Work Session 9/27/2012

A great turnout last evening allowed us to make progress on a number of fronts:

• Repaired small leak to RV-7 fuel tank caused by poorly-cured ProSeal.
• Rounded corners and debured edges on seat panels.
• Finish ironing on empennage parts.
• Positioned old panel and planned new panel.
• Positioned seat panels and planned further fabrication.
• Mounted carburetor and cowl and planned airbox.

This productive session was capped with dinner and a lively discussion at Al's Diner.

The next session will be on Saturday, September 29th, starting with breakfast from 7-8 at Al's Diner.

 Terry demonstrates finish ironing on seams.
 

Jim - "Mr. Methodical" - Cronin makes it right.

Chris, chief panel designer, checks out dimensions of the old panel with the new seats and Terry's RV-9 seat cushions in place.

Above: Seat panels and Terry's RV-9 seat cushions in place. The new panel will be a few inches shorter to allow more room for knees. Right: Andy rounds the corners and takes the edge off the four seat 0.070" aluminum seat panels.

 J-P carefully removes old ProSeal from RV-7 tank.  For reasons not understood, it did not completely cure, leading to a slight leak.   After cleaning, new ProSeal will be applied and the tank again tested.

"Some assembly required" - Airbox boss Joel studies the instructions for installation.

The first iteration looks quite good!  PVC piping was added to mockup air inlet and location of needed opening on the lower cowl.

Below: What it's all about - Joel describes his plans for the airbox and inlet while others listen or adds their thoughts.

Work Session 9/22/2012

Andy, Terry, J-P and Kent enjoyed splendid Indian Summer weather at the Skunk Works and made significant progress on final work on the RV-7 wings and the Skycoupe seating.  The final few components were riveted onto RV-7 wings, with Terry doing the pressing and J-P acting as the careful inspector.  He's well-qualified as a current RV-12 builder.   Kent made the final decisions on the aluminum seat backs and bottoms, which will mimic Terry's RV-9 seats in most respects.  Terry had some excellent ideas how storage boxes could be easily incorporated into the underside of the seat bottom and onto the seat backs, both of which will be attached to the existing seat pan with piano hinges.   Fortunately, we had plenty of pristine 0.070" sheet aluminum in our parts bin, adequate for all four seat parts. Grover Macnair has kindly offered use of his brake to cut the sheet this coming week, and needed parts to complete and mount the seat parts will be ordered this week.

This week we need to make progress on a number of fronts:

1. Seats (per above)
2. RV-7 - final touches prior to their being offered for sale
3. Panel - need to make decisions on materials and order two primary MGL instruments
4. Airbox - needs to be kept in the shop and completed, including mounting on carburetor, then lower cowl must be adapted to it.
5. Cowl - Cecil Boyd has offered to help remove a few wrinkles. Opening must be made for airbox.

Stay tuned for dates and times for next work sessions.  We'll try to hold one during the week and one on weekends from now until we fly, so everyone can carve out time to help.

0.070" sheet for seat bottoms and backs marked and ready for cutting.

J-P checks the RV-7 plans for the remaining work.

Terry at work under the watchful eye of "Mr. Rivet"

Work Session 9/20/12

Jim, Terry, Andy, Chris, Kent and Tim spent several hours assisting Tom Malechuk with planning for the wing struts.   The right wing was mounted and supported at the tip to provide the required two degrees of dihedral.  After some deliberation, it was decided to provide independent mounting of both ends of both fore- and aft struts.  Tom suggested a series of steps, and the first was taken - removal of excess length from the struts, donated by Brian White when he restored his Super Cub a few years ago.  Cutting a section off of the strut allowed us to inspect the inside walls for corrosion - the initial look was good, with a nice coating of the original linseed oil still in place.

Tom also inspected the RV-7 wings and showed a few small blemished we'll remove prior to offering them for sale along with the tailfeathers.

The work session was completed with a light dinner at Al's Diner, to the enjoyment of all.

Tom Malechuck inspects our work on the RV-7 wings.

Andy and Chris check the dihedral angle on the right wing and Terry and Jim look on.

Terry's chop saw makes quick work of the strut.

Outline of needed work on now-shortened strut, to be done in Tom's shop.

Work Session 8/5/12

Great News!  Konrad is back from his extended medical leave and is looking great!


Terry, Joel, Bruce, Konrad and Kent stopped by the Skunk Works to sand the left wing prior to its next two coats of Poly Spray, aka Silver Coat.

Thanks to the expert prep work by Chuck, sanding of this wing was much easier than on the right wing.   

Terry will now add two more coats of Poly Spray, then we'll meet up again on Tuesday, 8/7/12 after 5PM to sand again before the final two coats.

The tank sealant will have cured out by Tuesday, allowing riveting on the RV-7 wing.

Below:  Terry, Joel and Bruce sand the underside of the left wing.

Work Session 8/4/2012

A good turnout on this relatively cool Saturday morning allowed us to make good progress on several fronts:

A small leak in the RV-7 fuel tank was isolated and corrected with tank sealant.

