Popular Flying March/April 1976

Popular Flying -IA

HomeConstructors—

SLINGSBY'S

STOCKTHEBESTINAIRCRAFTMATERIALS: SitkaSpruceforspars;FinnishBirchPlyforleading edges;Ashforenginebearersandfairleads;GaboonPly forfuselageplanking;MultiLaminatedBeechforpropellorblanks;GlassCloth;EpoxyResin,Polyester Resin,GelCoatandFlameResistantResinforcowlings andfairings;Perspexforcanopiesandwindscreens;Steel Tube,SteelSheet,AlloyTube,AlloySheet,AlloyBar andSectionsforallmetalparts;StreamlineSteelTube forStruts;MadapolamFabric,TauteningDope,AluminiumDope,FinishingDopeforcoveringplusallthe accessoriesyouneedincludingWheels,Shackles,Pins, Nuts,Bolts,Tyres,Tubes,DiscBrakes,Parachutes,etc. WeSTOCKtheASH360,360-channelV.H.F.Radio,1 microvoltsensitivity,2wattsR.M.S.output,lowpower consumption,willworkfromadrybatteryforaircraft withoutelectrics.PYEVANGUARDSon129.9and 130.4megacycles.AircraftAerials;CarAerialsfor V.H.F.Magneticbasejustclampsonyourroof.Microphones;Headsets;Plugs,etc.

InstrumentsinstockincludeBendixJ.8.Horizons; F.A.A.-approvedwithlowconsumptiontransistorinverters;A.S.I.s;Altimeters;Turn&Slipswithrelease notes;V.S.I.s;Clocks;OxygenSystems.

WritefordetailsorsendforCatalogue - 50p. (Refundablewithorders) SLINGSBYSAILPLANES

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Whynothavemoretospendonyouraeroplane andequipment?

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Accident,LifeorEndowmentCover forPilotsandPassengers (DoesthePassengerLiabilitySectionofyour Policycoveryourfamily?)

FLYINGFORFUNfromAtoZ

Altimeters,Asia,AGS,Adhesives,Alternators, Betas,Brakes,Bolts,Batteries,Baffles,Brackets,Bushes, Condors,Carburettors,Cables,CylinderTempKits,Controls, Crankshafts,Canopies,Cowlings,Cylinders,Compasses, Dope,Drives,Ducting.DrainValves.

Engines(Continental,Gipsy,Lycorning,Ardem),Extinguishers,ExhaustPipes.

Filters,FuelCocks,FuelPumps,Fittings,FlyingWires,Fabric,Fork Ends,Fasteners.

Generators,GMeters,Gyros.Glue,Grommets,Gaskets,Gauges. Harness,Hinges,HomebuildersService.

Instruments,InvertedSystems,InformationPackages,Inspection Panels, Jodels,JubileeClips,Jets.

KitsforVWconversionsandCylinderTemperature.

Leads,LogBooks,LandingLights.

Magnetos,Manuals,MasterCylinders,MixtureControls. NavigationLights.Nameplates,Notices,INuts,Needles.

OilPressure,OilTemperatureGauges,0Rings.

Plans,Propellers,Plugs,Plywood,Pins,PilotHeads,Plexiglass Pulleys,Pistons.

QuickReleaseFasteners.

RevCounters,RateofClimbIndicators,RodEnds,Rings,Racing specialists.

Stampes,SmokeSystems,Starters,Shackles,Spruce,Spinners, Switches,Spats,Screws.

Tigers,Turbulents,Tyres,Tubes,Turnbuckles,Tailwheels,Tanks, Tape,TowingHooks.

Undercarriages.

VoltageRegulators,Ventilators,VacuumPumps,Valves.

Wheels,Wires,Windscreens, XeroxCopyingService. Yourenquiriesarealwayswelcome. Zerohourengineoverhauls.

Andwrite,callorvisit

ROLLASONAIRCRAFTANDENGINESLIMITED BRIGHTON,HOVE&WORTHINGJOINTMUNIC.AIRPORT, SHOREHAM-BY-SEA,SUSSEX,BN4SFJ

Telephone:Shoreham-by-Sea(Sussex)62680

FROMTHEPFAOFFICE:

ItisregrettedthattheP.F.A.cannolongerabsorbthe currencyfluctuations,increasedpostalchargesand generalInflation,andthefollowingchargeswillhave immediateeffect.

PriceP.&P.

Light AircraftDesignExample3.50 35p byLloydJenkinson

LightPlaneDesignbyL.Pazmany 4.5030p

Light AirplaneConstruction5.0030p byL.Pazmany

PracticalLightplaneDesignandConstructionbyW.Fike2-7030p

LightAircraftDesignHandbook3-5044p

EditedbyF.Maccabee

TheP.F.A.Handbook2.5075p EditedbyStuartMcKay

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PFATie.DarkblueTerylenewithtiny silverwings2-1615p

PFADiary19760-8010p

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EvansVP1orVP2drawings,perset30.2475p

CurrieWotDrawings27.0075p

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PazmanyPL4ADrawings44•28125p

C.A.I.P.Leaflets(20)3-0050p

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AllpricesincludeVAT(whereapplicable)andaresubject tochangewithoutnoticeduetoincreasesinpricesand currencyfluctuations.

