A Wake Up Call

I got woke up this morning by the a phone call from my friend at the powder coater.  He told me that I could come in and sandblast my fuselage myself if I wanted to save some money.  I jumped out of bed and headed right over.  He had me finish up some of his projects before we rolled my fuselage in.  I now have a whole new respect for the guys at the powder coating shop... this is tedious work.  It takes forever to just clean a section and it is extremely messy.

I got most of the tail sandblasted, and some of the front done.  I wanted to blast the tail to see exactly how much I would need to repair in a few weeks.  The left longeron has a few holes in about the last 6 feet of tubing.  The great part is, there is a tubing splice at about the 7 foot mark, so I'll just cut this tube out on both sides and have them replaced.  Better to do both now, rather than one now, and another one in about 5 years when the plane is recovered.  I knew when I got the deal I got on the fuselage, that there would be some repairs required.  So far, so good though.

I plan on going in tomorrow morning early and finishing up blasting the fuselage.  Then I plan on taking it to Lake Hood where I'll build some floorboards and start with some of the interior.  I have a date at the welder's of July 15, and I don't want to waste any time.

Fuselage Time

Today I picked up my "new" fuselage.  Was super excited to get a huge piece of the cub.  It's used, but in pretty good condition.  I brought it home and removed the remaining pieces.  I dropped it off this afternoon at the sand blasting shop to get blasted so I can inspect it further and prepare it for modifications I''d like to do.  I called around to different shops today about modifying the fuselage the way I'd like it.  Most shops would not let me assist in helping, but Dan's Aircraft was very reasonable and said that they'd let me assist the welder.  This will cut the cost down substantially and also allow me to keep tabs on the progress.  I plan on bringing it by about the 15th of July.

I'm planning on rebuilding the fuselage first now.  Once the fuselage is done at the sand blasters, I'll have all my mods installed.  Then I plan on starting with the interior.  I'm going by Plaschem tomorrow to discuss with a fellow the use of carbon fiber with my rebuild.  One the phone last week he told me he has floor boards, rear seat and storage bin under the seat, and a lower extended baggage that just drops right in the fuselage.  With these mods he said I'd save around 20lbs on the average rebuild.  I like hearing this.  We will see tomorrow.

My "newish" fuselage.  Lots of new adventures planned with this thing!

The 180lb/3rd Seat Mod.  Being previously installed, this saved me lots of money.

The X Brace over the roof.  Another mod previously installed that might save my life again, and also saved me tons of money.

This is the only area that will require a bit of attention.  The left hand longeron has a slight bend in it and I want to change the X Brace back here.  Rather than being boxed in, if we X the tail, it seems to withstand the beating the tails get on these birds.

I flew again on Monday with Era Alaska.  It was a heck of a day... 9.5 hours behind the yoke of the 1900.  This is good, because we all know I could use the money for my rebuild project.  I got to visit Barrow on one of our legs.  It was good to see all my friends up there, and believe it or not, I missed that place!  Sure feels good to be based in Anchorage for awhile though.  The trip from Barrow back to Anchorage in the 1900 was 3 hours long!

Time's Flying

As stated in the title of this post... time's been flying.  It's been 6 weeks since the accident, and I can't tell you how much my life has changed.  Some for worse, but mostly for the better.  Still stiff some mornings, but for the most part I'm thankful I get a second chance at life.  God has been good to me.  He has let me go back to work, he's let me continue to fly, and most of all he's introduced me new friends.

I went back to work for Era Alaska yesterday.  I got lucky, I was called mid week last week and asked if I'd like to work out of Anchorage.  You don't have to twist my arm... no commute to work, and I get to sleep in my own bed every night.  I will miss working out of Barrow, and hope to get to work up there again, but right now with physical therapy and still working with the FAA, it's nice to be close.  It felt so good to hop in the Beech 1900 and blast out of Anchorage.  The 1900 I'll be flying out of Anchorage is strictly freight; no passengers.  We went to Aniak, then onto St. Mary's with a very full plane load of supplies for the villages and outlaying villages.  I got the leg home, and was impressed with myself... I picked right up where I left off with call outs and procedures, even greased the landing back here in Anchorage.  I'm looking forward to flying the Beech more this week.