One wing was final-sanded and is now ready for its final white coat.

The second wing was prepped by Chuck Borsuk and received its first two coats of Poly-Spray (silver coat) by Terry.

Next work sessions:

Sunday, August 5th, Joel and Terry will meet at 3PM to close up the RV-7 wing.

Sunday, August 5th, a few people are needed at 5PM to sand the 2nd wing prior to its receiving the finish silver coats.

Tuesday August 7th, a few people are needed at 5PM to give the 2nd wing its final sanding.

What's next?

1. White finish coats for all flying surfaces.
2. Transport flying surfaces to Chuck Borsuk's hangar at Franklin County for storage.
3. Finish RV-7 wings and sell all RV-7 components.
4. Focus on Skycoupe fuselage, especially the firewall forward, airbox & cowl, seats & panel.

Triple Tree - is rapidly approaching.  Kent will have a small booth there again which will serve as a Bear Creek / EAA1114 meeting place near the campgrounds.  Workshops for fabric covering, sheet metal fabrication and composites will be offered. If you did not attend last year, consider it this year.  We expect a large group of EAA 1114 members to be there.   See this link for details for the Fly-In, which takes place this year on 6-9 September.

Tim and JP with the leaking RV-7 fuel tank.

 Tim applies sealant to the culprit - a coax cable.

Left wing, prepped by Chuck Borsuk, ready for Poly Spray (silver coat).

Dr. Gardner prepares for the operation.

Terry at work - it was hot in there!

Michael and J-P wet sanding the right wing.

Tim inspects Terry's work on the left wing.

Tim and Terry admire the first two silver coats.

J-P and Michael wet sanding the right wing under Terry's watchful eye.

Right wing, after sanding, ready for finish coats.

Right wing, after sanding, ready for finish coats.

Work Session 08/04/2012

Preparing the second wing for painting:
The Bear Creek Skunk Works team is sanding a wing of the Stitts Skycoupe for painting by Master Painter Terry who invited his Dad to visit his hangar and meet the skunks!
Answering present to Terry's call where Kent and Tim Misegade, Chuck Borsuk, Michael Crowder, Tom Hall and JP Bernoux (behind the camera).
http://youtu.be/Y6p2T08WeXQ

The Master Painter in his garb is swearing in his new apprentice:

Work Session 6/30/2012 - Wing prepping for painting

Five members of the Bear Creek Aero Club (Terry, Andy, Chuck, Mike and Kent) braved the heat to work on the Skycoupe and RV-7 wings.  We started with a hearty breakfast at Al's Diner at 7AM.  Noel Fallwell, on his way to work on his RV-6A at Siler City, join us.  We then headed out to the Skunk Works.  Between the shade of the hangar and strategically-placed fans, it was really quite comfortable.  Kent finalized design of the seat backs and bases - at the next work sessions we'll be fabricating a trial set of seat parts from surplus, unusable 0.025" sheet aluminum, a great way to learn sheet metal skills.

Terry and Andy worked on the RV-7 wings, which are nearing completion. Mike and Chuck cleaned and finished prepping the wings using irons set at 225 degrees.  This tedious job focuses on flattening the edges of fabric and tape and smoothing out areas where the Polybrush coating was thicker than needed.   During the work on the wings, Terry's new rotisserie came in VERY handy, as can be seen in the photos below.   Terry designed the fixture to hold wings, metal or otherwise, as well as a fuselage and even a motor.   This sturdy structure is sure to see frequent use in the coming years, and Terry is to be commended for his creativity and hard work in its creation.

While working we discussed some opportunities for the BCAC to participate at the upcoming Triple Tree Aerodrome Fly-In on 5-9 September.   Kent will have a booth there again and quite a few BCAC and EAA1114 members plan to attend this great grassroots event which is often compared to the EAA annual convention during its earlier years when the focus was on homebuilding, restorations and fun flying.

Chuck and Andy check out the rotisserie, securely supporting the right wing.

One person can rotate the wing to the horizontal position.

The brilliance of Terry Gardner - the bow wingtip is free of any support, the wing being attached at the wing root and strut brackets.

Terry devised this jig made of PVC tubing to hold an RV wing in the rotisserie.

Andy and Terry at work on the RV-7 wings.

Chuck worked for 2+ hours in the heat to smooth out the remaining ripples on the wing prior to it receiving multiple coats of silver.

Andy uses another Terry Gardner fixture to move the RV-7 wing (Terry was holding the other end).

The fixture allows the RV-7 wing to be easily rotated on a set of steel supports, also created by Terry.

Andy and Mike give the upper surface a quick wipe-down with Polyfiber cleaner.

Shot of the underside of the wing shows how it is supported on the rotisserie from the wing strut brackets.  This keeps the rotating shaft far from the wing surface, allowing plenty of freedom of motion during spray painting.  Shafts located too close to a surface can leave a 'shadow' when inconsistencies appear in the paint.

Mike holds up the front curtain of the paint booth to show the right wing, ready for painting on the rotisserie.