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popular Flying

EditorhdCommittee:

ALANDUNN MIKEGRIGSON

JouIN FlAmNins

LAURI!MANSFIELD

EditorialAddress:

TerminalBuilding. ShorehamAirport. Shoreham-by-Sea, Sussex.BN45FF

Telephone: Shoreham-by-Sea61616

PFAEXECUTIVE COMMITTEE

President:

.A/CMDR. 1. C.PAUL,C.13.,D.F.C.. M.A..C.Eng..FL

Chairman:

D.F.FAULKNFRBRYANI

Treasure).

L.Siusw.D.Ae.,C.Eng.,M.R.Ae.S., A.ALS L &ET.

EngineeringOfficer:

F.I.V.WALKLR,CLECR.,

CommitteeAlenthers:

DotR,.BIANCHI

PrIERCHANNON

EDWARDDAVIS

ESDRAY

ELFINDUNFORD

ALANDUNN Miss PsiHOLMES

ERNIEHORSFALI

1:101NiANSHE

RHRINOWE\ JOHNPHDH-CAR

TomRIMiAN

MIKI.VAISIV

WIIKS

BitLW0000mos

M-71811713:3

9, 0ING11550C>

Founded1946

IndividualmembersInp,£7.50p.a. Thefintudingandrepresentativebodyinthe UnitedKingdomofamawurconstructors andoperatorsofultrafightandGroup ()petaledaircraft

P.E.A.(CLAIR)Ltd

CIDERCHIHMLN—

OliverSmith'sSiroccocomesinn)land

LII Sywell.

MARCH-APRIL1976

1-3 Tim.FETES

4 INSPECMRCALLS

5-7 PROJECTS

5-9VINTAGENEWS

10-12AIR(RAFTCO\EKING MA FERIALS

13 I REMEMBERCONSIRUCTINGIHEKIWI

14-15 FYROJcii115(15

16 AIRCRAFTFORIIIEFlOMFBUILDER

17S Rl'T NEWS

17 CAVALIERSQUADRONNEWS

ISLETTERS

19THEPARCEL

20-23 BUILDINGSPRITE—PAICE 2

23 BOOKREVIEW

The viettv expressedinPOPULARFL)/NGarethoseofthe contributorsandnotnecessarilvthoseoftheP.FA.ThePubhshers retaintherighttordhseorwithdrawadvertisementsattheirdiscretionandclonotacceptfordelayinpublicationorfor clericalorprimer'sownalthougho'er):rareistakentoavoiel mistakes.

EDITORIAL

AswelookforwardtoaNew Season, SoWe canlookforwardto anewcropofHomebuiltsgradually emergingintothelightofdayand wealsolookforwardtorecording theoccasionortheirfirstflightsin thesepages.Eachyearweacclaim newnumbersmakingtheirdebutat theAnnualRally,butsadtothink that,ofthosegracingthenewcomersranksatSywel'75,atleast threearenolongerwithus.The Pilotorone,whomercifullyescaped unscathed, was heardtoadmitathis localStrutMeeting,thatthefault wasPiloterrorHeagreedthatill themonthsthathismachinewas active.hehadnevertrieda'power off'approach.Not,thatis,until thatlinalflightwhenpowerwent 'oil.'ofitsownaccordandtheresultantmisjudgmentofglideangle madethechosenlieldinaccessible. alast-minutechoicefinishedwith thepredictablepile-up.Theone brightthingthatconicsoutofthis latterreportisthat alleastWe have Memherwhoishonestenoughto admittohisshortcomingsandallow ustoanalysethem

theirprojectjustabouttosatisfythe requirementstokeepaPPLva Sothetimearrivesthatpotentialprizewinneremergesfrom thegardenshed—andwhatsortofa Pilothavewe?Isheascompetentas hewaswhenhequalifiedforhis LicenceXyearsago?Thatnew squadronorjust-completedpotentialprize-winningbeautiesthatwe hopetoseeintheline-upforthis year'sRallytheirBuilder/Pilots mightdowelltothinkbackonlast year'sevents.Aretheyreallyas competentastheywere—willthey respondquicklyenoughinan emergency?

Of course, thereareexceptionsto everyrule,ontheonehandthereare doubtlesssomehomebuilderswho havekeptuptheirskills,andonthe otherhandweknowofatleastone builderwhohasnotonlyarranged hislirstHighttobecarriedoutby anexpert.buthasallowedmany hoursofflighttestingtoproceed beforeevenattemptingtotryhis handathisownmachine.

Photo:AirPortraits

Itdoesn'tseemunreasonableto supposethattheenthusiasticHomeBuilder,spendingyearsofhistime tosaynothingofallhissparecash, isnotthemostlikelypersontohave keptuphisexpertiseatthecontrols ofanultra-light.Infactwethinkit safetosaythatmostConstructors managetotaketime away Irani

We'dliketothinkthatALL thoseprizewinnersatthevarious Ralliesthisyearwillstillbeairworthycometheturn or another year.Sadtothinkthatanyoftheir Ownerswillbefacedwithamassive re-buildjobafteralltheworkput in.Andsowewishyougoodluck andKEEPthathomebuiltflying!

