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Thread: Bolivia 4-Place Build

  1. #81
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    Windshield makes it look like an airplane.Click image for larger version. 

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  2. #82
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    I'm looking for suggestions for ferrying a C-120 from Coeur D'alene, ID to northern Georgia. Looks like I'll be taking a few days off after Thanksgiving to go get a friend's plane and bring it down here for two aspiring mission pilots to build time in. I'd like to make it fun and stop at some grass strips along the way. It would be neat to meet of few of you and see the areas you fly in if possible. I'll have the owner of the plane with me who still hasn't soloed yet. We will be near gross with fuel and a couple sleeping bags on O-200 power so performance will be pretty limited.
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  3. #83

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    Quote Originally Posted by DJ View Post
    I'm looking for suggestions for ferrying a C-120 from Coeur D'alene, ID to northern Georgia. Looks like I'll be taking a few days off after Thanksgiving to go get a friend's plane and bring it down here for two aspiring mission pilots to build time in. I'd like to make it fun and stop at some grass strips along the way. It would be neat to meet of few of you and see the areas you fly in if possible. I'll have the owner of the plane with me who still hasn't soloed yet. We will be near gross with fuel and a couple sleeping bags on O-200 power so performance will be pretty limited.
    If you end up taking a bit more northerly route, drop in. I'm in NW SD, right on the MT/SD border, about 60 miles north of the Black Hills. SD33 on the sectional.

  4. #84

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    I am 2 miles north of 1V2 in western Nebraska, east west strip with authentic cow poop included. Drop on in and I will feed you some corn fed Nebraska beef. Brian


    Fly Safe

  5. #85
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    Graham, TX KRPH, have two 670 grass areas next to the runways. Fun to talk Cubs. My hangars are the only thing on the east side of the airport.
    https://goo.gl/maps/mmpzJ42ofSizEF6S6
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  6. #86
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    DJ
    If you need a ride from the airport to Coeur d’Alene, or a place to stay, I’m not very far away from there. And would be more than happy to help if I can.


    Bill Rusk
    Very Blessed.

  7. #87
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    Thanks guys it all sounds good. I was thinking the longer southerly route would be a good idea this time of year to avoid getting stuck in a deep freeze if the airplane had an issue, but looking at the chart there is a lot of high ground between Idaho and Texas. Any suggestions?

    Happy face when the fiberglass job went ok. Three fiberglass rookies. Jonathan and I were moving too slow. Before we had the second layer of four wetted out, the 200g batch of West system in the mixing cup kicked off. I didn't think we had the hangar warm enough but I guess so. Jeff was working on his project and ran over to help. He mixed (smaller batches) and I think it turned out good. We will see tomorrow.

    I ordered some shorter 45 degree tank fittings and they made the tank outlet situation a lot better.Click image for larger version. 

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  8. #88

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    Very helpful to see the fuel tank to fuel line connections. Thanks!
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  9. #89
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    Glad it helps but remember you saw it on the internet. I'm no pro builder.

    Looking at the route down through Salt Lake to Albuquerque and then I-40. Less blizzards but mountain winds and high passes.

  10. #90

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    DJ, my strip just S of Amarillo/I40. I’d feed y’all and put you up for the evening. My strip is on the short side but it can be cheated to make longer. Barry, that you got the Saint tips from, is also close and lives on a longer strip. Holler if we can help.

  11. #91
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    Quote Originally Posted by DJ View Post
    Glad it helps but remember you saw it on the internet. I'm no pro builder.

    Looking at the route down through Salt Lake to Albuquerque and then I-40. Less blizzards but mountain winds and high passes.
    You could go from Idaho to Cortez, CO, then Santa Fe, NM, and east from there. Save a few miles and it is all fairly low (by our standards) and very pretty. Winds have been light lately.
    If it ain't broke - improve it

  12. #92
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    We come south out of the Salt Lake City area, Huntington, UT -Monticello, UT- Aztec, NM- Sandia East, NM- Hereford, TX- Graham, TX.
    Steve Pierce

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    Will Rogers

  13. #93
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    Headed out for fabric.Click image for larger version. 

