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Revamp of my Experimental PA18-95

My goal is to use this thread to detail the process of revamping my Experimental PA18-95. I look forward to all the valuable input I can gain from this well seasoned group. Hopefully someone can find my thread helpful too in the future! I have learned so much already from lurking in the shadows watching other projects here. This is my first Super Cub refurb, but I am no stranger to tools and wrenching. I still have a ton to learn, and I am looking forward to the challenge!

Forgive the length of this first post, once I get the back story out and the current state of the project in this initial post, I plan to just do update/question posts with pictures.

A little back story on the bird...In 2005 somewhere near Colorado Springs, Gregory Vandeputte birthed this plane from a section of J3 top longerons down. The fuse was put in a jig, from the door forward PA18-95 front was added, 18 birdcage, 18 controls, 18 baggage, some replacement sections of longerons and diagonals, and finally an 18 tail was added.

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In 2007 the wings were built, 13 rib, aluminum spar, PA-18 struts, completely new from Univair parts. Superflte 102 covering was added and from what I can best tell only a light layer of yellow topcoat on the fabric. The plane was fitted with a donor firewall forward O-200-A from a1972 150L and by September of 2008, the plane was issued it's airworthiness certificate and it began flying. Phase testing was completed in mid 2010. Gross weight was set at 1320 lbs and the W&B reports 885 lbs empty weight with 435 useful. The plane has a stock PA-18, 18 gallon tank in the right wing and a 9 gallon aux tank in the left wing.
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Since, the plane was only flown about 80 hrs from completion until the builder sold it to a local A&P in Colorado before the builder passed away in mid 2021. The A&P flew it very little, desired something bigger, then sold it to a gentleman in Omaha, NE who also flew it very little, basically from Colorado to Omaha after the purchase in the fall of 2021.

January 2022 is when I first came across the bird listed on Facebook Marketplace. Below is what I saw when I got there. I drove to Omaha with my A&P and brother in law to check it out. It had it's fair share of quirks (funky cowling was the biggest one), fit and finish left a bunch to be desired, but overall the bones and documentation seemed in order and the price/location was right. I saw great potential with the bird, left a deposit with the seller and my wife drove me back to Omaha a week later and I flew the bird home to central Iowa. To date, that was the one and only flight I logged in this bird since I bought it. It currently sits with 98 hrs since completion by the builder.

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I will start a new post now with what has changed since I got the bird and the next planned steps, stay tuned!
 
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Plan with the bird is to make a lighter weight somewhat minimalist basic VFR fun flyer, it will have some of the desired mods, mostly baggage and beefed up fuselage mods, tail handles and maybe some 26-29 ABW's, or as a purist friend of mine likes to call them "clown shoes".

Once I got it home, I immediately began disassembly and modifications. I started with a new mag harness as there was a miss, the harnesses were in not very good condition. Next up, the plan was a new cowling as it had a hacked up PA-11 cowling that didn't fit properly partially due to a 3" prop spacer from the 150L firewall forward setup. I soon discovered to get the new PA-18-95 cowling to fit properly I would need a new prop too...probably why the builder just added a 3" strip to the rear of the PA-11 cowling, to avoid the price of a prop. Well I had some cash burning a hole, so I ordered a brand new Sensinich composite ground adjustable STOL prop (still new in the box as I type this book). I also ordered up a fresh cowling from Univair. I wasn't digging the homemade exhaust either, so while I was under the hood, I ordered up a new Vetterman exhaust system. Nose is looking much better now!
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Moving to the interior, the floor boards (aluminum) were covered in yellow overspray and looked awful, ripped them out. Not sure what I will replace them with just yet, really like the idea of carbon ones. Come to find out, the home brewed adjustable front lazy boy seat frame interfered badly with the torque tube, rubbed paint off top of tube, ditched the current lazy boy seat setup for a Javron 2" lower, 2" back seat base and seat kit. Had to weld in a cross tube for the rear seat base legs, but no mountain for a climber. Still got to weld the lap belt tabs for the front seat to the floor. While the torque tube and pedals were out, I went ahead and blasted and painted them black. Covering was removed from the lower door as I plan to do an observer lower door. This basically put a wrap on 2022. The plane is currently hangared about 1hr away from my home. This has slowed progress for sure, also I spent a considerable amount of time in 2022 working on adding an instrument rating to my commercial certificate and now working on my CFI rating.

