And so it begins

Mr. Ed · Sep 29, 2022

I made paper templates for all fuselage opening/inspection covers. Then used those to cut Kydex blanks which I glued to a piece of melamine.

Did a carbon fiber lay up over the Kydex and vacuum bagged.

Cut the individual covers out of the panel, trimmed, sanded and drilled. The covers fit perfectly over the grommets which fit into the recess from the Kydex templates. These will get removed, coated with a UV protective and then painted to match the metallic silver fuselage color.

For those folks that noticed there seems to be no way to remove the cover over the aft stabilizer tube…you can see in this photo that the front upper part of the cover is a separate piece. That piece will be permanently attached to the grommet just to give a finished look. Also, yes I know that opening is upside down. My upper longeron is located at the top of the fuselage, not through the middle like Piper designed. So the aft stabilizer support bracket mounts under that longeron instead of over. To allow the elevator horns to be inserted into the openings the openings needed to be inverted. And, the rectangular cover had to be moved up to allow access to the control cable attach points. That rectangular opening is only on one side of the vertical fin.

G44 · Sep 30, 2022

Wow! Looks fantastic! Thank you for posting, its fun to follow along.

Kurt

Mr. Ed · Oct 8, 2022

I painted the carbon fiber covers and metal belly pan. ADSB antenna is mounted in the belly pan. I made poster board templates for the windows and had Tap Plastics in Portland cut the windows out of 3/32” plexiglass. Original plan was to put an exterior door handle on the lower door per Piper drawings. I fabricated that when I made the door. I didn’t like that it contacted the fabric with the door opened so I modified the door. Steve had mentioned in a post that he welds the head of a hex head bolt to the handle post and puts a small Allen key on the key ring. Sounded like a clever solution so that’s what I did. I also have a key lock in the forward corner of the lower door. Getting the interior panels installed slowly. I plan to remake the aft bulkhead out of carbon fiber and put an access door in the upper left corner for quick access to the ELT. I’m not loving the Kydex interior panels at this point but will live with it for now. They were all made a couple years ago, they fit well and I need to get this thing done. I’m tired.

skywagon8a · Oct 8, 2022

Mr. Ed said:
Original plan was to put an exterior door handle on the lower door per Piper drawings. I fabricated that when I made the door. I didn’t like that it contacted the fabric with the door opened so I modified the door. Steve had mentioned in a post that he welds the head of a hex head bolt to the handle post and puts a small Allen key on the key ring. Sounded like a clever solution so that’s what I did.

This is my solution to the door handle contacting the fabric issue. Sew a thin piece of leather to a scrap of fabric, glue that fabric to the fuselage covering fabric, then paint the airplane.
this picture shows the amount of abuse over a ten year period.

Besides, I don't like having to carry a separate tool to open the door.

wireweinie · Oct 8, 2022

Be aware that landing in rough stuff will cause damage to the transponder antenna. Keep an eye on it for chips and cracks.

Web

Mr. Ed · Oct 8, 2022

Thanks for the heads up Web, I hadn’t considered that. I probably won’t leave the antenna mounted. I don’t have a transponder for this project but did all the wiring so if I decide I need one it will be a simple installation.

Mr. Ed · Oct 13, 2022

I want to keep the water from running down the sides of the fuselage and into the metal belly. I found some “D” channel rubber molding that looks like it will work well. I glued that to the edges of the belly panel and it looks like it makes a good seal.

Nothing else done on it today…went flying instead of working.

DENNY · Oct 13, 2022

Everything fails over time, make sure you have a simple drain hole at low point and all will be well. DENNY

Mr. Ed · Oct 17, 2022

Denny, thanks for the reminder. I have drain holes everywhere but didn’t put one in this belly pan. Will do so.

Picking away at some small jobs in between typical fall chores. Started to make the carbon fiber “wraps” around the door openings. They capture the interior panels as well as protect the fabric. The cargo door opening is done in three pieces. The top of the opening doesn’t get wrapped as it shouldn’t be subject to the abuse the other three surfaces will endure. The cockpit door (lower) will be made in one piece.

I don’t know why these uploaded sideways…?

sj · Oct 18, 2022

Mr. Ed said:
I don’t know why these uploaded sideways…?

We have a plug in to flip iPhone photos the correct way (apple decided to ignore the orientation standard some years ago) but for some reason it does not always work.

Were these taken with an iphone or something else?

sj

Mr. Ed · Oct 18, 2022

Yes, iPhone.

Mr. Ed · Jan 7, 2023

Getting a little more done. I fit the windshield and got everything drilled. Now need to put in a bunch of nut plates. I laid up carbon fiber window trim and have been getting that all fit and drilled. After I lay up the front and rear skylight trim I’ll paint all of these metallic blue. Also have done some work on the firewall. Getting some stuff mounted and figuring out where the rest of the stuff needs to go.

