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New kid on the block - Smith Cub

For sure Dan if you need any pictures of anything just send me a private message and we can bypass the forum.
Floyd
 
The whole point in the forum is to help others who might have the same question. If you post the photos here you will be helping countless people for years to come.
 
Aluminum Panels

Now that I have templates for the upper & lower panels, it is time to try my aluminum snips. Panels will be made of 6061-T6, thickness .020

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First, I'll begin with the lower panels

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Aft baggage door

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Someone mentionned on one of the thread that cutting pieces of protective film with a soldering iron worked pretty good. Well, it sure does makes it easy.

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Makes perfect lines without sratching the aluminum.

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Portable bath
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Made a cover to protect the flaps cable



Next, the upper baggage section.
Dan
 

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Your right Steve, I do like how your able to resize the pictures so they fit on here. I’d hate to post something that I think is smart but only to find out it’s OLD news.
Floyd
 
Your right Steve, I do like how your able to resize the pictures so they fit on here. I’d hate to post something that I think is smart but only to find out it’s OLD news.
Floyd
It is a two way street. You will probably help someone else and someone might best an improvement or better way. We just keep learning till we are dead. I tell people I hope to be pretty smart when they start shoveling dirt on my face.
 
Looks like you are doing a great job..
One thing you might want to keep in the back of your mind when you are installing panels and floorboards is you may want to remove them after the plane is covered. You should be able to access all parts of the plane for maintenance. Also, you can't have too many inspection ports..
My 2 cents worth.
On a side note, I have a 200 hp Smith Cub and love it. I fly in the high density altitude SW US and it does great. I'll be happy to help if you have any questions. I've owned 4 Super Cubs and and worked as an A&P and IA on several rebuilds, so I am always thinking maintenance
Mike
 
Looks like you are doing a great job..
One thing you might want to keep in the back of your mind when you are installing panels and floorboards is you may want to remove them after the plane is covered. You should be able to access all parts of the plane for maintenance. Also, you can't have too many inspection ports..
My 2 cents worth.
On a side note, I have a 200 hp Smith Cub and love it. I fly in the high density altitude SW US and it does great. I'll be happy to help if you have any questions. I've owned 4 Super Cubs and and worked as an A&P and IA on several rebuilds, so I am always thinking maintenance
Mike

Mike,
200 hp Smith Cub? Wow!! Post couple photos of your cub if you can!
All the tabs on this aircraft will have anchor nuts. It is time consuming to install them but I beleive it is worth it. Easy to install and remove panels when required. I'm glad to see that there are several members with Smith Cub. You help will certainly be appreciated and it is reassuring to be surrounded by such a group of knowledgeable people.
Take care!
Dan
 
Aluminum Panels - Upper Baggage Section - Part 1

This one is a little bit more challenging due to the fact that the elevator trim cables and the flaps cable go through this area. The box is easy enough but the learning curve to fold the covers makes me appreciate the metal tech trade. But hey, working with this 3-in-1 Shear / Brake / Slip Roll metal machine makes easier for sure. Learning new skills is just what’s all about, Right?



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Little template just to make sure Good thing that I did a cardboard before... Riveted to the upper Baggage Panel
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Front Panel - Upper Front Panel UpperMade couple clips to attach side panel
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I try to use anchor nuts vs metal screwsFixed on the side panelNow the flap cover attach to the front panel
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Ready to go

Part 2 is coming up!
Dan
 

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Aluminum Panels - Upper Baggage Section - Part 2

All the cutting & bending is done, time to complete the upper baggage section...


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Parts almost readyNeed to reinforce the top panel with bracesBetter support now

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You can see the pulleys for the trim cablesSide panel to be added

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Better view of trim cables coverFlap cable coverGiant microwave!

Next...Upper cabin.
Dan
 

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I mentioned earlier on this thread that I built carbon fiber floor panels for my experimental SQ-2 cub. I created this PDF explaining my process. I list material sources (links) in the PDF for everything one might need to purchase. This is a first draft. My wife just brought me a beer and appetizers so I'm not going to proof-read this before posting! Please send me feedback. Email and phone contact info in the PDF (or PM me here on the forum).

Create carbon fiber floor panels http://eaerofab.com/docs/Ted_CF_Floor.pdf

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Last edited:
Top-notch workmanship Ted! Very instructive and well detailed. It is certainly the option of choice for saving weight and adding a touch of class to one’s project. Thanks for sharing! Dan
 
Aluminum Panels - Upper Cabin Area - Part 1


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Need couple measurements firstCabin back panel with its counterpartFitting itDone!

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Top panel in the makingNeed a stiffener to keep it straightDone!

Next will be the side panels with ''D'' window.
Dan
 

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Dan
Sorry it took so long...
I bought it from the original builder. Engine is a pumped O-360 with an 84 inch Mac prop. Incredible performance at our altitudes (mornings are around 8000 DA). Stalls at 30 mph at around 1800 lbs. I removed the die spring struts and put on a set of Acme Aero gen 3 struts. I run 26 inch goodyears because of the cactus needles where we land off airport. Tires do great in the rough clump grass and cactus. Would love to keep 31s on but they wouldn't last long here in the high desert.
Mike75B in front d12.jpg
 

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Aluminum Panels - Cabin Area - Side

Took me a while to figure out how to make theses ''D'' windows. I guess, there's more than one way to skin a cat! (Question: Why would you skin a cat???)

