Projects - November / December 2002
 

Thanks to those builders and enthusiasts who have sent me their photos and reports. Thanks as ever to PFA Engineering for providing a number of photos and information on newly completed projects and of course to their builders for providing the information in the first place. Please send me the details of how you are getting on with your project, even just a photo and a few comments will do! My address is: 16 Wisden Avenue, Burgess Hill, West Sussex RH15 8TL Tel: 01444 8705990. Email: nhitchman@aol.com

 
Image coming soon G-BEBT Andreasson BA4B 038-10158

Rebuilt and flown by David Hockings Deanland Airfield, Lewes, East Sussex BN8 6AR

G-BEBT was damaged during a landing accident at Breighton. David Hockings has rebuilt the aircraft with major repairs required of: the main spar in the lower right wing and leading edge skin, the right elevator and tailplane attachment brackets, and the forward fuselage. Following repair the aircraft was repainted in its original scheme. Flight testing was carried out by Brian Cornes, during which the photograph was taken

 
G-BWVC Jodel D18 169-11331 Being built by Jim Cripps jim@jimbocripps.fsnet.co.uk

I thought you might like the latest pic of my D18 now that it's together, apart from the engine that is. Work is going well and I am currently putting in the last of the control runs, those for the rudder. Sorry about the dust on the wings!! The aircraft is in my Barn/Hangar which I built especially for my plane. I am hoping to have the Wee Beastie up and flying some time next year.

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G-DWPF Tecnam P92-EM Echo 318-13838

Being built and flown by PI Franklin and DJM Williams, Guernsey. Report and photo by Geoff Jones

The first homebuilt to be completed in Guernsey since Mark Parr's WAR FW190 replica G-SYFW, Dave Williams' and Peter Franklin's Tecnam P92EM Echo, G-DWPF, is pictured outside Dave Williams' garage where it was built. Construction started in late February 2002 and it was rolled out for final pre-flight inspection on 31st July 2002. The P92 was designed by engineers at Partenavia in Italy and is of metal construction. 'PF is built as a microlight version and is fitted with a Jabiru 2200 engine. Alignment of the wings in relation to the tail was within 1 mm (far greater tolerance is allowed for in the plans). Inspector for the project was Bob Wright from Jersey.

The weighing of the completed aircraft was done on high spec scales used by Guernsey based motor racing team and came in at the target 265kg. A Microair Avionics (Australia) radio is fitted. Although UK registered, a "permit" was also issued by the Guernsey authorities to sanction the P92's test flights from the states airport.

David has previously built two aircraft, whilst Peter is new to the game. Both have PPLs with considerable experience on a variety of light aircraft types and will share test flying. After completion of its 15 hours test flying in the vicinity of Guernsey, it is planned to fly it to Dinan in France, where it will be based. First flight of G-DWPF at Guernsy should have taken place by the time you read this (it was cleared to fly 9th Aug).

 

G-BTOT Piper PA-15 Vagabond

Restored by John Rogerson, The Tavern, Ease Howle, Ferryhill, Durham DL17 8SA. Owned by Matthew Rogerson and Steven Raw.

Piper PA17 Vagabond G-BTOT is now back in the air and flying again following a one year rebuild after a hand propping accident which damaged both wings. The rebuild consisted of making two new wings, buying new struts and starboard undercarriage leg plus a complete strip, inspection and recover using ceconite fabric and a traditional dope finish. The Vagabond is fitted with a Roll's Royce O-200 engine and a lightweight starter. This wonderful vintage aircraft made its first flight after the rebuild from fishburn airfield in April this year in the capable hands of Robert Ryle, another vintage Piper Vagabond owner.

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Thorp T-211 Being built by Stuart and Janet Gilroy

After visiting the PFA Rally at Cranfield for a number of years, we decided to take the plunge. Our specification was for a metal aircraft with a tricycle undercarriage and the Thorp T-211 kit fitted the bill. This aircraft was originally designed back in the 1960s by Mr John Thorp, who later went on to work for Piper and designed the very successful PA28 Cherokee range.

Although the Thorpe is designed around the continental 100 hp engine, we had become of the development of the Wilksch Airmotive WAM-120 diesel engine, which is supposedly a direct replacement for the Continental. Since starting the kit, we had made contact with two other Thorpe builders and decided to see what their views would be on fitting the WAM 120. Both were enthusiastic about the idea, so we spoke to our respective PFA Inspectors, who all gave the "Thumbs Up". We then needed to conduct a feasibility study that would cover such items as C of G, engine mount and redesigned cowlings. This was carried out by a stress analyst engineer who, after looking at our proposals, was able to give the good news that this engine could be fitted to the Thorpe T-211 airframe. Wilksch are hoping to fly this aircraft and engine combination before the end of the year.