Mr. Ed · Jan 7, 2023

I

I’ve also been working on cockpit labels. I made up a couple pdf files of what I wanted and had them printed up for a dry rub application. The lettering transferred well but a test piece didn’t pass the durability test so I ended up spraying a clear finish over top. The required experimental “billboard” (you can see part of in the lower photo) was hand painted as is the N number on the instrument panel.

Gordon Misch · Jan 7, 2023

Looks like you're ready for another inspection visit. Very impressive, sir!

skywagon8a · Jan 8, 2023

Mr. Ed said:
IView attachment 64281
The required experimental “billboard” (you can see part of in the lower photo) was hand painted .

Are you aware of FAR 45.22(b)(1)(ii) ? http://www.faa-aircraft-certification.com/45-22-exhibition-antique-other-aircraft.html
This FAR allows you to eliminate that billboard if you place an X between the N and the registration number like this NX1234 instead of like this N1234 on the outside of the airplane.

Mr. Ed · Jan 8, 2023

skywagon8a said:
Are you aware of FAR 45.22(b)(1)(ii) ? http://www.faa-aircraft-certification.com/45-22-exhibition-antique-other-aircraft.html
This FAR allows you to eliminate that billboard if you place an X between the N and the registration number like this NX1234 instead of like this N1234 on the outside of the airplane.

I became aware of that a little too late…after the N numbers were already applied to the tail. Re-doing that is more of a pain in the butt than living with the interior signage. Thanks for the heads up though.

skywagon8a · Jan 8, 2023

Mr. Ed said:
I became aware of that a little too late…after the N numbers were already applied to the tail. Re-doing that is more of a pain in the butt than living with the interior signage. Thanks for the heads up though.

Oh well, next time you'll remember.

courierguy · Jan 8, 2023

I've always kinda liked the EXPERIMENTAL placard inside requirement (if that's what you're referring to...), it gives any passengers something to cogitate over prior to lift off, "amatuer built," etc. If they don't want a ride after reading it, I don't want anything to do with them anyway! I too, didn't know about the X trick.

frequent_flyer · Jan 8, 2023

skywagon8a said:
Are you aware of FAR 45.22(b)(1)(ii) ? http://www.faa-aircraft-certification.com/45-22-exhibition-antique-other-aircraft.html
This FAR allows you to eliminate that billboard if you place an X between the N and the registration number like this NX1234 instead of like this N1234 on the outside of the airplane.

If 14 CFR 45.22(b) is applicable then why cannot 45.22(b)(1)(i) be invoked instead of 45.22(b)(1)(ii)?

I suspect the problem for many EAB is compliance with "or as an amateur-built aircraft and which has the same external configuration as an aircraft built at least 30 years ago". Who decides what "same external configuration" means? (I'm assuming EAB rather than Exhibition).

CubCrafters splits the "EXPERIMENTAL" placard across the door hinge where it is only visible when the door is open.

skywagon8a · Jan 8, 2023

CubCrafters has a long history of bending the rules. Just because they do it a certain way, it doesn't mean it is the correct way. They used to build brand new PA-18s under an obscure rule until the FAA cracked down on them making them get their own TC.

hotrod180 · Jan 8, 2023

skywagon8a said:
CubCrafters has a long history of bending the rules. Just because they do it a certain way, it doesn't mean it is the correct way. They used to build brand new PA-18s under an obscure rule until the FAA cracked down on them making them get their own TC.

I live in the PNW, kinda near Cunb Crafters.
I don't recall them building "brand new PA-18's" before the Top Cub was introduced--
they rebuilt customer's airplanes, as good as new or better, and that was how they marketed their work.

dgapilot · Jan 8, 2023

frequent_flyer said:
If 14 CFR 45.22(b) is applicable then why cannot 45.22(b)(1)(i) be invoked instead of 45.22(b)(1)(ii)?

I suspect the problem for many EAB is compliance with "or as an amateur-built aircraft and which has the same external configuration as an aircraft built at least 30 years ago". Who decides what "same external configuration" means? (I'm assuming EAB rather than Exhibition).

CubCrafters splits the "EXPERIMENTAL" placard across the door hinge where it is only visible when the door is open.

45.23(b) says the Experimental, or Light Sport needs to be displayed if only the N is displayed. You need to read both 45.22 and 45.23 to see when the additional placards are required. Not also that the regulation requires the “same external configuration” so not applicable to wide fuselage, aftermarket wing tips, large baggage doors, or extra passenger entry doors.

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frequent_flyer · Jan 8, 2023

dgapilot said:
45.23(b) says the Experimental, or Light Sport needs to be displayed if only the N is displayed. You need to read both 45.22 and 45.23 to see when the additional placards are required.

14 CFR 45.22(b) A small U.S.-registered aircraft built at least 30 years ago or a U.S.-registered aircraft for which an experimental certificate has been issued under §21.191(d) or 21.191(g) for operation as an exhibition aircraft or as an amateur-built aircraft and which has the same external configuration as an aircraft built at least 30 years ago may be operated without displaying marks in accordance with §§45.21 and 45.23 through 45.33 if:

Note that 45.23(b) is not applicable since it falls in the range "45.23 through 45.33".

