A I R P L A N E R E S T O R A T I O N P L A N - D O R O T H Y choppergirl@air-war.org Changelog: 2016/12/16; 2017/1/14; 2017/1/17 A I R P L A N E B U Y L I S T ================================= "OK " indicates we have item in sufficient quantity "!!!" indicates we have item, but mor steps need to be taken to finish item "$ " indicates estimated price GENERAL OK File crate & File Folders $15 Vj-24w plans from Vula or other source ($from Scott @ vula.org) Gypsy Plnas !!! Woodhopper Plans (!Print out) OK Digital Calipers OK Aircraft Spruce Catalog OK Wicks Catalog PAINT REMOVAL OK Citristrip OK Vinyl Siding Scrapers OK Scotch pads OK Rags OK Prep & Etch Phosphoric Acid OK Lemon Juice ALLUMINUM POLISHING Disc Grinder for rounding corners Alluminum polish kit 7 inch Harbor Freigh hand held buffer aircraft polish (*WHICH KIND*) RIVET REPLACMENT 1/8" diameter aircraft rivets (galvanized steel) length Grip length around .100 300 1/4" length (*WHICH KIND*) 1000 1/8"length (*WHICH KIND*) dielectric grease (*WHICH KIND*) Drill bit, size .128" ideal... #31 or #30, to drill ideal 3/8 rivet holes N rivets would be just fine for our project. Q would be best in high stress areas or thicker metals To drill out rivets, use a handheld drill in short bursts, and a drill bit larger than rivet shaft, but not larger than the rivet head. You want to stop just as soon as the head spins off, when you get down to the surface. Also, before you begin, punch out the center broken stick with a hammer and punch tool. CorrosionX is a well-liked spray which provides a persistent coat. Other comparable fluids are CorrosionPro Lube, CRC Heavy Duty, and LPS-3. Boeshield T-9 is nearly as good in a salt water test. Also maybe some gun oil type products, like KGCoatings. BOLT REPLACEMENT Replacement missing AN bolts Undercarriage (*WHICH KIND*HOW MANY*) Fuselage (*WHICH KIND*HOW MANY*) Tail Boom (*WHICH KIND*HOW MANY*) Tail Wheel (*WHICH KIND*HOW MANY*) Wing Attachments (*WHICH KIND*HOW MANY*) Motor Mount (*WHICH KIND*HOW MANY*) Fuel Tank mounting bolts (*WHICH KIND*HOW MANY*) Propellor (*WHICH KIND*HOW MANY*) 0-6 lbs Torque wrench (search for "inch pounds" and "beam type" torque wrench) If you want a high end one look at snap on 1/4" electronic ones, you can get them on EBay for 1/2 price they read to 2 foot pounds = 24 inch pounds Locktite (what color) (*WHICH KIND*) Visible Locktite (for outside bolts) (*WHICH KIND*) Safety wire diameter (*WHICH KIND*) diameter (*WHICH KIND*) UNDERCARRIAGE Zinc chromate paint alluminum tractor paint (*WHICH KIND*) bungies cotter pins and washers for wheels Door hinges for rudder pedals COCKPIT New seat belts 3 point harness Seat Stickers Lightweight door hinges for Rudder Pedals Rudder pedal fixtures Better Control Stick side to side (modification/improvement needed) Seat alluminum or steel support mounting bars FUSELAGE Aluminum/Chorme/Silver colored Tractor Paint "Dorothy" Stickers 2x Cotter Pins for Axles to keep wheel on 2x Large Washers for Axles to keep wheel on Dacron Covering for triangle behind pilot to reduce drag MODIFICATION Aircraft Grade L channel 4" extension tube and insert sleeve TAIL Tail wheel (*WHICH KIND*) Springs for Tail Wheel (*WHICH KIND*) Additional coat hanger type wire for aileron/tail/rudder hinges (and oil them with mineral oil) CONTROL CABLES New Control cable of right size ?x? (*WHICH KIND*) Contol cables control cable parts (*WHICH KIND*) Swage tool (*WHICH KIND*) tension meter (*WHICH KIND*) WINGS Missing alluminum rib material (*WHICH KIND*) Jury strut parts (*WHICH KIND*) Strut teardrop fairings new WING COVERING Dacron Latex Paint White Black Red stitch needle (*WHICH KIND*) stitch tread (*WHICH KIND*) Critical covering to Close gap between wings STRUTS New Jury Struts and fixtures Aerodynamic Fairings for main struts ENGINE Replacement rubber seals for everything that are ethanol compatible Rpm gauge CHT sensors and meters for every spark plug EGT sensors and meters for every exhaust outlet Lightweight hour meter and RPM gauge for every engine Extra second gasket to decrease compression new right sized spark plugs (*WHICH KIND*) correct piston kit new seals new drive belts D cell battery holder x 6 (or lithium battery pack) D cell batteries x6 (or lithium battery pack) 2x Exhaust pipes for Chotia 460 engines 1x Intake manifold for Chotia 460 engine Moisture coverings for Engine Exhaust and Airfilter when not in use CARBUERATORS Mikuna Carburator x2 New Rubber Carb Housings Jetting needles