Tuesday, January 17, 2012
Goodbye BD-4
Our BD-4 project headed to its new home in Memphis, TN yesterday. Its new owner, Fedex B777 pilot Gerry Huser, is seen in the pictures below with BCAC members Mike McCann and Chris McClure, just before Gerry departed to points West. Pictures courtesy our Great Leader, BCAC president Terry Gardner, who is working feverishly now on our other project, the RV-7 wings, and has even found time to work on his RV-9. Look for the BCAC to resume regular Saturday meetings as we move forward on multiple fronts to get the Skycoupe in the air this spring.
Sunday, January 8, 2012
Welding workshop at Bear Creek 1/7/2012
Sunny weather in the 60s greeted a crowd of 20+ people to the Bear Creek Skunk Works for a free welding workshop, demonstrations of the Skycoupe's powerful Lycoming O-290-D engine and display of BD-4, RV-7 and RV-9 projects. Thanks to the BCAC's newest sponsor, Steve Johnson of Everything Aero or Thomasville, NC (aerovoltz.net), our Skycoupe now sports an incredibly light, compact lithium starter battery. Its amazing 400 cranking amp power resulted in the engine starting after only a few spins of the propeller. What makes this even more amazing is that the spark plugs in the engine have not been cleaned or gapped since the engine was run last in 1995! The plugs will of course be replaced prior to completion of the plane, by the latest Tempest plug technology from another sponsor, Aero Accessories of Gibsonville, NC. See pictures below from this fun meeting.
Welcome to new BCAC members Todd and Kelly Wichman, Brian Vandivier and Carl Lindgren! The Aeroclub now has 10 FULL and 12 ASSOCIATE members, exceeding the goal we set last fall. Better yet, we have been fortunate to gain the support by some of the biggest names in homebuilding, including Aero Accessories, PolyFiber, Everything Aero, and just this past week, Wicks Aircraft Supply and Dynon! All are enthusiastic about our 'back to the roots' effort and have pledged financial support in a variety of ways.
What's Next?
Skycoupe - Terry will be assigning tasks soon, many of which can be done in parallel. One of these, design of the panel, is already underway, thanks to Chris McClure.
BD-4 : we have taken an inventory of the material acquired and will be offering it all for sale to the BD-4 community. We're being aided by the leaders of their type club, BD-4.org
RV-7 : the empennage is complete and could be offered for sale now. The RV-7 quickbuild wings will be completed as a BCAC project and then offered for sale.
We expect the proceeds from the sale of the BD-4 and RV-7 projects to yield substantial revenue to the BCAC, lowering the final cost to members for completion of the Skycoupe. Please do not hesitate to mention these two projects being for sale to anyone who might be interested.
Next work sessions - expect a resumption of our twice-weekly sessions during the week after 4PM and on Saturdays. If we are to achieve our goal of flying the Skycoupe to Oshkosh this summer, we'll need everyone's help. Having the airplane at AirVenture 2012 is important for a number of reasons we'll discuss at our next session.
Brandon Troy, son of EAA1114 member Barry Troy, learned basic welding skills.
Brandon was very proud of his work, and his bead was not bad for a beginner. Darth Vader (aka BCAC member Mike McCann) looks on from behind.
Completed RV-7 empennage now ready for sale to some lucky RV builder.
Terry fires up the Skycoupe's powerful 125 HP Lycoming O-290-D engine.
A strong crowd of 20+ BCAC and EAA1114 members attended the welding workshop and demos.
Part of the BD-4 project now for sale, prior to transporting from Cox Field to the Skunk Works.
BCAC members Jim Cronin and Kent Misegades test the power of the Lycoming running at idle.
Below, new BCAC sponsor Steve Johnson of 'Everything Aero' (aerovoltz.net) with his amazing Aerovoltz lithium starter battery installed in the Skycoupe. Compare its size to the standard battery box it will replace. Steve also donated us a shiny new battery box for this mini-mite.
Welcome to new BCAC members Todd and Kelly Wichman, Brian Vandivier and Carl Lindgren! The Aeroclub now has 10 FULL and 12 ASSOCIATE members, exceeding the goal we set last fall. Better yet, we have been fortunate to gain the support by some of the biggest names in homebuilding, including Aero Accessories, PolyFiber, Everything Aero, and just this past week, Wicks Aircraft Supply and Dynon! All are enthusiastic about our 'back to the roots' effort and have pledged financial support in a variety of ways.