We seem to agree that many EAB would not meet the requirements of 14 CFR 45.22(b) so the rest of the discussion is academic.

frequent_flyer · Jan 8, 2023

skywagon8a said:
CubCrafters has a long history of bending the rules. Just because they do it a certain way, it doesn't mean it is the correct way.

Why would putting the "EXPERIMENTAL" placard on the door hinge be bending any rule? The purpose is for the placard to be visible to anyone as they board the aircraft. I am not aware of any requirement for the placard to be visible after boarding.

"the operator must also display on that aircraft near each entrance to the cabin, cockpit, or pilot station, in letters not less than 2 inches nor more than 6 inches high, the words “limited,” “restricted,” “light-sport,” “experimental,” or “provisional,” as applicable."

skywagon8a · Jan 8, 2023

hotrod180 said:
I live in the PNW, kinda near Cunb Crafters.
I don't recall them building "brand new PA-18's" before the Top Cub was introduced--
they rebuilt customer's airplanes, as good as new or better, and that was how they marketed their work.

There is or was at the time an FAR which allowed the issuance of a new data plate and airworthiness certificate if the airplane was assembled from all approved parts. I don't recall the FAR number, perhaps dgapilot can help with this? The intent of this regulation was for a collection of airplane parts to be made into an airworthy airplane. Cubcrafters was abusing this privilege by extending the privilege to many airplanes on Piper's type certificate. That's when the FAA said "all stop. Get your own certificate." At least that is the story which was going around during that period of time.

This may or may not be related to the period of time when the FAA began a big crack down on the use of unapproved parts.

mvivion · Jan 8, 2023

skywagon8a said:
There is or was at the time an FAR which allowed the issuance of a new data plate and airworthiness certificate if the airplane was assembled from all approved parts. I don't recall the FAR number, perhaps dgapilot can help with this? The intent of this regulation was for a collection of airplane parts to be made into an airworthy airplane. Cubcrafters was abusing this privilege by extending the privilege to many airplanes on Piper's type certificate. That's when the FAA said "all stop. Get your own certificate." At least that is the story which was going around during that period of time.

This may or may not be related to the period of time when the FAA began a big crack down on the use of unapproved parts.

That is accurate. Since those aircraft were “Piper PA-18”, guess which manufacturer assumed liability for them? My understanding is that Piper wasn’t happy.

At least one of those planes was found to have some used parts.

MTV

RaisedByWolves · Jan 8, 2023

skywagon8a said:
There is or was at the time an FAR which allowed the issuance of a new data plate and airworthiness certificate if the airplane was assembled from all approved parts. I don't recall the FAR number, perhaps dgapilot can help with this? The intent of this regulation was for a collection of airplane parts to be made into an airworthy airplane. Cubcrafters was abusing this privilege by extending the privilege to many airplanes on Piper's type certificate. That's when the FAA said "all stop. Get your own certificate." At least that is the story which was going around during that period of time.

This may or may not be related to the period of time when the FAA began a big crack down on the use of unapproved parts.

Something along the lines of you could build an airplane out of surplus parts as long as the serial number didn’t fall in the original manufactures range. Then it was a piper pa-18 and all the stcs applied. They were using Univair frames and wings, and piper held the liability for all the new airplanes.

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Steve Pierce · Jan 8, 2023

Jim bought several wrecked Super Cubs and paperwork of others and built pretty much new airplanes around that paperwork. There were some issues when people took the Super Cub out of the barn and found out another one was flying with that N number. He then figured out the Spares and Surplus clause which allowed an airplane to be built out of surplus parts as long as the serial number was not within the original manufacturers serial number range. I have seen many J3d and AT6 done this way. As posted they were still Piper PA18s. Piper didn't like that and petition Congress to change the regs which they did. If you can prove you started the project before it was resended you can still register one that way. I met Jim at Oshkosh many years ago under the wing of a Super Cub but it was different in lots of ways. He was closed mouth about it simply saying they were testing some things. Those things evolved into the Top Cub. I used to know how many Data Plate/Spares and Surplus Super Cubs but have forgotten. Seems like more than 20. They bring good money because they were essentially new PA18s and all the PA18 STCs apply. The first ones had the early Airframes fuselages until they switched to Univair. They also had Dakota Cub wings and then went to Univair.

sj · Jan 9, 2023

hotrod180 said:
I live in the PNW, kinda near Cunb Crafters.
I don't recall them building "brand new PA-18's" before the Top Cub was introduced--
they rebuilt customer's airplanes, as good as new or better, and that was how they marketed their work.

They did! I own one!

sj

Mr. Ed · Jan 10, 2023

Skylight front and aft trim plus angle trim for the front side of the swing out windows.

Windshield to skylight trim. The aft trim piece is molded to allow a 1/16” neoprene seal between the trim and fabric.

Back to painting all the trim.

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