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First, I make a marker with a lead (5mm) to trace the shape of the ''D'' window.

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Bubble level to keep it square with panel.

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Couple strips cut-out in order to form the ''D'' shape.

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Draw bend lines & drill a hole at each intersection.

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Cut at an angle.

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One strip done...

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and bent.

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Drilled & clecoed in place before cutting out the window.

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Ready to be installed.

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In action!

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I chose to install a strip on top and around the window for better look. File it all around to make it flush with contour

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Countersink rivets

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Next I made all the trims for the windows.

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I wanted to make sure that I could remove the side panels when required, so I made a small part and....

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...I installed it under the top strip and screwed it to the frame (3 x countersink screws). To remove this panel now, it only takes a minute!

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Side panels and ''D'' windows...Done!!

Dan
 

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Battery / Storage Box

I just can't decide where the aircraft's battery should be installed..Firewall or under the passenger seat? Trying to weigh the pros and cons on the matter...But one thing is sure, the importance of stowage and storage in a PA-18 is indisputable. Therefore, I will be building a box that will go under the passenger seat and that can accomodate most of the batteries on the market. So, I the options will be there (Battery / storage or storage only) when time comes. Let's begin...

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I have built two different boxes (cardboard) to see which one would do the job best

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Other view...

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Chose that one...Less complex to built...I think :help

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Couple bend lines

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Photo for the Feds...

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Bending done for the main structure

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Drawing for the front and back cover

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All parts ready to be installed

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Dimpling and riveting

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More to follow!
Dan
 

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What engine are you planning on using and what is your mission for the airplane? I prefer the battery in the stock Super Cub location because most of my flying is light and it keeps the CG further aft. The underseat and firewall mounted batteries move the CG further forward than I like. Of course you are experimental so you can use the small EarthX battery and save a lot of weight.
 
Hi Steve,
The mission for this bird is to be a Gentleman’s bush plane. I have no intention to be the guy that lands & takes off the shortest distance but rather be the guy that can go anywhere (On & OFF Airport )in a comfortable cockpit well equipped for Day / Night (IFR if I have to). Flying for the Army, I discovered the Canadian North. We flew from Montreal to CFB Alert (2500 Miles) straight North every year for months and seen all these beautiful landscapes that I would like to share with others. That’s why I bought a 0-360 and equipped this aircraft with 72 gallons of fuel (Main tanks = 2 x 24 Gals and Aux tanks = 2 x 12 Gals). I prefer to have the fuel in the wings vs belly pod. Something that I learned up North is don’t trust forecast weather and the fuel cache. I slept in the open many times due to the fact that I was stuck in bad weather based on a CAVOK forecast!! As the say ‘’One Man, One Kit’’.

I love winter flying! That’s why I hesitate to locate the battery way back there. By having it located on the firewall (Earth X as you mentioned) I would remove around 10 pounds of cable, keep the battery warm and probably get better starting and also easier access for maintenance or boosting cables. I’m also planning to buy a Catto prop which would save a bit of weight.
Hope this give you a better insight of the mission...
Dan
 
Souds like a good plan. The Catto prop will help conciderably with the forward cg issue we have with certified 180 hp Cubs with the 1A200 prop which is very heavy.
 
Darn! Modifying Top Panel - Cabin Area

Darn!
When I sat on the passenger’s seat to take references for the top panel I did not, well you guessed it…Sit on a cushion, daaaaaah!! So, after fixing the cushion part, it was crystal clear that I needed more headroom. Did not have the choice but reshape the top panel…

Panels Aluminium 002 (1).jpg
Always start with a little drawing

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Trial fit

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Let's bend it!

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Done...Let's work on the top panel.

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Transfering drawing to the panel

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Don't you hate cutting open a brand new panel Aaaaaargh!

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Getting there!

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Assembling cabin parts together

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Better clearance now

Dan
 

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Cabin - Front Panels & Floorboards

I did move to the front section of the cabin area to make the side & front panels + floorboards. I had ordered all the plywood needed for the floors so I decided to go ahead with it even though I was really tempted to revert all this after reading Ted's post: Making Carbon Fiber Floors (See post #44).

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After cutting out all the plywood boards to the right size , the inevitable sanding session.

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Recipe for me was 3 coats of urethane and sanding between coats.

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All the wooden boys are taking a sunbath together.

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While the wood is drying I started to trim the side panels...

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...and installed them

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Side panels with floorboards.

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Panel in the pedals area. Need to bend it in the middle to accomodate the diagonal cross tube.

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All cabin panels done with their floorboards

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Rearview

More to follow!
Dan
 

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Hope you continue this detail through the entire build. Really helps first time builders

This is my intent for sure! What is obvious for most of the boys on this website is often not obvious for us, the first time builders!! I've spent a lot of hours searching on the multiple threads / books / part's catalog and on, just to understand the obvious. It is like going to the Supercub University and be the teacher & student at the same time. I just love it!
Dan
 
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