"TIME"FLIES byDAVIDBUCKLE

ThisisthestoryofhowIcametobuildthefirst CavaliertoflyintheUnitedKingdom,someofthe frustrationsandexperiencesduringitsconstruction and,finally,aresumeoftheaircraft'sperformance andabilities.

First,afewdetailsaboutmyself. I'm aFarmerfrom Yorkshire(wherespadesarecalledspades,asyouall know)andIstartedflyingin1968afterbrokenbones andoldagemademeretirefrommotorcycleracingat theageof25in1964.

I flewclubaircraftforawhileafter I gainedmy PPL.1wasFedupwithdrivingtotheairporttosnatch ahurriedhour'sflying,thendrivinghomeagain.On onememorableoccasion. I bookedtwohoursand, duetosomethoughtlessindividualwhodidn'treturn ontime, I gotagrandtwentyminutesflyingin. I decidedthentotrytogetanaircraftofmyown—I couldkeepitonthefarmandflyitfromthere—the onlytroublewasatthattime I didn'thavethe'ready', orinthecurrentidiom.'bread'.topurchaseareasonablesortofaeroplane. I alreadyfanciedtheFrench builtMinicab,thenoneday I sawanadveitwhich said"JointheP.F.A.Buildyourownaeroplane". Nothingcouldbesimplerthanthat,so I rushedoffthe tenbob,orwhateveritwas,forasamplemagazine, andthereonofferwereplansfortheMinicab! I wrote offtoArthurW.J.G.Ord-Hurnewhowasmost helpfulandsentmeabrochuieontheMinicab.

I almostdecidedtogoahead; I onlyhadonesmall doubt,andthatwaswhether I shouldspendallthat timebuildinganaeroplanewhichwasundoubtedlya veryfineperformerbutratherdatedinappearance. I don'tgetallnostalgicaboutoldaeroplanes—Iprefer tolooktothefuture,nottoliveinthepast,so I was delightedwhen I heardaboutaCanadianmodification oftheMinicabwiththeoddnameofSquaircraft Cavalier,whichlookedmodernbutretainedsomeof thecharacteroftheoriginalMinicabdesign.Iwas unsureiftbeglassfibrefueltankswouldbeacceptable. butaquick'phonecalltotheP.F.A.officebrought there-assuring(?)reply—"Ifyoucanproveit'sstrong enough,youcanbuildthewholedarnedthingoutof glass.fibre!–.

Thisseemedtobetheone,so I sentfortheplans andfeltquitesickwhentheyarrivedand1realised whatwasinvolved.OntheadviceofP.F.A.inspector DonHarker,who I hadcontactedwithaviewtohim inspectinganythingImightcommencetobuild,Fput theplansawayinadrawerandoccasionallygotthem outandstudiedoneparticulardrawinguntilit graduallystartedtomakesomesense.Eventually I felt I couldstartonthetaskofbuildingmyaeroplane, possiblyinasshortaperiodastwoyears,whichwas abitambitious,butIwaspreparedthatitmighttake sixyears•–anditnearlydid!

ConstructionstartedinFebruary,1970withthe ribsforthewings,ailerons,tailplane,elevator,fin andrudderwhicharesawnoutofmarineply.These werecompletedinoneweekand I thenhadafrustratingwaitforsprucefromSlingsbySailplanesto buildthefuselagewith.

I decidedtomakeallthemetalfittingswhile I was waitingforthetimber,butsoonfoundoutthatthe Americanchromemolysheetandtubingwasnot easilyobtainable,soIapproachedP.F.A.about substitutionwithEnglishmaterials.Afewlettersand 'phonecallsandtwoyearslateitheclearancecame touse55I4sheetand145tubing.

Meanwhile,thetimberarrivedandthefuselage quicklytookshape.Theplanswerefairlyclearand thefuselageis'selfjigging'providedthebulkheadsare accuratelymade.Thefuselagewascompletedandthe finandsuperstructureadded,thenworkstartedon therudder,tailplaneandelevator.Theelevator,like theailerons,isabitfiddlytobuild,whatwithtapeied ribsanddelicatetrailingedgeandplywoodribcap strips,andittookquitesometimetocompleteit.

Forquiteawhile I hadbeenworkingwithanagging stomachpain,which I dismissedasanulcerorsomething,buteventuallyitgotprettybadandIwas rushedtohospitalfromwhere I emergedminusmy appendix!ItwassixmonthsbeforeLstartedserious constructionagainonthemainspar,rearsparsand dragspars.Alsoaboutthistimethecanopymould wasstarted.

Themainsparwaslaminatedduringtheperiodof electricitystrikesandfuelshortageswhichtheunions sothoughtfullylaidonforus.Wehademergency lightinglaidonincasethepowerwentoffatacrucial moment,butluckwaswithusandtheupperandlower mainsparlaminationswerecompletedwithout incident.Mainsparsarealotofworkbutifeverything ispreparedthereisnothingtobefrightenedofandthe actualprocesscflaminationwithAerolite306and mediumhardenertookfiveminutes!

SiroccobuilderOliverSmithassistedwiththelower sparlaminationandBruceDay,alocalboatbuilder. helpedwiththeupper.Mr.Day,whotaughtmealot aboutglassfibrelaminates,washelpingwiththe canopywhenhegotropedinforabitofwoodwork aswell!Thankyou,gentlemen.

