Replacement Drawing #7

I mailed off a check today for a replacement for my drawing #7 that was ruined when it feel in water when my basement flooded. I also placed an order for the correct bushing stock since I ordered the wrong size last week.

Form blocks, Form blocks, Form blocks...

First chance to use the my router

Today I spent a few hours working on my form blocks. It is kind of daunting for me because this is what is setting the stage for the whole wing. I want to make sure I get it right. I went and got a 1/8" round over bit for putting a radius on the edges. I have read several peoples build logs where they have hand sanded the edges.

A Good 4th of July

Today I got some stuff to run new lights in the garage, and I also stopped by Harbor Freight and picked up the 30" bending brake and some clamps. I spent the rest of the afternoon wiring up the lights, and realized that I will need a few more. At least now I have a well lit workbench.

I needed to finish my form backing block so I cut that out with my jig saw and sanded it down. I have had really good luck with my Harbor freight belt sander so far. Once I had it sanded down I clamped the two together and started drilling my jig pin holes. That is as far as I made it today.

Harbor Freight 30" Bending Brake w/ two c-clamps

Slight set back for hammering over flanges

Drilling jig pin holes

One small step...

A lot has been going on and I have not held true to my goal of doing a little each day. However, I have finished my main formblock.  I have rough cut the backup block and will use my router with a different bearing to finish it.

A few months ago my basement flooded and while I was picking things up off the floor my rolled up drawing #7 fell in an inch of water. I didn't think anything of it at the time, but when I unrolled it to check against my form block it was ruined.

So now I need to call Bob and see how much for another one. The real progress is last night I ordered my first sheet of aluminum. The goal for this week is to finish all the form blocks and have them ready. I'm going to start with the nose ribs first and go from there.

I also downloaded Eric Newton's last two build manuals and have read through them.

And So It Begins!!!

I actually started today. I figured I better have some progress to show when I meet the other Bearhawkers at the Texas STOL Roundup next weekend. I didn't want to be the guy that just talks about building a plane (which is what I was quickly becoming!)

Last weekend I picked up a sheet of mdf to start making the form blocks. Today I lined up some sheets if carbon paper and taped them together. Then I taped it to the mdf. 

Next, I taped drawing #7 to the top and carefully traced it out with a tiny fine tipped screwdriver. I took quite a while to go over everything. After I finished I removed everything and retraced the lines left from the carbon paper with an ultra-fine tip sharpie. 

I used my jigsaw to cut outside the lines by about a quarter inch. Then I started sanding it down to the line with a drum sander in my drill press, but I'm going to finish it up with a good, slow hand sanding. The drum sander is very hard to get a smooth uniform edge. If you are not super careful and light on the pressure it will dig in and make a rolling, curvy edge.

So, to finish the day, I don't even have one form block 100%, but I HAVE started!

Still Preparing

It has been a while since I updated anything. I am currently still getting prepped for the build. I originally thought that I would wait until I had all the tooling I figured I would need to complete the build, but as time has carried on I have come to the realization that if I continue in this mindset throughout the build that I will never complete it, let alone, get started.

On another note, there is a STOL Competition scheduled for April 11-13 down in Llano, TX that I am planning to attend. I am going to drive down to it, but I have not decided if I am camping or getting a hotel yet. I am trying to get a few friends together that might be interested in going. It is supposed to be modeled after the Valdez, AK STOL Competition. Bearhawk Aircraft are one of the sponsors for the event and are going to be competing as well.

More tools....

Still acquiring tools while I am reading everything I can and while I study the plans before I start. I added a vice and bench grinder to the mix as well as a Husky 33 gallon air compressor. I got a pneumatic squeezer off eBay for $150.

Tooling up!

I got everything I put on my Christmas list in regards to tools:

Craftsman Professional Router

Craftsman 10" Drill Press

Storage Bins

Laminate Trim Bit

Wiss W12 Snips

Wiss Aviation Snips

Fly cutter

Craftsman Professional Air Hose

Everything assembled

I got this rack from a GameStop that was throwing it out. It has good caster on it and makes a great tool/storage bin cart. I just need to get some peg hooks. 

