Simon's Ultimate 10-200 project

Discussion in 'Ultimate' started by Snap, Jul 18, 2016.

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  1. Jul 18, 2016 #1

    Snap

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    Hello Bipe-Maniacs!

    I just wanted to take the chance to introduce my Ultimate 10-200 project and myself.

    I’m Simon, 27 years old and an aviator for nearly 14 years now – I started flying gliders at the age of 14, attained my license just after my 16th birthday. Nobody in my family is into aviation, but me. My younger brother made his gliders license a few years later but quit flying to pursue his car passion half a decade ago. My flying reached a low when I went to university – work was hard, money short. After the end of my engineering studies I was able to get back into aviation and aerobatics. In spring 2015 I bought a Pilatus B4 PC11AF glider (the one which is allowed to do unlimited aerobatics), to train at the local flying field. Last winter I did a full overhaul: Paint, Cockpit, trailer etc. – see pictures below.
    Unfortunately I had heavy rudder flutter on the first test flight after the overhaul. I was inverted with about 115 kts and wanted to do a tailslide. To fly absolutely straight I relieved the pressure of the pedals. A few seconds later I found myself shaken around in the cockpit. I smoothly pushed -4.5 g’s to get the glider into a vertical upline to reduce speed (leave the reverberation speed) and gain altitude, in case I’d have to bail out. With decreasing speed I was able to regain rudder control and landed the glider at out airfield. The fuselage skin had buckled in the tail section, see pictures. Additionally there is some damage to the fuselage rib in the area where the lateral forces of the wing are transmitted to the fuselage. (Gliders typically have one big main spar and only a small bolt at the trailing edge to transmit those forces to the fuselage.)
    While doing the paintjob on the Pilatus we stripped all the paint from the wings, but kept the old paint on the fuselage to move the cg a little aft without having to use those big lead ballast lumps in the tail section. Neither the books (operator & repair manuals) nor the manufacturer called for a mass balance of the rudders. “This aircraft is built so rigid it isn’t able to flutter”. Well – I was critical about that statement because flutter is a matter of elasticity and damping and can affect nearly everything. The fact that this glider type has no possibility to be mass balanced and has been repainted over years without any trouble got me assured – regrettably. After I reported the incidence Pilatus suggested to remove the paint from the control surfaces. They didn’t do a flutter analysis with different masses in the 70’s when the airplane got its permit to fly.
    Since the glider is certified and Pilatus Aircraft sold all spare parts to an Austrian guy the repair will sum up to ~20kUSD. I’m still waiting for the confirmation of cover of the insurance. Otherwise I’ll have to slaughter my first big airplane love.

    Enough said about the Pilatus – we’re here for Biplanes, aren’t we? ;)
    February 2016 I found the ad of an Ultimate 10-200 project on Barnstormers. I wasn’t really about to buy another airplane because I was in the middle of the overhaul of the Pilatus. Told my girlfriend about the Ultimate airframe, she replied with “Why don’t you shoot him a mail, you got nothing to lose?!” She was right of course. Three days later Jesse (Seller) and I agreed.
    Jesse did a great job in crating the Ultimate in the following weeks. Even with a broken collar bone he motivated his friends and family to help with the crating. The 450 cubic ft crate went on its journey to Europe in June; two days ago I picked it up and trailered it home. The crate and the parts on which I’m not working are stored at my parents’ site; the parts in work are stored in my small garage which I converted to a workshop. For the assembling jobs I’ll use the workshop of my flying club.
    Jesse is also in this forum, this is a thread from him describing some bad welds on the fuselage:
    http://www.biplaneforum.com/showthread.php?t=4164
    As far as I’ve been able to check the fuselage I’m going to salvage it. I’ll have close looks at every spot the pre-preowneer did to the fuselage and might also have it X-rayed. I’m not that trained in running a TIG-Welder so I’m only going to tack the pieces in place and have a professional aircraft welder do the main job.
    The wings are looking really good, I’ll change the leading edges to some plywood ones and do a close check on the wings. Generally I’m aiming for a low weight Ultimate with a fixed pitch prop, clean cockpit and many small detail works. I’ll take my time with this project, so don’t except a fast progress. Anyway, I’ll keep you updated with many pictures and questions. I appreciate every comment, criticism and suggestion. Since I’m no native speaker my language might lack some technical expressions and grammar. If something isn’t clear please ask about it.