Afteralotofwork,thesparswerecompletedand theassemblyofthewingcommenced.Thewingis taperedandtwisted,butnoelaboratejigswereneeded. I haddecidedthatiftheribswerecutwithabsolute accuracyandtherearsparswere'spoton'also,the wholethingwouldbeselfjiggingiftheribchordlines werelinedupwiththesparreferenceline.Thisproved tobecorrect—thecrankintherearsparstakescareof thewashoutandthewholethingwenttogetherwithout

MomentofTruth;HotelHotelreadyfortakeall (Photo:G..1.Taylor)

Popular Flying,March-April.1976

tooMuch trouble.Virtuallythewholeofthewingaft ofthemainsparwascompletedwiththesparface downonthebench.

1haddecidedthatIwouldeventuallyneedahangar fortheaircraftandthatitshouldbebuiltintimeto enabletheaircrafttobemovedinforfinalassembly andnowseemedtobethetimetostartonit.Thefirst concretewaslaidonNovember5th.1972andsix monthsofsparetimelateritwascompletedandthe aircraftmovedin.

Thewingwassupportedonasimplejigwhich enabledmetoturn .tupsidedownofstanditupright andthis 1did quiteoftenonmyown,untiloneday. whenitwasalmostcompleteandgettingquiteheavy italmostgotawayfrommeIsaveditwithadesperate effort,andrealisinghowpreciousandirreplaceable thatwinghadnowbecome,Ftookmuchgreatercare andcalledinassistancewhenIneededtomoveit ga

Mostofthemetalfittingshadbeenmadebythis timeandafteratrialmatingofthewingsandfuselage andafewhappyhourssittinginthecockpitadmiring thewingsandtwiddlingthingsonthepanel,the fittingswereboltedupandthecompletecontrol systemrigged.thenitwasalltakentopiecesandthe Whole shootingmatchcoveredwith Doc roilfabricand sprayedwithInternationalpolyurethane.

Nowitreallywasfinalassemblytime.tortheairframeatleast.Thecanopy.whichImodifiedtoslide forward.wascompleted.gearlegsandwheelsfitted,in factthewholeaircraftwascompletefromthefirewall aft.readyforweigffingandcalculationoftheengine mountlength.Oncethiswasdone,themountwassoon madeandtheengineinstallationandhook-upwent quitequickly.Thenosegearwascompletedandrated andworkstartedontheenginecowling.Thiswas mouldeddirectlyona'plugwhichwasbuiltaround theenginewithperforatedzincsheet,plaster,polyurethaneroam,etc.Thewholejobtookabout3weeks fromstarttofinishandproducedaquiteacceptable cowlingNowtherewerejustoddjobstodo--alotof oddjobsinffict,andalotoftestsandcheckingand re-chccking.

Finally,myinspector,DonHarker.andIthought wehadanaircraftwhichwouldfly,andflysafelybut wehadnot,itappeared,amassedsufficientpaperwork yet.Youmightthink''whowouldgiveupatthis stage?'".Well,Inearlydid.Afterliveandahalfyears

PopularFlying,March-April.1976

offrustratingexperiencesandindifferenceonthepart ofmanypeople,thefinalpaperassaultwasalmosttoo much,butpeserverencewonthedayandthetest permitapplicationwasquicklyprocessedbyMr. WalkerofP.F.A.Engineering,taxitestswerecompletedsatisfactorily,andfinallyon5thDecember.

1975theaircraftflewfromnlylandingstriptoTeessideAirportwithTestPilotAlanTurleyatthecontrols.Everythingwentaccordingtoplan,soafterthe usualchecks or majorattachmentpoints.etc.,thetest programmeproper\vasstartedandcompletedwithno snagsinthreedays.

Theaircraftffiesbeautifully:itissensitivebutnot oversoanditsexceptionalstabilityandabilityto IR'handsoff'shouldmakeforverypleasantcross country11\nlg

Accuratespeedfigureshavenotbeenobtainedyet. buteconomycruisewiththe125h.p.Lycomingis around130mph.

Theaircraftunsticksat46mphandtake-off distance,ongrasswithnowind,is600-800ftdependingonload.

Stallcleancomesat40mphI.A.S.withanatural buffetat44mph.

Stallwith30'flap,poweroff,35mph.Bulfetspeed 40mph.

Bestclimbandglidespeedis70mph.

Theaircraftemptyweighs1072lbs.andallup weightis1650lbs.

Theaircraftgathersspectatorswhereveritgoes.I amquitedelightedwithitsperformanceandhandling andIhopesonieoftheprideInowfeelwillbeshored bythemanypeople,toonumeroustonamehere,who helpedinmanywaysduringtheconstructionofthe aircraft.

Ihavetried,quiteintentionallyitoprovethatone canbuildanaircraftandhelpandencourageother peopletobuildatthesametime.Attimes,ithascost mebuildingtime,butiiireturnIhavereceivedhelp fromotherbuildersandfeelthatco-opetationand sell-helpwillleadtogreaterunderstandingand integrationoftheratherfragmentedorganisationto whichweallbelong.

Climbingbackdownoffmysoapboxitjustremains formetothankagainallwhohelpedwiththeproject and,ofcourse,mywifeDorothyforputtingupwith itall

6-AZHHwingduringconstruction.

