PROJECT NEWS

Projects which inspire others to build their own aircraft Compiled by Mike Slaughter

Project News

There is a healthy number of New Project registrations again this month, made up primarily of the usual suspects, but less common these days is a new Europa start, along with another KFA Safari, interestingly the latter is reviewed a few pages further on in this issue.

There are a good number of aircraft ready for that all important first flight in this month’s Cleared to Fly list. Not only are they new builds but, in some cases, it’s an ‘orphan’ aircraft’s first flight courtesy of an LAA Permit to Fly. The LAA fleet not only grows from new builds but also older aircraft that make the transition from a CAA CofA, or is imported and does not meet the criteria for a CofA, to a Permit to Fly. Sometimes these are well known types migrating on mass, or they can be one-offs, one such individual is the Pilatus P3 G-BTLL, seen below.

Stephen Foreman and his wife have built what they believe to be the last Zenith CH-601-HDS kit produced by the American kit manufacturer Zenair. I’ve flown in a couple of 601s and seen a fair few more, but I never realised the difference between the HD and the HDS variant. The HDS is the speedwing, which I’m told adds 15-20mph over the thicker wing HD model, 110mph at 4,800rpm has been suggested as the economical cruise. It's only the outer wing panels that differ between the HD and HDS and they can be interchanged. The 601 kit is not highly finished and does require ‘building’, even so, the pandemic restrictions gave the couple the opportunity to largely finish this aircraft in a little over one year.

To get in touch with Project News, and tell your story, report a milestone or just to send a picture, email: projectnews@laa-archive.org.uk. Please share your story!

G-BTLL (s/n 323-5) Pilatus P3-03

By Russell Dagles

Built in 1956 and operated by the Swiss Air Force until its disposal, Lima Lima, as she became in the UK, sat in a couple of hangars for nearly 30 years due to a paperwork problem. The CAA were not keen to give her a ‘ticket’ and the PFA at the time were unable to deal with such a heavy aircraft. Moving forward, the LAA is now able to adopt more vintage aircraft and the possibility arose for the Pilatus to gain a Permit to Fly.

She was re-assembled, overhauled and flown at Guist, in Norfolk, on 15 October in the hands of John Baker and is now firmly in the LAA world.

Right The P3 on her test flight with John Baker at the controls. Photo: Mike Page.

G-CLLN (PFA-047-11340) Pietenpol Air Camper

By John Scott

My Air Camper was first registered as a project with the PFA in 1989 but soon after was abandoned. In 1995, I was looking to build another aircraft following the successful completion of a VP1 (which is still flying) and the inevitable motor bikes.

Peter Sturgeon, the VP’s Inspector, suggested that I might be interested in a stalled project he knew of, with very little work having been done on it. There was an impressive bundle of spruce and a PC60 GPU (ground power unit) engine which had been converted for aircraft use.

The deal was done and after negotiating with Jim Wills for Above Alan James preparing for that first flight.

Photo: Daniel Scott

Below Left to right: Builder John Scott, test pilot Alan James and Inspector Peter Sturgeon.

Photo: Daniel Scott

a set of his revised plans, Peter Sturgeon agreed to be the Inspector and the build began with wing ribs and a stack of metal fittings.

After 25 years of sporadic building, G-CLLN moved from workshop to hangar. Thanks go to Peter for his encouragement over the years and to the LAA which has been very helpful, especially with clearing the engine and its installation. Permission to test fly was given and Alan James of G-BUCO and the Pietenpol Club, kindly agreed to conduct the first flight which was successfully carried out on 16 September.

G-CLZA (LAA 162-15679) Zenair CH-601 HDS

By Stephen Foreman

Having built and flown a Zenair CH-601-HD for 10 years (selling it in 2014) my wife and I began thinking of building another CH-601, but this time with the tapered wing. On checking Zenair’s website it appeared that the HDS kit was still available to purchase and Zenair agreed to manufacture, what I believe to be, its last HDS kit. It is now focused upon manufacturing the 650 model but, at the time of writing, the first UK example is yet to be completed.

In April 2020, after a few weeks’ delay, the kit arrived in the UK and was soon being delivered by Metal Seagulls, who spent the day with us carrying out the inventory, a great service. Once again, our house was filled with sheets of metal, raw stock, canopy, wheels, brakes, gear legs, etc., and the shed came to life again.

Although at the outset I had no particular timescale in mind, with two lockdowns, building progressed faster than expected and by May 2021 the majority of the build had been completed. The 601 HDS kit does not come matchdrilled, plus you are required to fabricate quite a lot of the parts from raw stock, although in most cases parts are cut roughly to size for you to finish off to the correct shape and dimension as per the supplied drawings. As a shed dweller I am happy to spend my time fabricating, drilling thousands of holes multiple times, taking the work apart for deburring and etching, and then puzzling my way through reassembly, and finally riveting.

I am also fortunate that the build process is very much a team game with my wife, who has always been involved in both the building and paperwork. She enjoys setting out rivet lines, helping resolve the occasional problem and fettling pieces of metal, but still refuses to wield either the drill or riveter!

Our grateful thanks go to John Cook, our Inspector, who was always available to carry out inspections at short notice, and to Gary Johnson who has an HDS and provided valuable help via Messenger whenever called upon, and also offered to come and help if I got really stuck.

Once the detailed build paperwork had been submitted to LAA Engineering, there was an anxious wait but after a few weeks and a few queries, Jon Viner issued the authorisation to test fly the aircraft. A big thanks also needs to go to the LAA admin team (especially Adele, whom I Above The very smart Zulu Alpha completed and test flown. Photo:

Stephen Foreman

Below left The fuselage is built onto the wing centre section. Photo:

Stephen Foreman

Below right Stephen was able to accommodate the fuselage with one wing rigged. Note tapered outer wing section. Photo:

Stephen Foreman

regularly emailed) who always dealt promptly with all correspondence and paperwork, despite the difficulties caused by the pandemic.