    The next day’s I’ll go ahead and pull everything out of the crate and move it to the cellar or the garage. I’ve got to finish my workbench and shelves, so you’ll see some more pictures of the Ultimate parts soon.

    Have a great one!

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    Jean-luc, Jerry, Eagle28 and 2 others like this.
  2. Jul 18, 2016 #2

    Jean-luc

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    Hi Simon
    Welcome
    Very nice project;and hope to read more about
    Jean-luc
     
  3. Jul 18, 2016 #3

    Cameron

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    Welcome.
     
  4. Jul 19, 2016 #4

    EAABipe40FF

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    Welcome.

    Even w/o seeing her I'd say your girlfriend is a keeper. My wife is responsible for our purchase of the SA750 project..... Honest.:)

    Warm regards,

    Jack
     
  5. Jul 19, 2016 #5

    Jerry

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    Welcome to the club, Simon... beautiful looking glider.

    Look forward to seeing your progress on the Ultimate.
     
  6. Jul 19, 2016 #6

    Snap

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    Thank you for the warm welcome guys! I'm pretty sure we'll have lots of fun together.

    Thanks for the compliment on the glider, I nearly taxed my brain about the color and paint scheme. In the end I built a 7,5:1 model of it and tried different designs with car wrapping film till I was satisfied. Hopefully I will be able to fly it again soon, too bad I only had one flight till the overhaul. Had to cancel several airshows etc.

    Concerning my girlfriend I'd say she's definitely a keeper. The only argument we have from time to time is that the Ultimate has no second seat. I had to promise that the next aircraft will be a two-seater. :D

    The following video shows her and me in the ASK21. Her first aerobatic flight ever, great fun for both of us. We'll participate in the two-seater glider aerobatic competition later this year. I was able to win the advanced category last year, so this year is for the fun.

    [ame]https://www.youtube.com/watch?v=Mwt7CFmgaI8[/ame]


    The last two evenings I studied the plans of the Ultimate. Found that the bellcranks of the ailerons have already been welded in the gusset. Where can I find the other ADs? I'd like to check if every ADs has been done.

    I've got both lower wings in my garage by now and am pretty impressed by the quality. Unfortunately no one knows who built them. The fuselage really seems to be a factory fuselage including pushrods, engine mount and control linkage, but for the wing I've got no more details of the built than the pictures below that Jesse sent me some time ago. Maybe anyone of you has a clue who built them?

    Furthermore I'm kind of insecure about the trailing edges of the ailerons. As per the following thread there seems to be some confusion in the exact built of the TE.

    http://www.biplaneforum.com/showthread.php?t=2969&page=2

    Mine are kind of built by the plans I have (1/4" radius) but I'm not sure about the exact form, mine are only slightly bevelled to protect the covering I guess. See picture of the TE below.

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  7. Jul 19, 2016 #7

    Knight Twister

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    Cool video. She's a screamer.:)
     
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  8. Jul 19, 2016 #8

    Jean-luc

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    Very funny :)
     
  9. Jul 22, 2016 #9

    Vossba

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    Moin Simon,

    where are you based? I saw Heilbronn on the Registration plates.

    Iam from Oerlinghausen where i fly my S1X which is nothing more than a 10-200 with a 290hp IO540.

    I you are interested lets get into contact

    BR Reinhard
     
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  10. Jul 22, 2016 #10

    Snap

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    She is. :D

    Did some glass bead blasting to some of the shallow corroded parts yesterdays and painted the stick section, see picture below.


    I'm right about to place an order at Aircraft Spruce about some KP4 roller bearings and rod end bearings. I wasn't able to find out which rod end bearing fits the stick on the "elevator side". Either the plans don't show it or I'm simply to dumb to find it.

    The gap for the bearing has 7/16", so the Heim MD36-14 M should fit, shouldn't it? Bore is correct, width is correct, but will the head Diameter fit in there? Maybe also the Pitts guys can chime in, I think the section should be similar.

    MD36-14M NONE .1900 .437 .328 .273 .750 1.375 1.750 .750 #33 33/64 3/8”-24 2,848 .07 $55.75
    http://www.aircraftspruce.com/pdf/2016Individual/Cat16150.pdf

    ...and is there really only a clevis pin that secures the rod end bearing for the elevator?! :eek:
    => AN393-17 as per plans.

    And which rod end bearings fit the reverser and the bellcrank? I simply can't see in the plans...

