N6408C Bearhawk 4 Place Builders Log

FIRST FLIGHT - May 18, 2021

2021-06-03T09:06:00.000-04:00

Taxi Testing and Compass Calibration

2021-03-23T21:28:00.002-04:00

I've had four or five taxi tests and could not get the audio in the videos to work. This video shows how nicely the Bearhawk taxis and demonstrates the compass calibration for the Dynon Skyview HDX.

2nd Engine Run and Brake Seating

2021-03-16T15:14:00.001-04:00

After starting and running the engine for the 2nd time, I was able to taxi and seat the brake pads to the rotors. I am not able to cycle the prop. Will need to pull the prop and check to see if I pulled the plug off the crank. I'm pretty sure I did!

First Engine Start

2021-03-16T15:12:00.001-04:00

What a fun day! Engine started on the 2nd attempt after the battery was jumped off.

Fuel Flow Test

2021-03-11T15:06:00.001-05:00

Very happy with the fuel flow test result. I was able to achieve a gravity flow rate to the engine driven fuel pump of 32.8 GPH. Boost pump to the servo was 56.2.

Weight and Balance

2021-02-27T14:56:00.001-05:00

The results of the W&B are as follows. Empty came in at 1,560 lbs and I was very happy with that!

Installing the Wings

2021-01-22T14:47:00.001-05:00

It took a team to install the wings!

Wing Painting

2020-12-23T14:37:00.001-05:00

I really enjoyed painting the wings. The Stewarts Paint System is fantastic! You just have to remember to etch the aluminum before priming and painting. I painted some smaller AL parts and forgot to etch. The paint does not stick as well.

Installing the Hoerner Wing Tips

2020-10-31T14:28:00.001-04:00

These carbon fiber Hoerner style wing tips increase the total wing span to over 36 feet! The tips are 18" each, so I decided to install a rib for rigidity to each.

Wing Assembly

2020-09-29T14:19:00.001-04:00

The Bearhawk (Model B Ribblet Airfoil) is pre-assemled at the factory. My job is to install the fuel tanks, ailerons, flaps, rigging, wing tips... Prime and Paint! It took me almost 3 months to assemble and paint both wings.

Moving Day

2020-09-14T14:16:00.001-04:00

The day has finally arrived! We are moving the fuselage to the Statesville airport where it will stay until I have completed assembling and painting the wings.

Tail Feathers and Preparing for Moving Day!

2020-09-12T14:15:00.001-04:00

Airbox - Multiple Iterations

2020-08-26T13:56:00.001-04:00

I originally wanted a conical airbox from James Aircraft to sit in front of the Fuel Servo. I just could not get it to fit. So after multiple attempts, I ended up casting a square fiberglass box for a rectangular K&N filter. That also had some fitment issues, so I reluctantly modified the bottom of the cowling with a fiberglass blister to accommodate the final version.

Gull Wing Doors with Carbon Fiber Frames

2020-08-03T09:30:00.001-04:00

I really wanted a light weight CF door covered in Lexan. I got what I wanted, but I'm not sure I would do it again. It was quite a job fabricating the CF door frames. I lined them with Kevlar to prevent galvanic corrosion and aluminum backers where there will be rivets. The handle came from Hendrick Manufacturing and are typically used on RV's.

Painted Engine Cowling Fitted and Installed

2020-07-24T13:52:00.003-04:00

Painted Engine Cowling Fitted and Installed

Installing the Windscreen / Windscreen Fairing (Challenges)

2020-07-16T12:17:00.004-04:00

Whoops! I trimmed the windscreen too short! The Bearhawk 4 Place uses the Cessna 170 windscreen. Only slight trimming is need to fit the windscreen to the boot cowl. My trimming was not slight. The fix is to enlarge the windscreen fairing and fabricate a piece coving piece for the inside of the windscreen. These pictures tell the story...

Fuel Lines ~ Firewall Forward

2020-07-16T10:36:00.003-04:00

The firewall forward installation of the fuel lines was very straight forward. No issues. I optimized the routing by securing the lines to the engine case/sump with cushioned high temp adele clamps. Routing from the firewall goes like this: Port side lower bulkhead fitting to mechanical (engine driven) fuel pump Mechanical fuel pump to forward facing fuel controller

Installing the Hartzell Trailblazer 84" Propeller

2020-07-15T11:52:00.003-04:00

I am using the Hartzell 83" Trailblazer composite propellor. This was tested by Mark Goldberg of the Bearhawk factory (AviPro Aircraft). Everyone I spoke that has flown behind this prop LOVES it! Very lightweight and exceptional performance. Hanging the prop is fairly straight forward. Hartzell technical service department was very helpful. I confirmed a few

Detail Painting

2020-07-05T13:48:00.018-04:00

Paint Finishing & Details

New Fairlead for Rear Seat Bracket

2020-06-22T13:40:00.022-04:00

You can see in this picture after installing the rear seat, the left rudder cable rubs against the left rear seat bracket. These pics demonstrate the fix.

Ignition System - The Magneto vs. Electronic Ignition Decision

2020-05-19T12:43:00.000-04:00

If 100 aircraft owners read this blog, I’m certain there will be 100 different opinions on the following subject. Based on my purpose, environment and mission, this is how I (eventually) came to the decision to use a traditional dual magneto ignition system for the Bearhawk 4 Place I am currently building. From the time I started considering the Bearhawk 4 Place quick build kit, I

Drilling the Wings to the Fuselage

2020-03-14T08:16:00.000-04:00

The following is my experience as I learned the process for attaching the wing (root) to the fuselage. Both main and rear spars come predrilled with 3/16” holes at the root attach point. The fuselage attachment fittings are predrilled with 1/4” holes. The end result is to attach the wing root to the fuselage by match drilling the main spar to the front attachment fitting to

Wiring and Electrical System

2020-01-17T11:09:00.002-05:00

Video from my YouTube Channel discussing the Wiring and Electrical System I won't get into the specifics of the ignition system in this post, but I need to say what ignition system I am going with for the purpose of understanding what I am wiring. Because, I previously stated that I would be using a Light Speed dual electronic ignition system. But I changed my mind and decided

The Air Induction System

2019-12-13T17:44:00.000-05:00

About a year ago Don Rivera, founder of Airflow Performance, hosted a Fuel Injection 101 course that I attended. I am using their fuel injection system on my IO-540. Don offered a perspective that stuck with me, "Engines are just air pumps". Good airflow entering the engine is just as important as a good exhaust system that can carry spent air out of the engine.

Engine Cowling

2019-11-17T10:30:00.003-05:00

Time to install the engine cowling... When building the Bearhawk, there are two sets of manuals. The AviPro Aircraft "Builder's Assistance Manual" for the kit, and Eric Newton's "Bearhawk Builder's Manual" for scratch builders that was written in 2008. Both manuals discuss the design and installation almost identically. Eric Newton's scratch builders manual is a little