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Worst day at work ever

I am proud of you for posting the story. I have a full video of a screw up I made in Idaho last fall. No metal got bent, but my ego was bruised for a long time! Short story, I had to make a go around at a NO go around spot. I aborted a bit late and only a turbo charged engine saved me from my poor decision making. I learned a LOT that day!

I was not as brave as you to post about it. I am only recently starting to talk about it.
 
I would not have risked a passenger on that flight, especially where there is a road.

Sorry to be the lone ass. Thanks for telling your story.
 
I think that was a Dan Dufault cub N118AK? He worked a lot of magic in that bird. One of the best flying Cubs ever
jim
 
I think that was a Dan Dufault cub N118AK? He worked a lot of magic in that bird. One of the best flying Cubs ever
jim
Yes...good performer and pretty light. It was 1120 on 31s before we bought it. With a pod and 35s it was 1160. With the lead times on everything else a quicker option is Univair's 10 ft tail section and build it back how it was.



Sent from my SM-G965U1 using SuperCub.Org mobile app
 
The rest of the story.

Day 1 was a 14 hour drive in with 4 vehicles. Our friends from International Tribal Ministries and Mano a Mano Foundation loaned two 4x4s and 5 mechanics. The recovery would have been almost impossible without their help. A trailer was not an option due to road conditions. I had a doctor and a dentist along to give medical and dental care to the community members while the mechanics were working. The last couple hours going in we used the 4-wheel drive, but no one got stuck and no landslides blocked the road (very common this time of year). We were blessed with good weather three of the four days.

Day 2 we hiked the 3 hours to the plane. The mechanics had the Cub apart in 5-6 hours. A contingent of about 25 locals waited patiently while we worked, fed us a meal of roast lamb and potatoes and did most of the hauling. We packed cylinders, instruments and all the small parts in 5 gal buckets with lids for transport on mules. One mechanic had 100 yards of bubble wrap and a roll of stretch wrap. He was busy packing as the others disassembled. That night we split up and stayed with the nearest neighbors in their thatched huts.

Day 3 the mechanics hiked out with the tools while the locals shuttled parts to the cars. The wings went out on people's backs, the engine on some poles. We turned a gear leg inside out, braced it with the upside-down cabane and lashed it in place. That allowed the fuselage to go rolling on one tire. By the end of the second day all the pieces were on the vehicles.

Day 4 we got an early start and 4-wheeled the 3 hours back to dry roads. About halfway home we rounded a narrow bend on the mountainside and saw a group of vehicles blocking the next intersection. As we approached, ten police in fatigues with weapons drawn, dismounted and ran up the road towards us. There was a lot of shouting and chaos. They demanded all cell phones and radios and warned us not to make a call. A couple of our guys got handcuffed, the rest were made to sit on the ground. I thought it was pretty extreme for a routine road checkpoint. I was right, it wasn't routine, they were looking for me!

The major who started interviewing me almost fell over when I told him I was the pilot and in charge of the team. He thought he was talking to a ghost because on social media I was dead and buried hastily by the wreckage. Turns out some local youth had visited the plane, taken a number of photos and posted them. We were told the comments ran pretty wild. The police had been "looking" for us for 3 days.

We were able to quickly and effectively prove our innocence. The day of the accident I had passed the routine narcotics check with K-9 presence, before takeoff, and had evidence of this. We had notified the Civil Aviation authority the same day of the accident and I submitted a full report the following week with all the details of our plans to recover the airplane, including dates and locations. I had also invited Civil Aviation inspectors to accompany our expedition. They ended up deciding it didn't quality as an air accident and declined to investigate.

With this info, our doctor’s credentials, and the fact we were recovering the plane and not trying to hide anything, the officers relaxed. Our name was clear. But, they still had a problem. If they let us go, it would be admitting a pretty costly mistake on their part. A 1-minute phone call to Civil Aviation, or their own officers at the airport who had signed my flight plan, would have saved launching 3 squads and 2 helicopters on a 3-day goose chase. Needless to say, we got a police escort the rest of the way home. Then they detained and questioned the whole team till 2am at the police headquarters.