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    Last edited: Jul 22, 2016
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  11. Jul 22, 2016 #11

    Snap

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    Hi Reinhard,

    nice S1X you got there! Plenty of power I guess. :p

    Did you built it yourself? I only know about N40JU (10-200) located in Germany. Would be great if we could meet some day and have a chat about all the important stuff in life. I'm currently flying on the small "Degmarn" airfield near Heilbronn, the Ultimat will be located in EDEW.

    Is your S1X equipped with flaperons, too? I'm still looking for the right rod end bearing size for the stick on the "elevator side", maybe you've got a picture of it?

    Thanks for you note, "Hals und Beinbruch!" (= Break a leg!")

    Simon
     
  12. Jul 22, 2016 #12

    Neil

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    Jay Womack post on here from time to time. He has a 10-200 he built some years back and can probably give you first hand information on this.
     
  13. Jul 23, 2016 #13

    Vossba

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    Hi Simon,

    nope didnt build it myself, she has been build in the US and went to Germany a few years later.
    Shes not 100% 10-200:the lower Wings are unswept - the Gear is a Springear - no Aileron Interconnect and a 540 mounted up front :))
    For quite some time Alex Stegner flew it in Competition. Power is brutal with 290hp and 503kg/1109lb empty. Climb is 4000fpm with 360° Rollrate.

    Below 1500ft you can literally Hover and fly a 4 Point Torque Roll, because the Long Ailerons are in the Propwash.....

    There are no Flaperons and the ship Snaps well, both in and outside.

    Lets meet at some time

    Reinhard
     
  14. Nov 29, 2016 #14

    Snap

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    Long time no note, been very busy. Hopefully I'll manage to get some stuff done between christmas and new years eve.

    Luckily my Pilatus is back in the air. Did the test flights three weeks ago in Slovenia - everything is fine, no more flutter. Still some small details to be done such as sewing a new alcantara side pocket with a zipper, modifying the trailer, petting here and petting there... :rolleyes:

    I've also done small steps on the Ultimate, leading edges of the lower wings are removed, yesterday we picked up the plywood from ACS in Bremgarten and several small parts such as Clecos, bolts and rivets.

    The first parts are powder coated in white so that one can see eventual cracks. New bearings everywhere I can't reach for without opening anything once installed.

    Next steps are finishing the ailerons and soaking or steaming the ply for the leading edges.

    Last but not least a pic of my garage where I'm about to catch a cold the next weeks. :)

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  15. Feb 10, 2017 #15

    Snap

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    I wish I would be able to make faster progress, but I keep finding mistakes of the prev. owner that need to be corrected.

    Spade mount is misdrilled, so I'll renew the tubing and use some 0,049 wall instead of 0,035 to prevent plastic deformation.

    Reverser is too short on the one side, so I'll have to correct this, too.

    At least the woodwork on the wings looks perfect, as you can see in the pictures after sanding the old sheeting down due do transportation damage.


    Could a mod please move his thread to the Ultimate section? Thank you!

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  16. Feb 10, 2017 #16

    ndlakesdreamer

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    the weld on the right in this picture is pretty scary. Doesn't look to me like there is any penetration into the arm.

    bad weld.jpg
     
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  17. Feb 10, 2017 #17

    cwilliamrose

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    Is it possible that reverser was done that way on purpose? Maybe to increase the deflection or shorten the stick throw?? If it's just a little off it likely a mistake, if the two reversers are different it's definitely a mistake....
     
  18. Feb 12, 2017 #18

    Snap

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    @ ndlakesdreamer: In fact the welds are pretty close to perfect - it just looks that bad in the picture I took. Reason is that there seems to be a shadow from the drive arm itself. Anyways, I had to look at the drive arm once again after your hint, thanks for that. It really looks as if there is no penetration in the picture.

    @cwilliamrose: I had the same thoughts, but the other reverser is built as per plans, so this will definitely result in unsymmetrical aileron deflection. Unfortunately I checked the revers and bellcranks after having them powdercoated, but still better than finding out after years of flying out of axis in the competitions. :D

    And thanks Jerry for moving the threat in the Ultimate category!
     
  19. Feb 12, 2017 #19

    cwilliamrose

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    It will be interesting to see what deflections up vs. down you get with what look like 90 degree bellcranks.
     
  20. Feb 13, 2017 #20

    dimcuesta

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    Love the carbon seat!
     
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