As I had experience flying the CH-601-HD, I applied to carry out the test flying myself with John Cook, and this was approved by the LAA.

This was a first for me, to complete the build and be able to test fly our aircraft. There was a certain amount of nerves before the first flight and I have to make special mention of John Cook's help in this regard. His extensive flying knowledge and experience of multiple light aircraft types meant I learned more speaking to him prior to the first flight and flying with him during the test flying programme than I have learned in 25 years! His relevant knowledge of light aircraft, especially LAA types, is exceptional. Flying some of the first hours on the aircraft with John not only made the test flying process safer, it was also immensely educational and enjoyable.

For us the HDS has a good cruise speed and range, so is great for visiting airfields but is also a lot of fun to fly locally. It’s a very solid and well-mannered aircraft. However, like the HD, the undercarriage is a little agricultural and for the short duration between landing to rolling to a stop on grass you do feel a little shaken, though not stirred!

G-CLFD (PFA 179-14726) Brandli BX-2 Cherry

By Ray Rawles

Above An early trial fit of the main components showing the mix of wood and blue foam.

Photo: Ray Rawles

Above The control system and the retractable undercarriage mechanism.

Photo: Ray Rawles

The Brandli BX-2 Cherry is a design from Swiss, Max Brandli, circa 1979. At first glance during construction it looks like a conventional wooden aircraft, but it is of wood / composite construction. It has a pretty conventional looking wooden box fuselage with a stub low-wing centre section. The wooden wing panels, that detach glider style, use some blue foam ribs and a glass fibre covering. The design features a manually retracting undercarriage and a forward sliding canopy and LAA examples can use either a Continental C90 or a Rotax 912 ULS engine

My plans-built example, G CLFD, has taken 14 years to complete. I purchased the plans in July 2007 from Max Brandli and the project was registered with the then PFA. It has been an interesting build. Max was a brilliant designer, and the drawings are very detailed, but they are in German, however partway through the build the plans became available in English on a CD, which was a great help. Mike Fountain built the first BX2 in the UK and Dave Roberts the

New Projects

Above The finished aircraft ready and waiting for its maiden flight. Photo: Ray

Rawles

second, they have both been a great help. I am really pleased with the way it looks. My Inspector is Mike Smart, who has been a great help throughout the build. Foxtrot Delta has a Continental O-200, Talos Avionics EFIS, a Funke TRT800A transponder and a Yaesu FTA550 handheld radio, which I will replace with a panel mounted radio in the near future. The build was done in my extended garage but space was a problem. The tail surfaces were built first and stored in a spare bedroom, the main structure of the wings came next and finally the fuselage.

Bill Brooks flew it for the first time at Henstridge Airfield on 26 October, the LAA 75th anniversary Fly-It day; he was very happy with the stability and handling. What an amazing feeling to see it leave the ground, there are a few snags to sort out, hopefully they’ll be knocked off shortly. I cannot thank Bill enough. I would also like to thank my wife, Heather, for her encouragement, extra pair of hands and patience throughout the build.

If your aircraft has been featured in the New Projects list, please let Project News know of your progress at: projectnews@laa-archive.org.uk

n Van’s RV-12iS (LAA 363A-15789) 11/10/2021 Mr D Rix, 5 Branwell Avenue, Guiseley, Leeds, West Yorkshire, LS20 9FD n Europa XS Trigear (LAA 247-15793)

19/10/2021

Mr P Matthews, Castlemead Cottage, Biddenden Road, Sissinghurst, Cranbrook, Kent, TN17 2AB n Sling 2 (LAA 399-15791) 11/10/2021 Mr M Dutton, 2 Tylers, Sewards End, Saffron Walden, Essex, CB10 2LN n KFA Safari (LAA 402-15788) 7/10/2021 Mr A Blinch, 82 Sompting Road, Lancing, West Sussex, BN15 9LD n Van’s RV-8A (LAA 303-15792) 19/10/2021 Name & Address held by LAA Engineering n Sling 4 TSi (LAA 400A-15790) 11/10/2021 Name & Address held by LAA Engineering

Cleared To Fly

If your aircraft has featured recently in the magazine and has subsequently completed its maiden flight, Project News would like to hear from you at: projectnews@laa-archive.org.uk

n G-BTLL Pilatus P3-03 (s/n 323-5) 6/10/2021 Mr Russell Dagless, Holly Hill Farm, Holt Road, Guist, Dereham, NR20 n G-JIMC Van's RV-7 (LAA 323-14996)

19/10/2021

Mr James Chapman, Peckhams, Poling Street, Poling, Arundel, BN18 9PT n G-PKSE Jodel D112 (s/n 1765) 27/10/2021 Mr Kevin Dermott, Aztec, Unit Z, Tidy Industrial Estate, Hassocks, BN6 8SG n G-CINX Van’s RV-7 (PFA 323-14412)

11/10/2021

Name & Address held by LAA Engineering n G-FFFF Zenair CH-750 (LAA 381-15485)

8/10/2021

Mr John Bate, 93 Lindsay Park, Burnley, BB10 3SQ n G-CLLI DHC-1 Chipmunk 22 (s/n C1/0508)

12/10/2021

Name & Address held by LAA Engineering n G-CLYN Zenair CH-750 (LAA 381-15722)

15/10/2021

Name & Address held by LAA Engineering n G-IIIM Starduster SA100 (s/n 4258549)

16/2/2021

Name & Address held by LAA Engineering