I got pretty tired of them trumping things up and saying we had been "denounced" so I risked more trouble and challenged the Coronel on that. Was a social media post an accusation? Did it have more weight than the documents and evidence I had already shared with him? What right did they have to detain us, especially the doctors? He admitted they had no evidence against us and that we were voluntarily being taken for questioning. I responded that I would at least send the docs home, to which he countered with a threat to arrest us if we tried....sigh. He also informed me that the fuselage would be subject to a microscopic vacuum inspection in the morning and then released if the test was negative.

Bottom line, we survived the night. I crashed for 30 mins before I had to be up chasing documents for our 8am inspection back at headquarters. Thankfully I got in touch with a lawyer that I trust and he agreed to drop everything and come.


The fuselage passed the test. You might think "of course." But it wasn't that simple. The plane had been on the mountain for 10 days with no guard. People had been there touching it and taking pictures. Someone could have easily planted something on it in that time, or during the night at headquarters. There was a real chance I would go straight to jail.


That was February 17, and even though the judge said we could collect our goods after 5pm if the test was negative, we still don't have the fuselage. I've been back trying to get permission to inspect for damage but that was not allowed.

I believe God turns all these things for good, so that is the way I’m choosing to look at the situation. Will we get our parts back? Yeah, I’m pretty sure we will, but it may take a while. Meanwhile, since our paths have crossed, we will be praying for the officer’s salvation. Please join us. The value of one soul is infinitely beyond estimation.
 
Very thankful for great help, good roads, and the fact that a Cub might be the most repairable plane on earth.

Only got one picture of our escort.

30 hours of dirt roads took its toll on the 'ol FJ40. Lots of screws missing and bolts sheared on the natural gas controller from the vibrations.

Very thankful the crankshaft wasn't bent!IMG_20220306_205150_662.jpegIMG_20220306_205214_558.jpegIMG_20220306_205158_806.jpegIMG_20220306_205205_407.jpegIMG_20220306_205208_779.jpegIMG_20220306_205137_215.jpegIMG_20220306_205132_724.jpegIMG_20220306_205112_465.jpegIMG_20220306_205328_165.jpegIMG_20220306_205308_521.jpeg20220302_115249.jpeg20220217_024026.jpeg20220217_100057.jpeg20220303_173450.jpeg

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Well high time for an update.

We finally did get the fuselage back from the police on March 18. Rebuildable, but maybe a big job without a jig. We decided to seize the opportunity to build a four place Cub.

Most of that decision is prompted by a move from Cochabamba at 8350 ft msl to Rurrenabaque at 650 ft msl to work a more need-saturated area. 80-90% of the flying will be relatively low altitude jungle ops where the bigger frame and higher gross could be a benefit. With the stock fuselage I would hit 1950 lbs, aft CG limit and bulk out with two slim docs and their gear. 1950 lbs was my limit to have any performance above 14K. That shouldn't be as much of an issue at low DAs.

A big hurdle was finding some 2300 lb gross wings to take advantage of the extra volume of the four place. I really wanted Javron wings as we need to keep this Cub as light as possible to still have altitude capability. I had given up and was ready to scrap the four place idea when someone told me to call Bill Rusk. Turns out he still has a set of round tip Javron wings and was willing to part with them to help us out. Thanks Bill!

Airframes is promising July 28 or sooner for delivery. I'm hoping to do most of the work in Georgia starting in August and ship to Bolivia as complete as possible for final assembly.

So here is how its shaping up...

I'm reusing the Engine, Accessories, Gear, Tires, Shocks, Instruments, Radios, Seat, Pedals, Torque Tube, Trim, pulleys etc.

Working on finding nose bowl, tanks, struts, and tail feathers with oversized elevators.

I can get by with stock flaps and tanks (have so far) but it is tempting to try Carbon Concepts new 23 gal tanks that drop in the 18 gal wing bay, and PSTOL flaps would be nice but I don't "need" them. Kirk says the four place comes in flatter than a stock Cub. The fuselage must have something to do with that. He says the round tip wing will not come in quite as slow when heavy but unless you are really "squeaking it" the round tip will work fine.