What's Next?
Skycoupe - Terry will be assigning tasks soon, many of which can be done in parallel. One of these, design of the panel, is already underway, thanks to Chris McClure.
BD-4 : we have taken an inventory of the material acquired and will be offering it all for sale to the BD-4 community. We're being aided by the leaders of their type club, BD-4.org
RV-7 : the empennage is complete and could be offered for sale now. The RV-7 quickbuild wings will be completed as a BCAC project and then offered for sale.
We expect the proceeds from the sale of the BD-4 and RV-7 projects to yield substantial revenue to the BCAC, lowering the final cost to members for completion of the Skycoupe. Please do not hesitate to mention these two projects being for sale to anyone who might be interested.
Next work sessions - expect a resumption of our twice-weekly sessions during the week after 4PM and on Saturdays. If we are to achieve our goal of flying the Skycoupe to Oshkosh this summer, we'll need everyone's help. Having the airplane at AirVenture 2012 is important for a number of reasons we'll discuss at our next session.
Brandon Troy, son of EAA1114 member Barry Troy, learned basic welding skills.
Brandon was very proud of his work, and his bead was not bad for a beginner. Darth Vader (aka BCAC member Mike McCann) looks on from behind.
Completed RV-7 empennage now ready for sale to some lucky RV builder.
Terry fires up the Skycoupe's powerful 125 HP Lycoming O-290-D engine.
A strong crowd of 20+ BCAC and EAA1114 members attended the welding workshop and demos.
Part of the BD-4 project now for sale, prior to transporting from Cox Field to the Skunk Works.
BCAC members Jim Cronin and Kent Misegades test the power of the Lycoming running at idle.
Below, new BCAC sponsor Steve Johnson of 'Everything Aero' (aerovoltz.net) with his amazing Aerovoltz lithium starter battery installed in the Skycoupe. Compare its size to the standard battery box it will replace. Steve also donated us a shiny new battery box for this mini-mite.
Friday, December 16, 2011
Weight Watching
This session was a first stab at weight & balance of the Skycoupe. Although there were missing elements, notably the fuselage fabric and paint for the whole plane, we got a good idea of where we stand in regard of the Light Sport rule of max weight.
Here are pictures on how this session wound down:
First put the wings on (Terry had to fabricate temporary wing struts - fabricating time: 10 minutes!) :
Then look at the scales:
Hardly visible here, the tail feathers were also installed and counted (I don't mean the tail feathers of the dog!):
This is Terry's take on the weight status:
The Skycoupe had a total weight of #428 pound using the wing attach points as the horizontal datum
Left Main #190
Right Main #208
Nose #30
Total #428
This was with unusable fuel, full oil, with no battery, ailerons, struts, avionics, instruments, or panel.
I figured a quick conservative finished weight with 2 standard adults, 12 gallons of fuel, and all the missing parts and coverings/coatings etc. of 1288 pounds. Keep in mind LSA max gross is 1320 Pounds.
Thanks to Mike, Martha, Mike son Mark, JP, and Jim Cronin
Here are pictures on how this session wound down:
First put the wings on (Terry had to fabricate temporary wing struts - fabricating time: 10 minutes!) :
Then look at the scales:
Main Left:
Front:
Main Right:
Hardly visible here, the tail feathers were also installed and counted (I don't mean the tail feathers of the dog!):
This is Terry's take on the weight status:
The Skycoupe had a total weight of #428 pound using the wing attach points as the horizontal datum
Left Main #190
Right Main #208
Nose #30
Total #428
This was with unusable fuel, full oil, with no battery, ailerons, struts, avionics, instruments, or panel.
I figured a quick conservative finished weight with 2 standard adults, 12 gallons of fuel, and all the missing parts and coverings/coatings etc. of 1288 pounds. Keep in mind LSA max gross is 1320 Pounds.