And today I scored a brand new set of tools on eBay. I'll post pics of that when it comes in. Off to a good start for the new year. 

I need to update the cost page to reflect what I received.  These are things I didn't have so I am going to consider it money spent towards the project.

Folding Drafting Table

A lot has been going on. I decided I wanted a place in the factory where I could keep my plans besides the workbenches. I googled drafting tables and folding drafting tables and saw several, but none that were both cheap and easy to build with what I had access to. So I designed my own.

It turned out great. I used two 1x4x8's. I cut the first one in half and the second one I cut off the thickness if the writing surface which for me was 5/8" then I cut them in half on a 30° angle. I spaced them out the proper distance for the writing surface to slide in snug and clamped them down. 

Then using a 1/4" drill bit I drilled holes 6" from the ends. I was not drilling into studs. Instead I ran a 3"x1/4" bolt through the 1x4's and the sheathing of the wall and used washers and a nut to attach it firmly to the wall. Some 1 1/2" construction screws were added and countersunk to provide more rigidity. I then used eye bolts to attach the cable to. Total cost was less than $20 and it is very solid and folds out of the way when not in use. 

On a side note I have been reading through the Bearhawk Book that came with my plans as well as Russ Erbs CD. I also purchased Volume I of Eric Newton's Build Manual. I am getting excited to get started. 

I unrolled Drawing #7 for the first time today as well. I think I am going to take it to Kinkos and get them to make a copy and then I will do the cut and glue method for transferring it to the formug block. Or if I can find a roll of tracing paper or carbon paper I will do it that way. The point is I am not going to use/disfigure Drawing #7. I want to keep it original. 

EAA workbenches

It seems like a right of passage for home builders to build workbenches for their project therefore I, too, built my EAA workbenches. It took about 4 hours and about $100 in lumber.

 I am brainstorming about a wall mounted drop down drafting table to hold my plans. 

Got my plans today!!!

This is what you get when you open the box. 

From left to right: envelope, bear tracks card, picture, Mylar wing rib plan,

Bearhawk book (compilation of Beartracks newsletters), packing slip, plans. 

I am still in the process of getting The Factory set up how I want it, but I will post as I go along. It is supposed to be very frigid here in East Texas so I will use my indoor time to build some EAA workbenches. 

I have ordered an 18x24 portfolio to hold all the plans so I can flip thru them page by page, but until it gets here I got this artwork folder to hold them and flatten them out a little. 

Ordered my plans today...

The first of many obstacles has been removed. I should be a proud plans holder in a few days. I can't wait to get started. One thing that I should note is that I am not in a hurry to finish this. I enjoying building things and I am looking forward to the process as much as the end result.

On a side note I believe I am getting a new router for Christmas to make the ribs!

Reklaw, TX Fly-In

Went to the Fly in in Reklaw, TX last weekend! It was my first year to go and boy was I surprised. There were so many planes! I had no idea it was that big of a shindig!

Doing the research....

If you are reading this blog it is because the thought of building your own plane intrigues you. It has been on my mind since I was a kid and I discovered that people actually built their own aircraft and flew them.

The reasons to build are as varied as the types of kitbuilt aircraft to build. Cost, enjoyment, and educational value are a few of the main reasons. They are my main reasons as well. I am an avid camper and enjoy spending my time outdoors. My ideal aircraft is one that has a high useful load, is fast enough to cover greater distances, and has the STOL capability to get in to and, more importantly back out of, the areas that I want to visit. I am not able to go out and purchase a plane that meets these needs for me right now. But I can put money gradually into a project like building my own.

The search has covered a wide variety of planes. There are many kits out there that have reduced build times and good support. The Bearhawk designed by Bob Borrows is one such aircraft. It was originally available as plans only, but now, it is also available in kit form. A quick google search shows a myriad of  normal people like myself undertaking this project. The performance speaks for itself.

That being said, the Bearhawk is the plane I have decided to build. I will by blogging on this site about the progress so I have a build log and can contribute to the community and help others like those that have built before me. Bear with me as I embark on this adventure and feel free to contact me with questions and support!