(Photo:D.Buckle

AnInspectorCalls

byHarohlBest-Deveraux

Inspectionisanengineeringdisciplineandahighly skilledoneatthat-itrequiresaninquisitivedisposition.anabilitytoreaddrawingsandanequal abilitytosay"yes"or"no-withoutdramatics. particularlywheninspectinganamateur'sprideand joy.Manypeopleconsideraninspectorassomesort ofogrewhoscreams"scrapit"atthedropofahat, otherssayheisyourbestfriend.speakingasaninspectorbotharewideofthemark.

Arecentpublicationonmydeskstatesthat"A P.F.A.Inspectorshouldatalltimesconsidersafetyin Hightastheprimetaskofhisduties''.Ifthatslightly pompouspronouncementisthecasethenjustsnagthe aircraft,seethatitdoesn'tIlytoomuch.and"safely-. suchahackneyedexpression,willbeassured.No. inspectionisafarmoresubtleprocedure,surelythe logicalphilosophyistoreduceriskandfrontan inspector'spointofviewthisconsistsofobserving provenandrationalproceduresplusthedesigner's publishedrequirementsandspecifications.Inother wordskeeptothepointandinspect,conscientiously.

Somepeoplerinditdifficulttoriskoffendingafriend duringaninspection,suchpeopleshouldleaveinspectionalone.Aclassiccaseofthissituationwasa cantileversparwithabeautifullyfittedwoodenplug inamisplacedbolthole.Theinspectorfoundit difficulttocausehisfriendsuchanamountofrework torectifythedefectwiththeresultthathisfriendwas killed.Thechillfeelingisrecalledofonenightina GlasgowworkshopwhenasamerevisitingSassenach itbecamenecessarytotellanaggressiveandproud groupof constructors thatbuttjointsinthelaminationofabox spar. otherwisebeautifullymade,were notacceptable,butthatwasbetterthanamid-air collapse.

Howcanthe constructorassure himselfofa reasonableride?Thereisasimplecriterionwhichis toavoidanyfinalclosureofboxedorenclosed structureorthecoveringofanyattachmentwithout firsthavingitlookedal.andaccepted,andsignedfor.

Alas,someoftheinspectorsaroundareless particularthenperhapstheyshouldbesoassure yourselfthatthecertificationhemakestellsall.What hashelookedat.whichactualaircraftisitattachedto. whatisheactuallycertifying—theglueing.the theassembly,thedimensions?Thefinalinspector does not knowunlessthepreviousstageinspectorgivesa completestory.Thelittlebookofsoupticketsdoes notembraceeverything,itisbutabasisuponwhich youcanimprovebykeepingadequaterecords.

Onethingisimportant,ifyoulaterbreakdownthe stageoritemwhichhasbeeninspectedandcertified, atleasthavethedecencytorecordthefactandhave it re-inspected.

Makealistofstagesatwhichyoufeelinspectionis necessaryandthenseektheviewsoftheinspector. Putyourselfinhisshoesandaskwhatcouldbe coveredupandruntheriskofbeinguninspected.It paystobearinmindthatrippingopengoodworkcan befrustrating!

Afewactualexamplesofarecentinspectionmaybe enlightening.Theaircraftisapretty-lookingdevice withsexywingtiptanksandhasbeenalongtimein building.Problemnumberonewasthelittlegreen bookofsouptickets.Someofthestagesweresigned

butinacasualandabandonedway_The signatories wouldnothavesignedcheckswithblankspaces,or wouldthey?Ifyoudohaveanillegiblesignature. pleaseprintwhoyouarcand,importantly,markyour status.i.e.yourinspector'snumberoracceptable qualification,afterallyoumaynotbequalified!Also fillinbothticketsandidentifythestageandtheaircraft.

If,liketheseconstructors.youbuyanitemsuchas aready-madesparallboxedupandreadytogothen makesureyouhavesomepaperworkcertifiedbya competentpersonthatthematerialisofacceptable quality,thattheglueusedisidentified,andthatthe itemisineverywaytothedrawing.

Youmaydecidetoassembleyourownengine,and whynot'?InthiscaseabeefyLycomingwaspresented installedandreadyto go butthequestionunanswered astowhocheckedtheinternalassembly.Hadthe enginebeensubjectedtostorageprecautions,who inspectedthebearings,whoknows.butexternally heavily-corrodednutsmakeamansuspicious.Hence atime-consumingandexpensiveexerciseofl'pots or.

Letus thinkofwelding,surelyoneofthcmost contentioussubjectsinamateuraircraftconstruction andfortheaveragepersonpricedoutofexistenceby theCAA.titheorbloodmoneytomaintainapproval. ItisstrangehowMrFokkermadethousandsa aircraftweldedbygirlsbarelyoutofschoolandhow hundredsofamateursintheU.S.A.havenotfallen intopurgatorydespitelackof"approval-.Many peopleareledtobelievethatajointmadebyan approvedwelderisautomaticallyright—thisisnotso. Intheaircraftwearediscussinganenginebearertube welded,thencut.andre-weldedwithabuttweldin thetubeawayfronitheoriginal may beapproved weldMgbutisnotaeronauticalgoodpractice.Our weldingmustIseascalledforontheplans.After approvedwelding,still"Ardrox"thejoints,andtest forcracks,andcheckforbanana-shapedtubesand properdimensionswithouttheneedtospringthe assemblyintoplace.