Other items to decide: Fabric system, floorboards, baggage door, interior...

Suggestions welcome

DJ
 
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DJ, I finally had time this morning to catch up on this post. Man you live an exciting life! Keep up the great work you are doing and thanks for sharing all of this with us!

sj
 
How exciting!!!

As you well know, ounces make pounds, pounds degrade performance.

Even though you say you will be working low altitude, trees get really tall and scary when you are not climbing very fast and they are getting closer!! (remember wind above the trees may not be felt on the ground, and if it is a tailwind will keep you from climbing with any speed).

That said, I would be going Oratex just for weight and repair reasons.

I would use thin washers and bolts just long enough to be legal.

I would be very carful on adding weight.

Keller flaps and slats are impressive. I will submit that combination made the difference in walking away and not. Being in control at 25 touching the ground is a game changer when things go bad.

Steve's Gascolator, good shoulder harnesses and belts to the frame.

Have you considered doing a week seminar on building a cub, or installing Oratex where you get a bunch of us together this fall and we 'train' on putting a cub together using your project?

Might be a great time, and get your project further along.

George
 
I AM looking for volunteers to help put this together! We will be starting in early August as soon as we get the fuselage from Alaska. Working out of a friend's hangar at KLFT (Lafayette, Georgia). The goal is to get the fuselage as close to done as possible in two months under the watchful eye of Charlie Aileron. Firewall forward will happen in Bolivia. If we can locate a loaner O-360 to hang on the mount we will try to get the cowlings built as well. Web is building the panel. If anyone with Cub building experience wants to swing by and help they are more than welcome. I had a young guy scheduled to help me full time but he just got engaged and the the wedding is in August so I'm on my own again.

We are getting the frame without powder coat so we can add any necessary tabs, stringers and maybe a lower baggage door.

I have the Steve's gascolator and shoulder harnesses to re-use.

As to weight, the goal is to stay under 1200 lbs on 35s. We will find out if that is possible.

Our game plan to get there is this:

Catto 86/38
Parallel Valve O-360 on Conical mount
Lightened ring gear
Carbon fiber nose bowl
EarthX
B&C 8 amp
Slick mags
Vetterman exhaust
Javron gear with Acmes,
Experimental 35s on Greg Miller Wheels
Simple panel (G5, engine monitor, Airspeed, Oil T/P, Ipad)
Becker radio and transponder
1/2 skylight, no L-21 greenhouse
No headliner
No upper baggage
Fixed pilot seat
Early Cessna style copilot seat
Light minimum seat Cushions
Single controls
Carbon concepts rear seat
Round tip Javron wings with 18 gal tanks
Stock flaps (probably)

We probably need more weight savings to hit the goal of 1200 lbs.

Anyone have data on weight savings from:

Oratex
Floorboards (Carbon fiber, Aluminum, wood)
Javron Aluminum struts versus Steel HD sealed struts.
 
You should easily hit that weight. Go willow mountain for sure. I did a airframes willow mt. frame- l-21 glass, o-320, borer, pod, cert. 35’s and standard wheels, 6” gear, stock struts, two bag. doors, normal amenities, basic panel, square wings: 1204lbs. Check airframes Alu struts vs Javron- iirc, Javron’s are heavier. Airframes save about 12lbs over steel. Lose the oratex unless you want to reglue tapes for the life of your cover job... edit: sorry I just saw the fact that you’re going four-place- cool! Tons of room and they fly like a cub! And I still bet you hit <1200😄
 
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The 4 place has the lowered floor incorporated I believe. I guess I'd be a little nervous taking the Airframes aluminum struts to 2300 lbs. And it's a lot of money to save 12 lbs.
The Cub was 1145 on 35s with Piper wings stock tanks and thin Polytone. The 4 place frame is probably 50 lbs heavier. Plus extra windshield, floorboards, seats, heavier wings, bigger tail. Firewall forward will be the same but I'm not sure where I'll save the extra weight.

Sent from my SM-G965U1 using SuperCub.Org mobile app
 
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