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  14. #94
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    Univair front strut 12 lbs. It has a lot of oil sloshing around in there.
    HD 4130 rear strut 10 lbs.
    These are certified scales but the resolution is only 1 lb.

    I've been trying to keep "unnecessary" permanent weight to a minimum. I have added some for utility and ease of building.

    Frame was epoxy primed with Aerothane top coat. Might have saved a pound or two vs powder coat. The decision was based on practicality.

    Cessna sliding seats saved maybe a pound or two vs PA-18 seats.

    Overhead flap handle saved a little weight. I think we saved four pulleys and some
    cable.

    The L21 greenhouse glass (1/16th polycarbonate) weighed in at 7.1 lbs. The rear skylight is about 3.3 lbs of that. We could have replaced this with fabric for ~3 lbs of savings but I didn't want to spend the time cutting and modifying the frame.

    We upgraded the floor to .032 6061T6 (+1.7 lbs)
    Welded two steel channels in the rear pax foot area. (+0.5 lbs)

    These changes more than doubled the rigidity of the rear floor. The .020 and .025 2024T3 we started with was unacceptable for our mission. The two large floorboards from the rear stick area to the end of the extended baggage are removable in minutes and stiff enough for a stretcher or sleeping.

    Boot cowl is three piece .025 with stiffeners at the side and bottom seams. .020 might work but the large flat areas would oil can pretty bad.

    We will be making the tank lids out of .032 6061T6 with no stiffeners. This is like the lids Javron supplies with their kits. Heavier than CF but they save about a pound total over Piper lids. Kirk says he tried .020 and it lasted about 100 hours.

    Planning to use .025 for the upper cowlings.

    Sticking with the EarthX battery and SD8 dynamo and reducing electrical load with LEDs.Click image for larger version. 

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  15. #95
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    Is anyone interested in ferrying the C-120?
    KCOE to 9A5.

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    The heavens declare the glory of God; the skies proclaim the work of His hands. Psalms 19:1

  16. #96
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    Fabric going on. Using Steve's aluminum inspection point reinforcements.Click image for larger version. 

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  17. #97
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    Almost there Click image for larger version. 

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  18. #98
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    Paint scheme progression.

    We were goofing around with tape in the paint booth and not getting very far.

    Jodi came to the rescue. She likes this Carbon Cub scheme so we started with that and moved the lines back to keep the boot cowl a solid color. The kids wanted to help. Tirzah (4) drew me up some new wheels. We could move a 35 to the tail and put some 44s on the mains. What do you think?

    Merry Christmas everyone!Click image for larger version. 

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  19. #99
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    Red is on.Click image for larger version. 

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  20. #100
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    Very nice, well done. Those door openings are big!!

    Thanks for Keeping us updated.

  21. #101

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    That inside panel is very high. Make sure you can pull it out with the instrument panel in place for future maintenance and when that fuel valve fittings start to leak.
    DENNY
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  22. #102
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    Thanks Oli. The fabric and paint have been a labor of love by an anonymous volunteer at an undisclosed location somewhere in Georgia where the gravity is reported to be different. It is one of the lightest cover jobs besides Oratex.

    I love the doors too. A 55 gal drum goes through the opening standing vertical. Rear seat access is phenomenal.
    Last edited by DJ; 01-02-2023 at 07:34 AM.
    The heavens declare the glory of God; the skies proclaim the work of His hands. Psalms 19:1
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  23. #103
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    Quote Originally Posted by DENNY View Post
    That inside panel is very high. Make sure you can pull it out with the instrument panel in place for future maintenance and when that fuel valve fittings start to leak.
    DENNY
    Good point. It could be lower. Jonathan wanted things tight and clean and went the extra mile. It is .016 and pretty flexy. Will double check.

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  24. #104
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    Back homeClick image for larger version. 

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  25. #105
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    Boot cowl and trim detailsClick image for larger version. 