 
There are some major reasons for putting the WAM - 120 into the Thorpe.

No spark ignition - no magnetos required.
No mixture control.
No carb heat control - no carb icing (the demise many a pilot).
Less risk of fire.
No danger of carbon monoxide poisoning.
The biggest advantage is that the engine runs on Jet A1 - a third of the cost of Avgas.

The engine has been tested to 130 bhp, but runs at 120 bhp normally and burns 11 litre per hour at 75% power, against a Continental average of 21 litre per hour. So, as you can see there are alot of advantages. The cost of the engine, redesigned cowlings and engine mount will only equate to approximately 50% of the cost of a new Continental 100 hp. (Not so sure about that. The WAM and the O-200 are both in the £10,000 price range. Ed)

Bearing in mind that normally we are definitely not D.I.Yers (around the house or car), the kit has gone together extremely well. We are now three years into the build and the proud owners of a fin, rudder, stabilator, two ailerons and flaps, and two wings. The fuselage has just been started. Building the stabilator was like building a small wing, so when we got to the wings we had a fair idea of how they went together. Although we must say that the instruction manual is very comprehensive and has excellent drawings, some mistakes do still occur, but with the help of our excellent PFA Inspector, Mark Hammet, these have not been disastrous.

This project is proving to be extremely interesting, enjoyable and sometimes frustrating, but we have learnt an awful lot of things we never knew before and now have a much better understanding of what is beneath an aircraft's skins. We are now quite proficient at drilling, deburring and riveting, with some experience of rivet removal!

We still have a long way to go, but hopefully we could be flying by this time next year.

 

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Thorp T-211 Being built by Stuart and Janet Gilroy

After visiting the PFA Rally at Cranfield for a number of years, we decided to take the plunge. Our specification was for a metal aircraft with a tricycle undercarriage and the Thorp T-211 kit fitted the bill. This aircraft was originally designed back in the 1960s by Mr John Thorp, who later went on to work for Piper and designed the very successful PA28 Cherokee range.

Although the Thorpe is designed around the continental 100 hp engine, we had become of the development of the Wilksch Airmotive WAM-120 diesel engine, which is supposedly a direct replacement for the Continental. Since starting the kit, we had made contact with two other Thorpe builders and decided to see what their views would be on fitting the WAM 120. Both were enthusiastic about the idea, so we spoke to our respective PFA Inspectors, who all gave the "Thumbs Up". We then needed to conduct a feasibility study that would cover such items as C of G, engine mount and redesigned cowlings. This was carried out by a stress analyst engineer who, after looking at our proposals, was able to give the good news that this engine could be fitted to the Thorpe T-211 airframe. Wilksch are hoping to fly this aircraft and engine combination before the end of the year.

 

G-BZRV Vans RV-6 181-13573 Built by Ed Hicks, Pete Hicks and Nigel Hitchman

In the last instalment, we had carried out the engine runs and just had weighing and a few last minute jobs to do. The new oil pressure transducer was fitted and the engine run again. To our surprise, we still had no oil pressure indication! Surely we couldn't have two faulty transducers so I started thinking about how the system should work and what could be wrong. I then realised that the transducer might normally be screwed directly into the engine and thus been getting an electrical ground through the engine, but we had ours mounted remotely on a flexible hose in a a rubber "P" clip, thus it would not be grounded. So with a quick mod and with some locking wire round the screw thread of the transducer connected to one of the engine mount bolts through the firewall. Started the engine again and, like magic, we had oil pressure. Great, now to make a proper earthing strap as the final solution. A few more tie wraps to hold some wiring in place, baffle and seal finalised, placards fitted on the instrument panel (thanks to Mike Drye for getting them done), wing root fairing rubber strips trimmed and wheel pants and leg fairings fitted.

We were now ready for weighing and final inspection. Scales were borrowed from Roger Target, which were accurate and easy to use. Empty weight came out at 1045 lbs, which seems to be a reasonably lightweight for our specification aircraft with O-320 engine and Sensenich fixed metal prop.

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The CG was also well forward, which is great as a pilot, passenger and baggage are all aft of the datum, and fuel very close to the datum. Thus we can carry about 80 lbs of baggage with two heavier than average crew and minimum fuel and still be with the CG envelope. A mid range CG would restrict the amount of baggage that could be carries with two crew.

Final inspection went well with our inspector Trevor Hope pleased by what he saw. With the paperwork complete, everything was sent off to PFA Engineering for processing. Meanwhile it was off to Oshkosh for me and Kitty Hawk for Ed, to the Great Cross country air race, finishing at Oshkosh. By the time of our return I had the Permit to Test on my doorstep, it had been there for a while, I think PFA's turn around was two days.