Thanks to Mike, Martha, Mike son Mark, JP, and Jim Cronin
Thursday, November 10, 2011
Summary of recent work
Thanks Terry Gardner for the following summary of activities in the Aero Club the past week during my absence. Kent
Here is a brief rundown on the aviation happenings. The Skunkworkers poly brushed the left wing last Monday, good turnout for that (MM, JL, JP, TM). The rudder was recovered by Mike McCann and I last Thursday. It exhibited the same peeling problem as the leading edge of the wings. I tried a new technique and was able to do it with no darts! It looks much better too. Tim came over and we put the new mags on and timed and tested them. Tom Malechuck loaned us his timing synchronizer. They look like they function normally. The coupe is ready to run.Unfortunately, I didn't have any fuel on hand.We had a chili fest/rib stitching session on Sunday 2-8 and it started slow but went well overall. Since we had a large group(AT,MM,BE,JL,MP,AS, TM, KS) we polybrushed the other wing(1 coat).They also polybrushed the rudder I had finished Sunday morning before the group arrived. The new TIG welder arrived on the 7th it is magnificent. I picked up the necessary welding supplies at Airgas when I went over to JP's for another RV12 inspection. He is really moving along! We are ready to start figuring out tabs necessary for wiring runs and so forth on the fuse. I also found an appropriately price gem on craigslist,$150, and with a little work it works perfectly. The thought of making multiple trips to Lowes to shake paint was not sitting well with me. I figured by the time we were done with the 'coupe thru finish paint it would be a minimum 50 trips at about 20 minutes a shot. I also got a line on a 52" Pexto Foot Shear with good blades but needing a bit of work. The shear would be very nice, if it meets the price point, when cutting our new found sheets of stock.I will check it out next week. My A&P came up, on his own volition, a design using RV part and dual cylinders for the Coupe brakes. He said what we had (single heel brake operating 2 wheel cylinders) would be ineffective.Bruce Edwards came over for a stitching session Monday evening and we are 80% done with stitching on the left wing. That is all I can think of for now. I was trying to get another session for this week but life got in the way.
I also went over to Hari's for the shop visit Saturday, good turnout there as well.
Terry
Here is a brief rundown on the aviation happenings. The Skunkworkers poly brushed the left wing last Monday, good turnout for that (MM, JL, JP, TM). The rudder was recovered by Mike McCann and I last Thursday. It exhibited the same peeling problem as the leading edge of the wings. I tried a new technique and was able to do it with no darts! It looks much better too. Tim came over and we put the new mags on and timed and tested them. Tom Malechuck loaned us his timing synchronizer. They look like they function normally. The coupe is ready to run.Unfortunately, I didn't have any fuel on hand.We had a chili fest/rib stitching session on Sunday 2-8 and it started slow but went well overall. Since we had a large group(AT,MM,BE,JL,MP,AS, TM, KS) we polybrushed the other wing(1 coat).They also polybrushed the rudder I had finished Sunday morning before the group arrived. The new TIG welder arrived on the 7th it is magnificent. I picked up the necessary welding supplies at Airgas when I went over to JP's for another RV12 inspection. He is really moving along! We are ready to start figuring out tabs necessary for wiring runs and so forth on the fuse. I also found an appropriately price gem on craigslist,$150, and with a little work it works perfectly. The thought of making multiple trips to Lowes to shake paint was not sitting well with me. I figured by the time we were done with the 'coupe thru finish paint it would be a minimum 50 trips at about 20 minutes a shot. I also got a line on a 52" Pexto Foot Shear with good blades but needing a bit of work. The shear would be very nice, if it meets the price point, when cutting our new found sheets of stock.I will check it out next week. My A&P came up, on his own volition, a design using RV part and dual cylinders for the Coupe brakes. He said what we had (single heel brake operating 2 wheel cylinders) would be ineffective.Bruce Edwards came over for a stitching session Monday evening and we are 80% done with stitching on the left wing. That is all I can think of for now. I was trying to get another session for this week but life got in the way.
I also went over to Hari's for the shop visit Saturday, good turnout there as well.
Terry
Sunday, October 30, 2011
RV-7 has a new home - BCAC
Terry, Mike, Andy, Joel and Kent were up at the crack of dawn today (10/30/2011) to load up our Club's latest acquisition, an RV-7 project donated by Mr. Andrew Meyers of Apex. The tailfeathers are largely complete and the wings are about 50% complete. All of the parts are now safely stored at the Skunkworks and we'll be discussing future plans with this latest project at upcoming meetings.
