rmorton

HI Sam

I am a slow learner and am in no real rush. the plane will take at least 18 months to complete. I intend to build as many hours as possible before I make the first flight.

I got into this craziness when I realised that:

1. I wasn't too old to learn to fly

2. you can build your own plane for not too much money.

My first thought was a French designed would and composite called the Gaz'aille which I will build one day. The problem was that it is a three year project and is more suited to a more experienced pilot.

I then looked at Rans Cayotes but they are not easy to find here.

Ninja - lovely plane but it isn't an all metal plane and I really took a shine to the idea of an aluminium skinned plane.

After looking into importing the Zenair I found ICP. We visited the factory last year and was totally sold on the plane and the company. It is only a 3 hour drive from here too so if I really need help or parts I can go there in a day.

I am hoping to get my licence this year and still havent gone solo after 25+ hours not going to worry about it though as the rest is going ok. Just need to pass the theory and get plenty of practice in.

This was not fully my intention. I was doing chapter 13 because it is interesting work that can be done in my warm cellar and small parts to store. Then I was doing prep work for chapter 14, because I was looking for missing parts. Then I finaly managed to get my family to help and we ended up deburring holes and stuff for chapter 16, while sitting around a table chatting.After counting it is clear now, that 50% of the time is spend for preparing parts from deburing to priming.

I have put all the plastic bags instruments and small parts on some shelves in our cellar which helps give some perspective to how much there is to do.The only problem with that is as the shelves empty I will start to worry about what I am going to build next....

You are racing ahead now! It looks like the Airbus factory! Fuselage and wings at the same time? Don't get them mixed up ;)

I have managed to spray some epoxy primer, same colour as yours, and although I dragged a wire across it before it set I am really encouraged by the finish I got. Next phase is to do the elevator and last night I found the parts bag for the flaps... I think.

HI Sam,

yes I understood that the ULM class in Switzerland isn't so clear and not so welcome perhaps. PPL is definitely the way to go if you can. How far have you got with your training?

The French dealer is excellent very helpful and obviously dedicated the plane. I bought mine from him and collected directly from the factory who are also very friendly and passionate about all things that fly. We live on the wrong side of the border next to Geneva.

Richard

Hello Sam

which type of licence are you going for? Will you eventually own your own plane? You have chosen one of the best sites around what ever your interest. Welcome

Richard

Well we just got back from the south so I had to go and do something with the Savannah so I weighed the fibreglass parts :)

wing tip 1 = 680g

wing tip 2 = 550g

upper cowl = 1682g

lower cowl = 2246g

oil cover = 90g

the quality seems ok with a little filler and rubbing down I should manage a decent finish.....

Well if you fancy visiting France then this may be worth the trip :

France Air Expo - General Aviation Exhibition - France & Europe

I will be going for sure as it is only an hour from home :)

With mtow of 472.5kg with a parachute any weight saving is of interest. I will get the scales out on Saturday and report back.

I have to agree with you Thomas having you going through the same process with a fresh set of eyes and the tremendous support from all the old hands on here, has made this a very easy process so far

I look forward to that, I have considered them as they to have a good reputation although old technology(like me).

Hi Thomas,

ready top put the cowl on? I have some serious catching up to do! I am away on holiday at the moment but will have a go at weighing the tips and cowl when I get home. Out of interest is one layer of the woven mat enough for the tips and cowl? Is there any advantage in other types of mat such as carbon or kevlar? I would be interested in having a go at making some parts and will try like you did the fin and tail tips. Mine are a completely different shape to the fin and tail and need to be squeezed to make them fit.

On another subject did you get the electric trim? If so what type of connecting rod does it use? Mine has a ball joint and not the clevis that Ray Allen uses, just wondering why they changed it

Hi Thomas

they look great and a much tighter fit than the originals well done :)

Would it help to have a strip of all to protect the fibreglass? It would worry me that the rivet splits the resin in the fibre glass. That said it isn't structural as far as I can see.

The manual also says (in the section on assembling the brakes) to take out the breather screw in the top of the pedal cylinder, and fill from the calliper up (as described by rgmwa, above).Well, actually, that's not what they say. But, y'know, it's what they're trying to mean...)

Which means coming up with some sort of pump (also as suggested by rgmwa).

 

I think when I get to this, I will get a couple of metres of neoprene tube and fit it to a fluid container, the other end to the calliper.

 

With the container on or near the ground, I will put fluid in the container.

 

Then gradually raise the container, which should cause fluid to go up the lines and into the pedal cylinder.

 

This may be more controllable than pumping the fluid in. However, I will need to make sure that all lines are 'uphill' for this to avoid airlocks.

 

Well, it's an idea....

 

Please let us know what works for you?

Indeed it is a rebuilt 2004. It was rebuilt by the fellas that acts as the LAA expert on Rotax, so it should be as new. Saw it run and vibrates less than the new ones in our club plane. Cant wait to get to the stage where I can try it properly.

That will limit the range a little and if I have to go smokeless....

Move to France there are no inspectors until the end!! For me its Paint that worries me the most.

Hhah its all I need it would be cheaper if ran on coal too ;)

Slow progress as I had to go to the UK to get this:

would it be a bad thing to add a strip of packing material to the rib to get the same level as the spar? Maybe something like mylar or plastic card?

Could be a serious laps in maintenance and quality control.

Indeed, I saw the plane in the flesh before it left the factory. If you described it on paper you would never think it would work, but in reality it is one of the best colour schemes I have seen. Scott told me the colours are from his university and it really does look the part!

Hi Thomas,

that must be very frustrating! I got a set of squeezers from Browns and it seems to work well. I can't see that they take much load and so long as they grip the two sheets and don't allow them to slide against each other it should be ok even f the heads are a little displaced.

I am guessing it is all to do with dissimilar metals and corrosion. I think stainless and ali are fine though.

You've done that before havent you? :)