August 2nd was the first day I could get down to Garston Farm and with our Flight Release Certificate in hand, we were ready to go. A reasonable day for first flight, it was clear early on, but by the time we were ready to fly around 11am, it was cloudy, but with a 2500 - 3000ft cloudbase and almost no wind it was time to fly! Taxiing out everything worked fine, power checks OK, line up and call nearby RAF Colerne whose ATZ the strip is within. Everything ready, power slowly advanced, easy to keep straight, initially stick fully back until the rudder becomes effective, then let the tail rise and before I know it im airborne for the first flight - fantastic! Flaps up before we exceed their limiting speed, fuel pump off, check the T's and P's all OK, CHT getting high with the new engine so level off and increase speed. A slow climbing circle, keeping above the field or colerne, we are soon up to 180mph. CHT stabilising around 400F and everything running fine. Controls feel good, I keep the engine at 2500rpm as we are running in, this makes it more difficult to keep near the airfield as we are going so fast! Then I just flew around under the clouds for 15 mins going round in circles and figure eight's keeping a good eye on the instruments to ensure all was OK.

Time to slow down, extend the flaps, they work fine and then power off stall 52mph indicated, little buffet and a small wing drop as expected, but easy to recover and a bonus, the stall warning worked a few mph before.

Then descend to downwind with a couple of 360 degree steep turns to lose some speed but not have to reduce power too much. Longest final I've ever done at Garston Farm, but still a bit high, approach at 80mph slowing to 70 over the fence, a bit fast, but we touch down with a small skip about 1/3 of the way into the strip and stop well before the end hardly using any brakes. Its certainly alot faster than the Cub!

The cowlings then came off for a thorough inspection, but no problems found. Now off the Kemble for fuel and some data collection en route, with Ed on board as flight test observer. We now switched on the GPS to confirm the speeds, easy as it was a no wind day and everything looked spot on. The vacuum instruments all worked well and we could see the oil pressure and temperature as well as CHT and EGT all stable in the cruise. It used to take 20 minutes to get to Kemble in my Cub, in the RV its less than 10 but we made it a 30 minute flight to keep up with the engine running-in task. First landing on a hard runway was good, now to fill up with fuel. When we came to depart, they had just started an emergency exercise and the main runway was blocked by a simulated incident. So we were offered the short grass trip. No problem at all, with full fuel and two up, we were airborne in less than half the strip and climbing fast. Another 30 minutes flight around the area back to Garston Farm. Another inspection, followed by another 30 minute then a 1 hour flight, so in the first day I had done three hours in five flights.

The left wing is slightly heavy and we need some right rudder too, but these are easily rectified by a small trim tab on the rudder and by squeezing the trailing edge of the right aileron, which alters the airflow around the aileron - easier than a trim tab!

The back to work! A week later and a perfect day for flying, so another trip to Kemble for fuel, then off on the two hour endurance flight. With the speed of the RV this meant we covered the test area very quickly, and several times! Finishing off with a few touch and goes at Kemble, stop to refuel again, then back to Garston Farm. With everything now done, it was time for the PFA test program. With two crew, almost full fuel and some weight in the baggage compartment we were ready to go. All went well with the tests easily accomplished, confirming the fine handling and performance of the aircraft. The engine has ran great and we haven't had to add any oil over the six hours, despite being running-in with mineral oil.

With six hours flying over two days, everything was accomplished and the paperwork completed and ready for the Permit Issue. I posted the paperwork under the PFA office door at Shoreham on the Saturday evening, then went away for work for five days. Returning on the Thursday morning, I found a letter from PFA Engineering saying they had approved the Permit Issue and sent their recommendation to the CAA for them to issue the paperwork, together with a caution that we might not be first priority on the CAA's list. I phoned the CAA to see how it was going, saying that I was passing Gatwick later in the day. To my surprise they said I could pick up the paperwork that afternoon, excellent, only four working days for the PFA and CAA to process all the paperwork - who can complain about that!

Now it's time to get more used to the aircraft, polish the landings, get used to some crosswinds and have fun travelling across the country visiting airfields and going to fly-ins.

The full Permit was issued exactly two years after we took delivery of the kit. We all worked on it an average of two days per week for the two years, alot of work, but alot of fun too. Thanks to many great people for their advice and encouragement, but mostly to Sally Hicks for putting up with us and feeding us, Trevor Hope our inspector, Geoff Church for doing the wiring, Glenn Stanley for providing the wire, John Akerman for the wiring diagram and lots of advice, Roger Target for the painting, Ian Belmore for various tools and advice, Barry Clifford for the clecoes and lending us various parts, Andy Phillips (Andair) for fuel system components, Kevin Pearce (ST Aviation) for Microair Radio and Transponder and of course all the people at Vans's for producing a great aircraft and all at the PFA for enabling us to build such an aircraft in the UK.