I made a big purchase on Friday... bought a "new to me" fuselage.  Looks like the direction of my project will shift a bit, but all that truly matters is we are making headway.  So far, it seems like it'll be a worthwhile fuselage.  Has quite a few mods I wanted to do, but of course, I want to do a few more.  I plan on picking it up Tuesday, and bringing it to a place to get it sandblasted so I can do a good inspection and figure out if we need to do some repairs.  Once its out of the sandblasters, I'll find someone to weld the mods I'd like then I'll bring it back to Lake Hood and start building some floor boards, interior pieces, etc.  After I get all that done it'll go off to the powder coater for a final finish.

I made a new panel for 29A.  I made it out of lexan, so I can install the gauges and see if they'll rub against the fuselage or anything else.  Super excited to cut this all out and see how it looks.  It is the same size as my old panel, but I changed a few things up.

I ended up getting a call from a friend tonight wondering if I could go help another friend.  I got to borrow a cub and fly out about 15 minutes from town and replace a piece of exhaust on a cub with a piece of mine. The fellow who owned the cub was super impressed how quickly I got out there and how quickly we changed the part.  He wondered how he could repay me, and told him its all about karma.  I've had many different people help me over my career, and when given the chance to help I need to as well.  I also need to build up that good karma bank, as I'm sure I'll need help again some day.

On my way across the inlet for tonight's rescue mission.

Making Noise

The past few days I've been extremely busy.  I finished up on the prop strike AD on the motor for 29A.  Seems to check out just fine.  VERY exciting news, as it only cost me about $20 for the parts.  The engine is now put back together in the hangar and I'm working on rebuilding the baffling.  Its going to fit a lot better the second time, as I have an infinite amount of time to fix it.  My goal is to have the engine together for hunting season, that way if a friend needs to borrow the engine to keep up with their schedule, it will be ready and waiting.  I have an engine mount that I'm going to dig out of the shed and install after I get the baffling figured out.  Going to have to start putting some money at her now.  I need to buy an oil cooler, valve cover (which I'm currently bidding on on eBay), mag harnesses, and an air box.  About close to $1000 worth of goodies.

With the need of money, and having no money, sounds like I need to go back to work.  I let Era Alaska know that I'm fit for flight, and they were extremely happy to put me back to work.  I start work this upcoming weekend, then I have a few days off, but then I start up again the 1st of July and continue work until the 15th.  The best part is, I won't have to travel very far this time, unlike the commute to Barrow.  I'm being based out of Anchorage in the company's straight freight (no crabby passengers) Beech 1900C.  Hearing this brought a smile to my face.  I will miss Barrow, but being based at home I can continue to goto school this fall, and most of all, work on the cub!

I passed my 135 check ride on Monday in the Beaver.  It was very last minute, but everything went well.  I had two FAA examiners on board.  One was getting checked out in the Beaver so they were just along for the ride.  Both very nice people and surprised with my ability to man-handle such a beastly machine. I was all smiles the entire flight.

My plans for the near future on the cub are to finish the engine section up, then start with fabricating a new panel.  I'm going to build it out of plexiglass first, and install all the gauges.  My idea behind this is to see if everything fits where I'd like it to go.  I also found a fuselage that I deem worthy of using.  I plan on trying to grab it in the next day or two and bring it to the sandblaster to get it sandblasted and figure out which tubes need to be repaired/replaced.  Once done there, I'll bring it to the welder and have the mods installed that I want.  I think I might change my course, instead of starting with the wings, I'll build up the fuselage first.  Going to cost more, but in the long run, I'll have something to sit in and make airplane noises!

A Week of New Hope

This past week has been one of the best weeks I've had in awhile.  On Monday, I went out and flew the cub for the first time since the accident.  Felt so good.  Yesterday I flew the Beaver in preparation for my 135 Checkride.  It was amazing being back behind the power of a sexy beast!  When I advanced the throttle and heard her sexy growl, it sent goose bumps down my entire body.  I forgot how much fun the Beaver really was.  A bit more going on then the Cub, but its just a bigger Cub.  I look forward to flying her again soon.  Maybe tomorrow?

