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Old 05-25-2016, 01:38 AM   #1
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Default Rebuild N85CH Acroduster

The rebuild begins on N85CH. The frame is ready to recieve parts! Come along for the ride. I will be posting progress as we go. Pics are what it looked like before disassembly and were we are now.


image.jpeg   image.jpg   image.jpg  

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Old 05-25-2016, 01:46 AM   #2
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More pics


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Old 05-25-2016, 02:57 AM   #3
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Looked great before. Can't wait to see the finished results! Is that paint or powder coat on the frame?
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Old 05-25-2016, 03:23 AM   #4
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Depending on several factors like open cockpit or two place canopy, panel placement and pilot size etc. You may want to consider a seat pan to be able to use a seat chute. I can not use a back or chair in mine. I converted to a pan in the rear, would have been easier when apart.

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Old 05-25-2016, 04:34 AM   #5
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About 20 years ago I built one of those AD II fuselages for a guy and I think its one of the strongest structures I've ever seen for a homebuilt airplane. 1" upper longeron till the aft cockpit and 7/8" firewall to tail post for the lower. If built to plans there is some .028 wall cross members and intercoastals. Hell for stout for sure. Looking good, keep us posted and coming back for more.
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Old 05-25-2016, 09:39 PM   #6
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Thanks guys. I am excited for the project. Trust me when I tell you the pictures made it look better then it was.

New frame paint is Imron.

I have been considering a bucket for the front especially. Care to share some pictures
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Old 05-25-2016, 11:59 PM   #7
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I used the fiberglass seat that Aircraft Spruce sells in the back of my Acro Sport. The catalog states that it was originally made for the Starduster but who knows. I can tell you it sits real nice.
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Old 05-26-2016, 12:47 AM   #8
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how about one of these?
seat.jpg  
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Old 05-26-2016, 01:17 AM   #9
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How much does it weigh ?
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Old 05-26-2016, 01:42 AM   #10
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looks like 9 lbs. I am interested because of the narrow front seat width between the rudder pedals.

Hope to see you at Smoketown flyin again this year.
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Old 05-26-2016, 01:53 AM   #11
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Thanks for the reply on the weight. Calculate that against a standard 4130 frame and the aluminum web strips.

Remember, any extra weight is cumulative......a few pounds here and a few pounds there....... when you go to weigh the airplane the first time you may be in for "sticker shock"

Bob
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Old 05-26-2016, 02:39 AM   #12
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I don't remember what the glass seat weighed, but it was about an even trade for the plywood seat platforms I had in it. No where near 9 pounds.
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Old 05-27-2016, 12:45 AM   #13
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How about retaining the existing tube frame and web seat and adding side panels to protect the rudder pedals from a wide passenger ?

or, lighten the bucket seat in post #10 by using a hole saw to add as many lightening holes as possible.

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Old 05-27-2016, 12:51 AM   #14
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great idea on adding the lighting holes. That may be the ticket.
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Old 05-27-2016, 02:57 AM   #15
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If the rebuild of N85CH is anywhere near the Fairchild.....it should be a trophy winner.
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Old 05-27-2016, 09:39 PM   #16
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Thanks Bob. We shall see how it goes. The agenda for this build is to create a solid and practical example of a sport biplane that will appeal to those interested in light to medium aerobatics. I think it will turn out really well due to the fact that all of the core components seem to be of very high quality. It appears the original builder incorporated all of the availabe factory parts. The welding throughout is superb. I am really excited to build this airplane. I know that I won't make much if at all anything by building this airplane to sell, so I will just make it the way I want, and if that appeals to someone else and the money is right I will move on to another project. But for now I am just having fun dreaming.
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Old 05-28-2016, 12:15 AM   #17
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I'd love that plane! It's a Pitts Killer...just read the propaganda! ;-) what engine are you going back with?
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Old 05-28-2016, 01:40 AM   #18
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engine is a narrow deck io-540-c4b5 that i have for it.

Lightweight everything - battery/starter and a Catto Prop.

This aircraft had a 75 pound fully feathering prop strapped to the nose and 12 pounds of lead(reportedly- not documented) in the tail, so already almost 100 pounds lighter - and i haven't event started!!

Light weight possibilities also include:

1)elimination of the back instrument panel and use just a single front panel, 15-25lbs

2)a lighter push pull tube on the elevator - this thing is a monster. Need ideas: carbon fiber?? 5 lbs

3) as already mentioned light prop. 50lbs?

4) as already mentioned light starter and lithium battery 30 lbs?

5) lighter seat cushions (I put them in a trash bag for storage and was SHOCKED at how heavy that bag was. 20 lbs?

6)recover with super flite and DO NOT let it get out of control. We have done color sanding between coats of color and the results are fabulous, but i feel the key is proper primer sanding at the primer level and then ONE coat and ONE cross coat. This will keep things lighter. Currently has about four coats of whatever on it. Its thick!! 50 lbs?


So it looks like i can grab 200 lbs out of this airframe without getting too crazy.

Any more ideas for weight saving on this airframe?
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Old 05-30-2016, 11:18 PM   #19
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I tinkered with the scheme a little bit this weekend.

In actuality i spent 90% of my time arguing with my computer!!

Any likes or dislikes?
try this.jpg  
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Old 05-31-2016, 01:33 AM   #20
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I like the black and red!
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Old 05-31-2016, 02:59 AM   #21
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I really like those.....

A lot! Now you got me thinking.....
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Old 05-31-2016, 04:03 AM   #22
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Black I struts and aileron pushrods? Just wondering if it would help tie the black in? I dig it. What program are you using?
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Old 05-31-2016, 02:04 PM   #23
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I have some folks at the shop who like the black as well, so i think i will pursue that.

I am using Corel draw, which is a monster of a program, but that's what i have, so that is what i have been learning. I have spent many many days learning this program, and if i didn't need it for the shop here, I would have called it quits long ago. Th up side to this program is that it will spit out the scale-able vector files that go right into a vinyl cutter for paint masks....Which is how we produce our N numbers at the shop.
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Old 06-01-2016, 12:29 AM   #24
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I like the light grey one at the top the best. That one doesn't have a horizontal stabilizer or elevator though and I think that will be a problem if you want to do serious acro.
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Old 06-01-2016, 12:43 AM   #25
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Those checkers wrapping around the nose are going to be a real treat to mask. Look good in 2D, once you start wrapping lines around you need to decide what angle you want them to look "right" from. Went through 2 rolls of tape on my turtle deck trying to get them right.....


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