Throttle cable Mikuna Fuel Pump x3 K&N air filter K&N Cleaning Kit with Red oil ENGINE MOUNT Engine mount design Engine mount parts AN Bolts Rubber Washers FUEL SYSTEM Fuel tank (Comet Mach-1 like on Mac Hodges?) Fuel tank mounting bolts gas tank fuel lines Fuel Filter Primer Bulb? Premix oil (Amsoil Saber (blue stuff), Penzoil 2 stroke outdoor, or Quicksilver PWC full synthetic) INSTRUMENTS Low Speed Airspeed indicator Pitot tube and tube Altitude indicator Scanner battery turn coord RPM meter and hour indicator Compass Inclinometer? PROPELLOR Propellor for Cuyuna (*WHICH KIND*) Propellor for Chotia 460 (*WHICH KIND*) Digital angle finder WEIGHT AND BALANCE Digital scale (have) MISCELLANEOUS Video camera mount Aiptek Video camera ON PILOT Good Shoes (Sketchers) Helmet Goggles if needed Smart phone OK Variometer OK Family Service Walkie Talkies OK Handheld Scanner Battery pack for Scanner Bottle of Water Emergency blanket Multicolor Party Streamers (to be thrown) Multicolor Towed Party Streamers SMOKE SYSTEM Pumps (*WHICH KIND*) Lines Tank (*WHICH KIND*) Fitting into Exhaust (*WHICH KIND*) Switches Smoke Oil (*WHICH KIND*) OTHER enclosed trailer grey foam for woodhopper Work on it as something to do to relax TO DO: Paint Removal Polishing Supplies Rivet Replacement Welding Painting Bolts Needed Inventory and tubes from Aircraft Spruce Cabling Instruments Engine Engine Break in Cuyuna UL-02 Rebuild NKG B8SE (B8ES)? Spark Plugs Gas Tank and Fuel System Trailer WEIGHT LOSS Lose 20 lbs pilot RESEARCH Watch every eaavideo.org video on building airplanes; the more you know before you start, the more you know how to do things the best way. Go through all your magazines and dog-ear every useful page on building and flying, and sort Read back through the build threads you posted online, print out, highlight, and note any actual technically useful tips. Type up a detailed paper of everything you need to do to the plane to get it flyable and storable, and everything you need to buy along the way... estimated price... and from where.... NEXT Probably next on my agenda is to get some 3/8th galvanized steel rivets like the ones you sent me, but with a grip length centered around 0.100 And also, I'll get an alluminum polishing kit, and some polish. I'll do it section by section, mark a piece, take a piece apart by drilling out the old rust rivets, take off whatever little left over paint, polish each piece until it is pretty and shiny, then rivet it back together with new rivets. Plenty of work to do just doing that. To drill out rivets, use a handheld drill in short bursts, and a drill bit larger than rivet shaft, but not larger than the rivet head. You want to stop just as soon as the head spins off, when you get down to the surface. Also, before you begin, punch out the center broken stick with a hammer and punch tool. Then I'll probably try and take some kind of bolt inventory, of all the bolts I need that are missing, and get those from Aircraft Spruce in one batch. My plane uses mostly 3/16th and 1/4th AN bolts in the 2/2.5/3/3.5 inch length range. I'll also get an inch/pound torque wrench I'll get alluminum/silver tractor paint to paint my 4130 undercarriage, as well as some zinc chromate primer... After that, I'll probably get the plans and some aluminum tubing and get started on my wing that is missing all its ribs, and getting a swage-ing tool and some wire to replace my control cables. Maybe by then I'll have joined the local EAA which is 7 miles away from me, and can borrow one from somebody. By that point, my plane should look like this guys: http://shellprompt.com/deathtrap1/VJ-24w%20AZCully's/ After that, what's left... get the engines rebuilt and running, get some props, get a place to store a "finished big plane", and then probably what I dread most... cover the plane and paint it. I dread covering it, because once I do, I then have to be way more careful with things or I punch holes in them. I'll probably try and paint it the cheap way with thinned latex. Best paints and coatings: Alluminum Enamel tractor paint for metals & roof Zinc chromate for primer electrolysis (cheapest), lemon juice, and phosphoric acid for rust removal Brown urethane paint for wood (not latex) Cool Seal for roofs CorrosionX for bolts and rivets Citristrip for paint removal (also Caustic soda for greese and paint removal) 2000F high heat black for exhausts (not 1600) American something for wood stain Day Glo paint for tools Fingernail polish for keys