Plasticfueltanksmaybefunbutonthisaircraft whatdowefind?Whocertifiedtheattachmentbefore coveringitallup?Wehopetheinformationwill surface.Awordabouttankinteriors—theymustbe surgicallycleanandimportantlyhaveameansof accessforinspectionandcleaning,andtheymusthold pressure.ArowofP.K.screwsthroughtheskinisa badwayofassuringthisveryreasonablerequirement. Lookingintothetillercapandseeingdozensofmiscellaneousstrandsofglassclothandalunarsurface ofresinmixedapparentlywithShorehambeachreally doesmeanrework--doweknowwhatwentdownthe pipes?Ifsomebodysawthepipesfitteditwouldhave beenusefultohavethefactrecordedsomewhere.

Beforewiringgoandlookatastore-boughtaircraft andseehowtheendsareformedwithproperterminals andinsulatingsleeves.Observehowthewiringismade intoneatlooms.Ouraircrafthadadanglingbunchof spaghetti.

Snagsareplentyonanearlyfinishedaircraft,and manyhoursoftediousreworkandrectification.Much couldhavebeenavoidedbyrememberingthatatevery stageitiswisetoconsiderinspectionasimportantand essential.

.** Projects

Theusualpleatostartwith—wearefindingitincreasinglydifficulttocollectmaterialforusebelow. Don'tforget.ifyouwouldliketoseenews or your projectinprint,thendropusaline....

IANBURNEIT

PFA229 -ThisformerRutherglenTurbiG-APBO hasbeenrebuildingtorthelasttwelYemonthsin Sunderland,anditwasregisteredtoTAWatsonof theUsworthFlyingGroupon13-11-75.Their'furbs G-ARLZandG-AWPAhavealsohadthesame nomMalchangeofownership.

-104- Wewereverysorrytohearofthedemise or one or(he oldestTurhsrecently.ThiswasG-ASBW— hornandbredintheNorth or Scotlandandasaresult rarelyseenbyLINSoutherners.Whilstonalocalflight fromAnquhirieFarmnearStonehavenon11-10-75the enginefailed,andduringtheforced-landingthetank wasruptured.andtheaircraftburntout.G-ASI3W infacthosoneoftheoldestrecordedTurbulentnumbers.butdidnotflyuntil1966.BuiltbyJ.Smithit spentmostofitsearlytimeatScalloway.andWick movingtoAberdeen/Dvcein1969whenitwo,bought hyJ.SwansonandJ.Campbell.

537 -Thenowniuch-modifiedTaylorMono0AP Ri\-as officiallyregisteredtoMessrs.C. J. Chambers,G.D.Claxton.R. FL Walsh,andL.RWillioms atLastbachFarmon1-10-75.Wehopetoseethe resultsoftheirhardworkatSywell'76.

833— Anotheraccidentwehavevettorecordisthat hichunfortunately,belellJimScott'sLutonMinor G-A/PVon12-10-75.Whilstmakingalandingat Lording!)Farm,Adversone,Sussex.tosortoutaloose plug-lead_theenginefoiled,andtheMinorwas seYerelydamaged.

901 -OriginallystartedhvP.Martyrsonic)timeago. andpassedonhalf-completetoD.MetcolfthisJodel D.I1isnowregisteredG-BDMM.Progressisbeing maintainedinBromley,Surrey.

1405—FirstofnolessthanliveTaylorMonosto featurethistimeisthisonenowregisteredG-BDNG toD.IPhillipsofKemhle.Glos.ThePFArecords showthisprojectoriginallyallocatedtoaMr.E.Slack. Incidentally,ifyousellyourproject,orindeedacquire apart-builtaeroplane.wewouldappreciateashort linewiththerelevantinformation,askeepingtrackof sonieitinerantprojectsisratherdifficult!

1428 -SecondMottotoappearis 1. F.Barber'sGBDJ13whichwasregisteredtohimwithhisown logicalc/n '1B..IT.1 001'on2-9-75.Thisoneisbeing builtinBenfleet,Essex_

1431 K.Barlow'sMonoprojecthasnowpassedto A.J.TGrayofWrexham—towhomitwasregistered G-BDNOon15-12-75.

1454—Nick ColeregisteredhisMonoasG-BDNC on8-12-75.

1456 —ThisMonoprojectisnowregisteredGBDKU,andinfactisbeingbuiltbyagroupconsistingofNormanWhisler,MalcolmKnapp,and DavidKynastoninCambridge.Normanverykindly sentusaprogressreportindicatingthatthefuselageis boxed,thetailunitiscomplete,asareallthesparsand wingribs.AttheendoflastyeartheVW1500was strippeddownawaitinginspection,andaFib'was confidentlyexpectedduring1976.