The images below are from the last few work sessions.
The BCAC RV-7 wings in the custom-built, roll-able cradle before being stowed in the Skunkworks.
Nathan McConnell and his father made one last visit to the Skunkworks before Nathan headed for A&P school in Portland, Oregon.
Joel, Andy and Terry put the finishing touches on the undersurface of the left wing.
Terry, Martha and Mike practice rib stitching.
Below: New tool storage cabinet, parts bins and overhead lighting underneath the storage shelves.
The images below are from the last few work sessions.
The BCAC RV-7 wings in the custom-built, roll-able cradle before being stowed in the Skunkworks.
Nathan McConnell and his father made one last visit to the Skunkworks before Nathan headed for A&P school in Portland, Oregon.
Joel, Andy and Terry put the finishing touches on the undersurface of the left wing.
Terry, Martha and Mike practice rib stitching.
Below: New tool storage cabinet, parts bins and overhead lighting underneath the storage shelves.
Saturday, October 29, 2011
Work Sessions 10/26-30/2011
On 10/26/2011, the lower surface of the left wing was covered by Terry, Andy, Joel, Mike McCann, JP and Kent.
On 10/27/2011, the upper surface of the left wing was covered by Terry, JP, Mike, and Jim Cronin.
On 10/29/2011, Terry, Al Sutton, Mike & Martha, and Joel completed covering details on the left wing, and finished all shrinking. We have now both wings ready for Polybrush, then rib stitching.
Also on 10/29/2011, Kent, Tim and Andy mounted a nice cabinet, donated by Andy, that will be used to store tools and other small items from our projects. Tim and Kent mounted parts bins to the nearby wall and sorted AN fasteners. Konrad sorted a variety of small parts that were acquired with the BD-4.
After working on the 10/29/2011, our group adjourned to our favorite Mexican restaurant in Pittsboro and held a long and lively discussion on the incorporation of the Club and what sort of activities we can pursue in the future.
On 10/27/2011, the upper surface of the left wing was covered by Terry, JP, Mike, and Jim Cronin.
On 10/29/2011, Terry, Al Sutton, Mike & Martha, and Joel completed covering details on the left wing, and finished all shrinking. We have now both wings ready for Polybrush, then rib stitching.
Also on 10/29/2011, Kent, Tim and Andy mounted a nice cabinet, donated by Andy, that will be used to store tools and other small items from our projects. Tim and Kent mounted parts bins to the nearby wall and sorted AN fasteners. Konrad sorted a variety of small parts that were acquired with the BD-4.
After working on the 10/29/2011, our group adjourned to our favorite Mexican restaurant in Pittsboro and held a long and lively discussion on the incorporation of the Club and what sort of activities we can pursue in the future.
Monday, October 24, 2011
Larry Oppegaard's Sonerai Project
Our Skycoupe's previous owner, Larry Oppegaard, was so inspired by what he saw at the Skukworks, that he recently acquired a Sonerai project, one of John Monnett's (Sonex/Waiex) best-known early designs. Larry send comments and imagees below on the airframe and engine.
Thanks for sending the article about the Sonerai. I saw that there were a lot more items of interest in the Experimenter newsletter, so I re-joined EAA. I had been a member since about 1972, then let it go back in 1995. I’m glad to get involved again.
Thanks for sending the article about the Sonerai. I saw that there were a lot more items of interest in the Experimenter newsletter, so I re-joined EAA. I had been a member since about 1972, then let it go back in 1995. I’m glad to get involved again.
I have stripped my Sonerai project down to the bare fuselage frame, and will repaint it with white epoxy. I need to fabricate the front seat frame and flight controls, which someone had removed earlier. The wings need nothing, so they are just stored against my garage wall. I need to find a welding rig for borrowing or renting to weld up the steel tubes.
The engine is an 1834cc VW conversion with a Zenith carb. The wings, which fortunately need no work, are all aluminum. I flew one back in the 90’s and it was very responsive, with a top speed of 130 mph in level flight. The Sonerai is stressed for basic aerobatics. The wings can be made to fold for trailering, but mine doesn’t. There are several U-tube videos available.
Best Regards,
Larry
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