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Old 11-04-2017, 09:06 PM   #32
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Can you post what type of clamping/welding table system that is?
Thanks.
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Old 11-05-2017, 01:48 AM   #33
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Ref to saving weight, I don't think cutting the cooling fins is such a good idea.
A good friend of mine has been doing it in his engine shop for years without issues. ECI also does it on some of their cylinders and they sell tapered inter cylinder baffles to match.

They are tapered from about 1/8Ē at the fin closest to the cylinder base up to full diameter at the barrel-head junction.
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Old 11-05-2017, 01:58 AM   #34
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Can you post what type of clamping/welding table system that is?
Thanks.
Ryan
Itís from these guys.
https://weldtables.com/

They are awesome! All of the parts are laser cut. I had to do a tiny bit of cleanup here and there. You clamp the parts together and using good straight edge and squares, itís pretty easy to get a very accurate table. Then tack it up and finish weld. Base and casters are also available precut as a kit.

When I get back home I can post a picture of the whole thing.
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Old 11-05-2017, 12:16 PM   #35
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Thanks for posting your rebuild here. I, like you wanted to give other builders a resource of how we solve problems, and also as a way to learn from some other remarkable builders. Just because i am an A&P, IA, and shop owner doesn't mean squat when I have an engineering challenge that I have never encountered. I have learned a ton from the group here, and would not be as far along without their help. There is a wealth of knowledge here.

That is why experimental aviation is so fun. It gives us all a challenge and makes us seek out others who have solved the problems. With a real lack of these airplanes being built and rebuilt today its hard to find local fellow builders, so that is what makes this forum so great.

I certainly have found a lot of joy in rebuilding. I love taking a mess and fixing it into better then it was. I don't think i would have the time or patients to do it from scratch.

Happy building and rebuilding your project is looking great.

What are you thinking for cover and paint scheme??
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Old 11-05-2017, 01:45 PM   #36
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Kendall,
I really appreciate your comments. It took a while before I decided to post my progress because many times I donít know what Iím doing. It feels like I just make things up as I go along. I didnít know if anyone would really learn anything from me.

I read every new post on this web site over the last year and saved 100ís of the pictures to my iPad for reference. So many people have kindly and patiently answered my questions, taken my calls, emailed, and PMíd to help me out. As I thought about how much value I received from all of that, I decided I should try and do the same. To my surprise, a few people have even asked for my help.

Thanks again for all of the time everyone puts into this site!
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Old 11-05-2017, 01:54 PM   #37
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My lower wings and tail feathers were freshly covered with superflite supplies when I got the project. I will probably continue with that.

I am using Scheme Designers and they have been great to work with. Itís still evolving. I wonít show the design until itís on the plane. I have a hard time making a decision when it comes to the artsy side. Too much feedback on that and I may never be able to make up my mind!
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Old 11-05-2017, 02:07 PM   #38
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ELT mounted and tacked in place. Iíll install the nutplates after powder coating.

Itís only tacked so if I made a bad decision somewhere please let me know. It should be easy to access the way the side access panels were made on this plane.

I will probably need another tab and clamp to keep the trim cable from rubbing. I will know for sure when I put the tail together to mock it up.
181EA5B9-B0C8-4F85-925E-513B87C8A807.jpg  
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Old 11-05-2017, 04:18 PM   #39
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Can not go wrong with super flight. Give me a call at the shop if you need help with anything super flight related. I do really like their primer and top coats. Best I've seen.

Which one of designers are you working with over at SD?
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Old 11-06-2017, 03:39 AM   #40
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Quote:
Originally Posted by Ryan Mactaggart View Post
Can you post what type of clamping/welding table system that is?
Thanks.
Ryan
Hereís a picture of the whole table with a few accessories sitting on top. Let me know if you have more questions.
E9E0C3F5-29A6-4C2B-99EB-C02F42ABE84C.jpg  
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Old 11-06-2017, 03:47 AM   #41
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A few questions...

The plane had a ground power plug before. Is it worth the weight to reinstall it with the wiring and contractor? If I keep the battery maintained, how frequently would I need it? Iím new to injected planes and potential hot start challenges.
IMO, nope, lose it. I can count on one hand the number of times I've used a GPU in a little airplane. Like one of the other fellas said, big Lycoming hot starts are remarkably easy.

Larry
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Old 11-06-2017, 01:48 PM   #42
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Thanks for the offer! I will keep that in mind.

Iíve been working with Chris on the scheme.
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Old 11-08-2017, 01:01 PM   #43
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IMO, nope, lose it. I can count on one hand the number of times I've used a GPU in a little airplane. Like one of the other fellas said, big Lycoming hot starts are remarkably easy.

Larry
Thanks for the advice Larry. I havenít ever used it on my Cherokee in over 500 hours - it is a low compression, carbureted 540.

The pilot seat back will be easy to remove for access to the battery of that rare occasion I have a problem. Itís another place I can leave off a few pounds.
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Old 11-11-2017, 11:38 PM   #44
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Iím trying to figure out what to do with my panel.

The first issue is how much will have to be cut away for the canopy rails. There wonít be much left for support. Iím worried when the front passenger sits on top of the panels to get in and out it wonít hold up.
73F95EC5-8C6D-4176-82FB-1ABF5AEAC655.jpg  
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Old 11-11-2017, 11:46 PM   #45
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I also need about 8 3/4Ē vertically for he G3X screen.

Iím thinking about welding a 3/4 x .035 tube with some end plates in approximately he position shown in this pic. I think that would give plenty of support for the panel and allow a mounting point for the front seat shoulder harness. As of right now, there arenít any attach points for the front shoulder harness. I have no idea how they were originally installed.

Any other suggestions?
916CA04C-9968-48F9-9537-941E56C4C84E.jpg  
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Old 11-14-2017, 05:09 AM   #46
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Remote com and transponder brackets built and tacked in place.


4C79A040-DDDB-46E1-91F6-1F94A91F288E.jpg   6EFB863A-5A45-4273-A200-3BD1F135215A.jpg  
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