PopularFlying,March-April,1976

1528-W.T. Morrellsentusaveryamusingletter concerningtheregistrationofhisFREDproject G-BDBFsshichwearesurehewon'tmindUsquoting verbatim....-Nowyou'vedoneit!Youdidn'tknow [hottheC.A.&read'PopularFlying'.didyou?I receivedmycopyonthe24thSeptemberandonthe morningofthe25ththeyrangmetoaskiftheyhad putthewrongconstrtictor'snumberintheregistration list,anddidthey(PFA)wantthem(CAA.)tochangeit tothePFAProjectNumber.andhodthey(CAA) got me(me)intotrouble.andthey(CAA)wereblamedfor everything,and.Ohclear!IexploinedthatIputnb, memhershipnumberonthcregistrationformbecause itistheonlyoneIcallrememberexceptmyold BorstalnumberandIamtryingtoforgetthat.So%‘. partedithexpressions or mutualesteemandmerry laughter.and I satdowndazedwiththehonourofit albBLit,yousec,ilone or yourtenderlittlesecretsare saleandyotijusthecareful.vouShorehamlot.when youmakesnidecommentsaboutusyokels.

'or courseitwasallliesreally..-fheother2.262 FredsIhavehuntarehiddenillmyorcharddisguised astractors,appletrees,etc. -I heyhavebeencommissionedbyourSocialistgovernment(?),andon 31stFebruarynextallyourichownerswillhaveto surrenderyourposhforeignTurhsandthelikeand willhavetobin'aBritishFredfor£20,000eachplus VATandIshall go bankrupt,forniaone-man workersCo-operativeandeYeryonewillbeequal underour

Afterthat(forwhichMr.Nlorrellmustsurely qualifyIbraspecial PEA comedian'spriielinewsof bredisthatshemovesslowlyforwardwingsandtail unitsarecomplete,thebasicfuselageisfinished.and controlsbeinginstalledpriortocladding.Sy/well—77is tlieaimingpoint!

1589 AnotherCavalierprojecttoberegistered recentlywasH. B. Yardley'sG-BDKJwhichalsohas thecol'72207'andwillflyfromStokeOrchard.

1539— WehaveyettorecordthefactthatNI. Alliott'sSopwithTriplanereplicawasinfactsolda fewmonthsagotoPhilipMannatBooker,andtitthe momentisbeingactivelyworkedonbyDougBianchi. Itwilleventuallyemergewiththespuriousserialnumher'N5487'.

3224- One1-7.:FwemissedlastyearwasthatofToni Regan'sTitchG-BCTRatRedhill.Weyvillnodoubt beseeingalotofitontheRacingcircuitthisseason.

03-10004—David Harker'sHawkprojectwasregisteredG-BDNFon9-12-75

14-10021 --Anothernewprojecttoberegisteredon 14-10-75wasA_W.Odell'sBedeBD-5BG-BDKK.It isbeinghtUltattheRAE,Farnborough

35-10076—Peter Leago'sStardusterTooG-AYMA willhopefullybeseenthisseason—attheendoflast yearitwaswellonthewaytowardscompletionat AudleyEnd.

41-10106—Those ofyouwhoreadtheSundayExpresswillhavebeendelightedtosecthewholepage spreadofMikeWhittaker'sMW-2G-BDDXji.Nt beforeChristmas—weallwishhimwellfortheimpendingF/F.

Gyros

G-AWLM-TheCampbell-BensenCB.8MSG-

AWLM wassoldtoG.andG.D.Ward,of Hull on 16-9-75.

G-AXYX--Asaresultofthewell-publiciseddemonstrationofhisAirbuggyatPocklington.Yorks.last year,wearehappytorecordthatBillEkinhassince deliveredthefirstproductionWHEAirbuegyGAXYXtoW.H.BeeversatPocklington.

G-AYI-11-1—TheCampbellCricketG-AYHHwas boughtbyD.S.McGillivrayofBearsden,Glasgowin Octoberlastyear.

G-BDNF—NewGyrosstillcontinuetoappear—the latestisaBensenB.8M(c/nWC/1)whichwasrecently registeredtoW.F.O'BrienofCardiff.

OtherAircraft

G-APNS—TheoriginalGarland-BianchiLinnet G-APNSwhichwaslastheardofinManchesterlast yearwasregisteredtoMrs.P.B.Voiceon23-10-75. WhetherRobinhasboughtthePAS-buillEmeraude projectaswellisn'tclear.

37-10125BedeBD-4—Capt.S.J.Bartham,c/oGlen Wittan,BirchleyRoad,Cheltenham.

45-10126Esperanza—D.K.Brady,48ChurtonStreet, London,S.W.I.

46-10127CurrieWot(2Seater)—C.Turner,Dovecote Road,NewcastleuponTyne.

G-APWT—TheHAC-builtCurrieWotG-APWT whichdepartedfromtheRoyMillsstableatBooker lastJulywithsomewhatindecenthaste,isnowflying intheUSAasN67247.

G-AWI-IW—BetaG-AWHWhasnowpassedto C.E.Bellhouse,BigeinHill.

G-BDKS—AnotherManxKellyimportisthe AerotekPittsS-2AG-BDKSrecentlyregistered.

EI-BBD/BBFVP-1—RecentlyregisteredinIreland arcacoupleofVolksplaneswhichapparentlyaMr.B. Freeleyisbuilding—El-BBDforhimself,andthe otherforafriend.(Thinks—Iwishmyfriendswould buildaeroplanesforme!).

NewProjects

15-10107Sonerai—P.R.Cozens,48QueenStreet, Worthing,Sussex.

42-10108MotorTutor—E.P.Affleck,3Bessacarr Lane,Doncaster,S.Yorks.