Taxiing in after a fun day of learning in the Beaver.  Every time I look at this picture, I have to pinch myself to make sure I'm still alive.  I'm truly a spoiled young man getting to fly such a sexy plane.

Today I went in to the medical examiner to make sure I wasn't exceeding my own capabilities.  She gave me the big thumbs up, so I hope to go back to work soon.

I also made progress with the cub in the last couple days.  Finished my left aileron, so I now have all the control surfaces ready for cover.  Exciting!  I also brought the engine to the lake.  Tore into it for the prop strike.  So far it looks like the engine is getting a clean bill of health.  Had to buy a bolt for the back of the crankshaft, as per the instructions for a prop strike.  Amazing what really holds this little engines together and how much power something so small can put out.  I plan on having the heart of my beast back together this week, maybe Wednesday?  Then I have to start rebuilding the baffling and reassembling what I can of the engine.  I want to get it put together just incase someone needs it for hunting season.  Also so all I have to do is bolt it on the new frame and connect a few cables and wires when that time comes.

It just feels good to be going forward on her again.  I'm sure it's a year or more out, but I keep reminding myself that I truly am blessed I get a second chance to rebuild her.  Not just a second chance for my plane, but a second chance at life.  I've noticed a huge difference in my judgment and my flying.  I just hope to keep this up, and if I start to veer of course I'll remind myself of what happened last time.

Both ailerons completed, ready for covering.

The "heart" of 29A, minus her oil pan and accessory case.

The gears that make her work.  The center small gear is the crankshaft gear and the bolt in the center is what has to be replaced.  The other gears touching the crankshaft gear drive the magnetos, and the top gear is attached to the camshaft.  Super simple huh?

Time to Turn

I've been busy the past few days.  Flew for the first time since the accident on Monday.  In a cub none the less.  I really don't recall my "short landing" so flying came second nature.  Wasn't really scared but I flew with a friend, Steve, just in case, and he has a plane for rent.  Using my left leg for step turns hurt periodically, but the fun of flying out weighed the pain.  Only a few little things Steve found that he didn't like, but nothing that jumped right out and told him I was unsafe to fly.  I really enjoy being back in the saddle.  I'll start flying the beaver tomorrow, preparing for a check ride in the near future.  Look out... the skies are not friendly once again!

I haven't got as much done on the cub as I wanted but the left aileron is nearing completion.  The trailing edge is installed and most of the leading edge is installed.  I should have it done tomorrow.  Once this is done, I'll start tearing into the engine to take care of the prop strike inspection.  Looking forward to this.  I'm trying to get all the items that require very little money, but lots of time done before I head back to work.  I hope to work as much as I can during the summer, and then I'll start rebuilding the wings early this fall.  Have to save up, but if I can save enough the new and improved 29A should turn heads once again.

Progress

Making progress... slowly.  Bought a spar last week for my left aileron.  Brought my jig out of hibernation (under the shed) and set it up at the lake.  Got quite a bit of work done on the aileron Friday.  All the attach points are set, now its just adding the ribs and leading edge pieces.  Hope to have it done Monday or Tuesday.

My Aileron Jig and ailerons.

Been doing a lot of research into lightning the plane up.  My goal is 1100lbs empty weight.  Before the accident, she weighed in at 1156lbs.  Not sure how I'm going to loose 56lbs, but I'm going to shed it, ounce by ounce.  Thinking about using carbon fiber in places where heavier aluminum has been used in the past.  Also learning how the process of using carbon fiber fabric works.  Sounds like its a lot like fiber glass, but instead of using layers and layers of fiber glass, you only need 1 or 2 layers of carbon fiber.  To be continued...

My ankles are doing good.  I went to the doctor on Friday with hopes of being in a walking cast.  No such luck, but I got back in a week.  I hope to be ready to go back to work July 1.  I've been walking around the house without my braces on, making baby steps.  Physical therapy is going well also.  They think I should be up to speed by July 1 also.  Time will tell.

