Category: Fuselage

The floor boards were mostly fit to size.  However,  some final fitting was needed.  For removing large amounts of metal, the grinder was invaluable.

I then finished filing them to final size.

Jessica and I spent the rest of the day match drilling the mounting tabs to the floor and deburring everything.  They turned out very nice!  We even put seats in and made airplane noises!

 

Mounting the horizontal stab was a simple bolt on process.

I mounted the elevators and started calculating how much weight it would take to balance them.  You have to estimate how much the covering materials will weigh.  Then cast lead weights for the front of the elevators so their neutrally balanced.

I don’t have any pictures of the casting process, but it was the most frustrating part so far.  My welding torch that I was using to melt the lead weights wasn’t working properly.  It’s still over 100 degrees outside and with all my breathing equipment and other safety equipment on, I was hot to say the least.  Just about the time the lead would melt, my torch would go out.  This went on for hours.

Not one to give up easily, I persisted.  It took two days to get it right, but in the end it’s done right and it’s behind me!  Now on to much more fun parts of the project!

The manual mentions to be as precise as possible with the alignment of the control assembly to the pulleys, rear pulleys, and clearance of the bolts.  I took a considerable amount of time running strings to the pulleys and making absolutely certain the assembly will be bolted in the best position.

I’m happy I took the time to do it right!

 

The tailwheel took a little bit of filing to make the leaf spring fit into the tailwheel just right.  I’m very happy with how it looks!

Today we spent the morning organizing and checking inventory.  Then moved on to the rudder pedals.  I had planned on putting the landing gear on first, but the strut springs were on backorder.

So far I am very impressed with the kit!  Very good quality and workmanship.  Everything is bolt on so far, but there is some measuring to do to make sure everything is in the right place.

I’m purposely moving very slow.  I’m reading the manual several times, measuring 8-10 times and contemplating every alternative before I drill my first hole in this airplane!!

Mike arrived with two Bearhawks!  We only got one though.

My wife Cati jumped right in and took control of the situation!

Mike made quick work of unwrapping everything for unloading.  The fuselage came packed with all the parts.

The wings were packaged separately in two wing crates.

I invited my good friend Andy to help supervise.  He did a marvelous job!

The wings were surprisingly light!  I had built some EAA wing slings to hold the wings so we could return the wing crates.

Cati and Tori were very happy with how everything was moving along.  My oldest daughter Jessica was the one behind the camera.  So no pictures of her here.

We loaded the empty wing crates back on the flatbed.

Now our garage is full of Bearhawk parts!!  My whole family is really excited to get started on the project!

Good times were had by all!