PA-18 - Fuselage Swap - Has anyone done this?

[Andy Meyer]

I have a PA-18-95 that I fly often. Low time fuselage, mid-time engine and overall, it is in pretty good shape. It has new wings as a result of a taxing accident 10-15 years ago. The fuselage has also had one repair (years ago) where the belly fabric on the fuselage was strategically cut, peeled back, and a repair to the belly tubing was made. Then all was stitched back up and repainted. It all looks fine to this day and the repair appears to be in decent shape. That said, the fabric is ceconite from the 70’s and is showing some wear, and the floorboards appear to be original to the airplane. Thus, I am considering recovering the fuselage. This would allow me to swap out the floorboards and inspect the tubing repair. That said, knowing the fuselage is over 60 years old, I am wondering if anyone on here has ever elected to simply buy a new certified fuselage and do a parts swap? This would get rid of the old fuselage with the repair to the belly, it would allow me to easily replace the floorboards, and it would allow me to have complete piece of mind by enabling me to review the condition of all other parts/pieces within the fuselage. I realize this is a fair bit of work, but it also provides the surety ahead of time of knowing what I am in for vs. tearing into an old fuselage and not knowing the extent of tubing that will need to be replaced, and even after doing so, still having an old fuselage.

The airplane has had many recent improvements including HD gear legs, 26” Alaskan bushwheels, brake boosters, baggage door, cub crafter rear seat storage, cub crafters front seat, and it has a C-85-12F with starter and radio. It has good glass and good sheetmetal. New wings with good fabric and good tail surfaces and fabric. And it has two new props (climb and cruise). If I compare what I have to the costs of a new experimental kit, I feel like I have all of the “expensive” parts/pieces and just need to get them onto a good/new fuselage and would have a brand-new super cub…. Albeit, a 90hp cub, but I rather enjoy that.

All of that said, I do intend to build an experimental super cub at some point (hopefully within 3-5 years). So, I would also be looking to gain the educational experience of being able to see firsthand how a part is installed before disassembling it from the old fuselage and re-installing it on the new. Sort of why I am not interested in simply dismantling, repairing, repainting, and reusing my existing fuselage. I see value in the experience of having the new fuselage sitting next to the airplane as I disassemble and reinstall. I realize I may never recoup the cost of a “fuselage swap” (maybe I would?) but that really doesn’t bother me. And the time commitment also does not bother me as I like to have a project to tinker on. I would of course have an IA do all of the work to keep it a certified super cub

Would be curious to hear from others who have tackled a similar project. Thoughts, opinions, lessons learned?

Thanks,
Andy

 

[Dan Gervae]

If you do this you might as well factor in stripping, priming, and painting all of your components and doing what would basically be a restoration.....sticks, rudder pedals, panel, interior, Cables? it could get to be almost as much work as building a kit...LOL. all new hardware, pulleys, how are the instruments? You see what I mean? a recover and a restoration are very different things, and a new fuselage would be a restoration if it were mine. Just my 2cents....It won't be cheap, but it might be fun. You'll need to buy something to fly in the mean time.

 

[DENNY]

Nothing wrong with that plan. However, you may find that a lot of the interior pannels and glass will not just swap over without modification or new parts. The boot cowl will most likely not just line right up, so you will need to move gingerbread or make a new one. The engine or box of same weight should be hung on the front because the frame will flex some. Just be prepared for that. I would also not have the fuselage painted or power coated until you have fully assembled the interior and test fit the tail/gear and wings. Once you are sure every tab and modification is done correctly/all parts fit right than send it to paint. DENNY

 

[dgapilot]

So what is the approved data to install a C85 on a PA-18, supposed to be a C90!


Sent from my iPad using Tapatalk

 

[Andy Meyer]

So what is the approved data to install a C85 on a PA-18, supposed to be a C90!


Sent from my iPad using Tapatalk

Sorry, that’s a typo. It has a C90.

 

[skywagon8a]

Since you do

... intend to build an experimental super cub at some point (hopefully within 3-5 years).

Why not just start now with a new fuselage, using your assembled airplane as a reference as you progress? You can add components over time avoiding a major initial investment. You'll have a plane to fly as you progress. Then as you are nearing completion of your new plane, sell the old one. You don't say why the belly tubing was repaired. Was it damaged or was it submerged in water? Just because it is 60 years old is not justification for replacement. Also usually once an airplane is taken apart ..... well it usually takes a lot longer going back together and none of the pieces get misplaced. Particularly if the person doing the work has no or minimal experience in the process.

 

[D.A.]

I have a PA-18-95 that I fly often...That said, knowing the fuselage is over 60 years old...get rid of the old fuselage...it would allow me to have complete piece of mind...Albeit, a 90hp cub, but I rather enjoy that...

I'm completely behind you Andy. You have an airplane that you love, you just don't love the "Unknown" of a 70 year old (Give'r take) fuselage frame. I'm spot on with you. Having hung out around a dope and fabric shop for many years, I can't tell you how many times I've seen the scenario of: Owner flys into the airport for a recover - Airplane flys great, owner loves it, says it's clean as a whistle, just needs a quick recover. Pull the fabric off and the lower half of the lower longerons come off with the fabric. The owner had NO IDEA he was flying a rust bucket. NO indications on the outside.

You have a 70 year old Cub you're flying and you love it, as you should! BUT - - - BUT, how do you "KNOW" you're not flying around in a fuselage like the ones I've seen above? The answer - - - Change the frame. You'll now be in a Cub with no questions as far as rust is concerned plus it will be all 4130 and like you said, you've already made all the other improvements. Rust is real and piece of mind is important! If you feel like changing the frame, you should.

If your current frame turns out to be in better shape than most, use that as your basis to start your EAB Cub.