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  26. #106

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    If you make the sides of that top piece shorter and build it into a 3 piece it will be easy to access stuff behind the panel. DENNY

  27. #107
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    Quote Originally Posted by DENNY View Post
    If you make the sides of that top piece shorter and build it into a 3 piece it will be easy to access stuff behind the panel. DENNY
    Good ideas especially for a narrow Cub. Boot cowl is already built and nutplated as a 3 piece. Jonathan is doing final windshield fitting and door post trim strips. Then engine mount and engine mocked up to begin building the cowls.

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  28. #108

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    Leave the boot cowl and interior panels on when you install all the instruments and electrical, that way you will know you can fix/replace anything without pulling off the engine and boot cowl.
    DENNY

  29. #109
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    Did you make a inner windshield strip also for support. If so any pictures of what you did there.

  30. #110
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    Yes. Sort of...
    Kirk says he has tried without but it didn't work well. The windshield flexes enough to leak. He said about a foot of inner strip in the front center would be enough. Jonathan is experimenting with two smaller pieces to avoid the shrinker/stretcher routine. Even in the middle things are not quite flat or straight. I believe the Bearhawks do something similar.Click image for larger version. 

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  31. #111
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    3003 aluminum and the shrinker/stretcher is how I have made them. Not for a wide body though. Should be easier since it isn't as tight a bend. Takes time and patience.
    Steve Pierce

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  32. #112

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    I built that inside windshield fairing on my Bearhawk Patrol using strips of fiberglass. The windshield was in place just like you did on the outside. I just tucked in strips about 10 inches long, overlapping them as I went and used I think a rubber kitchen spatula to position them. I think I used 5 layers of 8 oz bi-directional. Total width is about 28 inches wide. Fabrication went quick.

    Click image for larger version. 

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    Last edited by bcone1381; 01-13-2023 at 10:14 AM.
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  33. #113
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    Nice...

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  34. #114

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    Before you build the doors or do much more metal work (bottom cowling) you might want to put the motor mount and motor or a box of equal weight on the nose, and put a set of gear under it. The fuselage will change shape when you add the weight on the nose.
    DENNY
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  35. #115
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    The doors come with the fuselage. I personally have never done that and never had a problem knock on wood.

  36. #116
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    Yeah doors are all done with their polycarbonate skin. The aluminum door frames fit quite loose and rely on the polycarbonate overlapping the structure for a "seal"

    Don't worry the the castle nuts are not the permanent hardware.

    Jonathan got a loaner O-290 hung this morning to build the top and side cowls around.Click image for larger version. 

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  37. #117
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    Cowl build in progress.Click image for larger version. 

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  38. #118
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    Quote Originally Posted by DJ View Post
    Yeah doors are all done with their polycarbonate skin. The aluminum door frames fit quite loose and rely on the polycarbonate overlapping the structure for a "seal"

    Don't worry the the castle nuts are not the permanent hardware.

    Jonathan got a loaner O-290 hung this morning to build the top and side cowls around.Click image for larger version. 

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    I did lexan doors on my seaplane doors like you did. About 3/8" over edge, before mounting I stuck each side in a brake and put a 10 degree bend on them. Seals better

    Glenn
    "Optimism is going after Moby Dick in a rowboat and taking the tartar sauce with you!"

  39. #119
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    DJ, I'm impressed with the progress you guys are making.

    What did you use for a nose bowl? I'm wondering what works and looks good for the extra width of the 4-place fuselage?
    "Fast is fine, but accuracy is everything." Wyatt Earp

  40. #120
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    Thanks Spinner2. I'm in Bolivia at present but we have some great volunteers fabbing it up there in Georgia.

    I bought Randy's carbon nosebowl that is an inch wider for the O-360 but I should have just called Kirk. I'm guessing he uses the cheaper stock width ones.



    Sent from my SM-G965U1 using SuperCub.Org mobile app
    The heavens declare the glory of God; the skies proclaim the work of His hands. Psalms 19:1

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