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Your going to want to ditch the die spring landing gear. They don't move on something that light.
Got rid of mine and bought a used AOSS set

Glenn
 
We made little progress in 2023, basically new paint from boot cowl forward....

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In April of 2024, well, the project promptly got put into reverse gear, we are going backwards now...

Upon looking the plane over closely, It appeared I was missing a lateral 5/8" structural diagonal tube that belongs in the bay just forward of the jackscrew, it connects the right top longeron diagonally to the left top longeron in the horizontal plane (shown with blue tape in pic below). I decided this now creates a great excuse to drop the mediocre covering to add the missing tube and add some other desired mods easily. We are "all in" now! No longer a couple small changes and back into the air. I am excited to basically rework exactly how I want it. The plan is to look really hard at Oratex when its ready for covering again.

So earlier this month I employed my wife, 14 yr old son and brother in law to help with dropping the wings. With that task completed, I got a little case of the cold feet and was a little reluctant to cut the covering off...after some back and forth, I figured it was the best and correct step forward. I dropped the firewall forward, cowling, boot cowl, windscreen and everything associated on my way to getting to a bare fuselage.

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My plan from here is to clean up the fuselage really well and inspect it closely for any problems. Upon initial inspection the overall condition looks great, a majority of the airframe was new tubing assembled between 2005-2008 and has only seen very little flying and been inside since built.

Considering the following mods to fuse:
3/8" tube tail boxing & X or H aft of jackscrew
Extended baggage angle for an extended baggage floor
Baggage dogleg
Rear grab handles
Exterior baggage door(s)
Add skylight, maybe go all out with L-18C greenhouse, not for sure on this one yet, but no better time than now
Maybe tabs for a pod?

Question:
Are there any special fittings that should be welded on for ski's? Not familiar with ski rigging on a cub, but would love to have the option!
 
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Well, I need some advice from you all...I guess the original builder thought if 1 bolt is good, 2 bolts must be better. Should a guy consider removing the vertical fin and welding these bolt holes back closed and reinstalling just 1 bolt in the correct orientation? Don't really know if this part is compromised in strength due to having 2 bolts, or if making the proposed repair would compromise the parts strength. Heck, for all I know, this may be a non-issue??? It just bugs me that it’s not installed quite right.

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Well, I need some advice from you all...I guess the original builder thought if 1 bolt is good, 2 bolts must be better. Should a guy consider removing the vertical fin and welding these bolt holes back closed and reinstalling just 1 bolt in the correct orientation? Don't really know if this part is compromised in strength due to having 2 bolts, or if making the proposed repair would compromise the parts strength. Heck, for all I know, this may be a non-issue??? It just bugs me that it’s not installed quite right.

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I have always seen one bolt on any Super Cub and it was oriented for and aft rather than side to side like yours.
 
I have always seen one bolt on any Super Cub and it was oriented for and aft rather than side to side like yours.
Same here...
So my question to whoever may know better than me when it comes to tube strength/integrity on a part such as this, what do I do with it? Leave it be or correct it (lower existing bolt is partially inline with the correct fore/aft hole location). What seems like the cleanest method (but not sure if the best), would be to remove vertical and weld up the 2 existing bolt holes (8 actually if you count the all holes in the tail post and the fin) and then drill the correct singular hole which runs fore/aft. Maybe there is another solution/repair practice I am not thinking of? Not looking for an engineer stamp from anyone, just want to make sure I don't do anything that could have unintended consequences, when I thought I was making it better.
 
If it is lined up correctly I would drill it correctly with it assembled and then weld up those other holes.
@Steve Pierce can you expand on what you mean by lined up correctly? Are you talking about vertically at tail post so hinges mate correctly to the rudder, or on a for/aft fuselage centerline, or both? When it comes to hinges aligning with the rudder, we are good there. As for the for/aft alignment with fuselage, is there a certain spec I’m aiming for?
 
If everything is lined up correctly the way it is fastened now then I would drill it before taking the other hardware out.
 

Stickman​

I am building a cub, I am at the point where I am looking for seats. Do you like the Javron seats? Do you remember what they cost?
Thanks
Gary
 

Stickman​

I am building a cub, I am at the point where I am looking for seats. Do you like the Javron seats? Do you remember what they cost?
Thanks
Gary
Well, haven’t sat in it yet, I think I will like the 2” lower and 2” back since I am 6’4”…I do like the quality, Javron puts out some nice parts! In 2022 money I got around $1700 in it. With Bidenomics in full effect, might now be $3400…IMG_5744.webp
 
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