Busy, Busy, Busy...

It's been a busy week so far.  Haven't worked on the cub much.  More of myself.  Lots of doctor's appointments, trying to get back in the air.  My ankles are doing well.  My range of motion is getting better every day.  Hope to be back in the air within a few weeks.

I've got the left aileron torn down.  Bought a new spar today and some brackets for the flaps.  Finally got them finished and in the shed.  Hope to get up early and work on the aileron tomorrow, maybe even finish it.  I'd be way excited to finish all the control surfaces.  All I'd have to do is get my rudder fixed and then I'm ready to cover them.  Maybe this weekend I'll start covering, or maybe I'll try my luck with fishing.  Who knows...

She Turns to the Right a bit...

Had a busy day yesterday with doctor's appointments.  Didn't get much done on the cub, but did seen to straighten and finish the right hand aileron.  This means I have one more control surface to tackle, the left hand aileron.  THe left one is by far the worst out of all my control surfaces.  I have to completely strip this aileron of its ribs and leading edges due to the spar being bent.  The best part is, the spar can not be spliced where it is damaged... this means I get to buy a new one.  Not bad though, one donor aileron, and I'll only have $98 into repairing all the flaps and ailerons, versus around $700 worth of parts if I were to buy all new parts.  Very thankful for the free things I've gotten.

Plan on going out to the lake tomorrow to see if the hangar is open to tear down the left aileron.  Also, start removing usable parts from my cowlings and tank covers.  This week I want to build up a set of floorboards out of 0.040" Aluminum and also an instrument panel.  I know, I don't have a fuselage yet, but if I rough cut these, it'll make me feel like I'm making progress.  Also, going to bring the engine over to the lake and continue the prop strike AD that is required to be done.  Then the following week build up some baffeling.  Let's see if I can keep this schedule.  Below are some pictures of the progress made.

This is the right flap... forgot I had to repair the spar with a doubler the last time.  Good thing it didn't get bent this time.

One seriously bend left aileron.  Hard to tell in the picture but it bends about twenty degrees up were it's dinted int eh center.

Fixed right aileron, ready to cover and fly.

Flapped... Now Ailerons

Finished the Flaps today. They look perfect!  Actually, I have two brackets to install on them in the morning, then they are complete.  Feels good to get something back together on the little lady.  I'm starting into the ailerons hopefully in the morning.  I have one with minor damage and the other with quite a bit of damage.  Have to replace the spar on the right one I believe.  I dug out my jig from the last time I rebuilt them.  Can't wait... not.  This will be an all day ordeal, maybe two.

This afternoon I went to my friend Scott's house to help with his cub wings.  He pulled the old fabric off early this spring and has been working on his wings when he has time.  He was installing leading edges today.  Got me excited.  I can't wait until I have all the wing parts required to get mine back together.  Maybe in a month or two.

Flappin Away

Almost finished the left hand flap today.  All I need to do is install a piece of trailing edge from the donor aileron tomorrow.  Feels good to be productive.  It might of been a small thing, but its progress.  Also tore down the right flap and forgot about a surprise I had to fix the last time.  The first time I rebuilt this plane, the only control surface that I had that was good was the left flap.  The right flap made contact with the fuselage when it was wrecked previously and I had to put a doubler on the end.  This time, no need for a doubler, just a fix to the end rib and brace.  But since I'm kicking the flaps out another four inches ( extend the flaps so I have less wing root to build) I needed to remove the doubler and install another one that was longer.

Also got up earlier this morning to see a few friends off to Afghanistan.  They will be there only a short while, three months, but keep them in the back of your mind.  It was sure nice to get out and say bye before they left and let them know how well I'm healing.  Also thanked them for keeping the C-130s working, because no matter how much I love flying planes, it really comes down to the maintainers who do the most rewarding work.

Went to physical therapy as well.  Things are progressing right along.  Hope to be back to walking unassisted by the end of the week.  Might be a stretch, but I sure miss flying.  Its like putting salt in the wound every day I spend out at Lake Hood, but as long as I make progress on the cub I'll survive.