30-10109Petrel—A.Whiter,46SancroftRoad, HarrowWeald,Middlesex.

29-10111FredSrs2—R.H.Gill,"Ashcroft'',Spring ElmsLane,Lt.Baddon,Nr.Chelmsford.

09-10112PittsS.I.—W.E.Roberts,2Whitefield Grove,Lymm,Cheshire.

29-10113Fred—J.D.Orr,333ColeshillRoad,Castle Bromwich,Birmingham.

14-10114BD-5-R.G.Williams,10BeechwoodRoad, EastoninGordano,Bristol,Avon.

35-10115StardusterToo—T.J.Gardiner,16Quaves Lane,Bungay,Suffolk.

02-10116BetaB.I..-C.M.Chown,4HighCross, Swimbridge,Barnstaple,Devon.

02-10017BetaMk4.-G.Jiggins,29SouthRoad, Sandy,Beds.

43-10118ColibriMk2—R.A.Harris,20Durham Crescent,Bulwell,Nottingham.

01-10119Cavalier—J.D.McCracken,66Malleny Avenue,Balerno,Midlothian.

25-10120TipsyNipper—A.SPearcey.Sugallan, DalridaAvenue,Stranrear,Scotland.

29-10121Fred—P.J.Gronow,Tawelan,Llangunnor, Carmarthen.

29-10122Fred-C.Hender,PearTreeHouse,Biddisham,Nr.Axbridge,Somerset.

17-10123PazmanyPL-4-D.W.Grigg.13Wellington Road,Crowthorne,Berks.

44-10124JungsterI—R.Owen,LittleDanewoodWest. ChurchLane,Danehill,Sussex.

FuselageofChrisTurner'sC'urrieWor 2 Seater

01-10128Cavalier—G.Jeffrey,LyntBridgeHouse, Inglesham.Wilts.

17-10129PazmanyPl,4—K.W.Fisk,BlackSwan. Homersfield,Harleston,Norfolk.

11-10130IsaacsFury—WJ.Evans,CroydonHouse, FelonsOak,Rodhuish,Somerset.

07-10131WoodyPusher—D.S.Gingell,94BullsHead Lane,Coventry.

01-10132Cavalier—G.J.Taylor,23ParkParade, Roker,Sunderland.

01-10133CavalierG-BDHM—D.H.Mitchell,Cothay PacificAirways,HongKong.

15-10134SoneraiII—R.J.Jones,TheCoppice,78 UpperHallPark,Berkharnsted,Herts.

14-10135BedeBD-5—J.A.Willis,15HighfieldPark Road,Meadowside,Launceston,Cornwall.

47-10136PietenpolAircamper—D.Phillips,579WestwoodheathRoad,Westwoodheath,Coventry,Wsrcs.

11-10137IsaacsFury—R.J.Beecham,Keynes,Austin Way,GerrardsCross,Bucks.

01-10138Cavalier—W.J.Woodbine,99Ladyshot, Harlow,Essex.

17-10139PazmanyPL-4—A.R.Rash,Amarillo,Old Road,WickhamSt.Paul,Halstead,Essex.

02-10140Beta—J.L.Kinch,Mo-Dhachaidh,Saltburn, Invergordon.

29-10141Fred—R.Yates,3LowRoad,Wyberton, Boston,Lincs.

43-10142ColibriMk2-L.J.Welburn,Cleveland Sailplanes,MelmerbyIndustrialEstate,Melmerby, Ripon,N.Yorks.

60-10143TaylorTitch—J.Sharp,209Ballochney Street,Airdrie,Lanarkshire.

62-10144EvansVPI—G.Postance,43DorothyAve., Peacehaven,Newhaven,Sussex.

62-10145EvansVPI—C.J.Painter,16Holmesdale Road,Dronfield,Sheffield.

63-10146EvansVP2—P.Harris,96LowerNortham Road,HedgeEnd,Southampton

34-10147Cassutt—P.Lewis.Sunrise,ThornhillRoad, Stalbridge,Dorset.

60-10148TaylorTitch—C.Thompson,5Broomfield Avenue,Eaglescliffe,Stocton,Cleveland.

844LutonMinor—D.Platt,c/oXVSydn.RAFLaarbruch,BFPO43.

845LutonMinor—A.C.Batson,ThreeTuns,86High Street,Arsley,Beds.

916JodelD.11—D.HMitchell.c/oCathayPacific Ltd.,HongKong.

917JodellD.H--P.J.Sharp,6HighFirsCrescent, Harpenden,Herts.

944Jodel1).9-C.R.Shilling,"Pendowill-,Blisland. Bodmin,Cornwall.

1465TaylorMono-MBlyth,50BrookfieldRoad. Bedford,Beds.

1466TaylorMono—F. Cosgrove,KileenService Station,DublinRoad.Newry.

1825Minicab—N. Bayler.10ScyclaClose,Heybridge Maldon,Essex.

1826Minicab -WG.Milner,13HuntingtonRoad. A.shby-de-la-Zouch.Leics.

1827Minicab-R.B. Webber,HayrishFarm.S. Tanton,Nr.Oakehampton,Devon.

1828Minicab—M. C.Underwood.Beeches.Hardingham.Norwich.

3020CurrieWot—B. V.Mayo,79HuginAvenue, Broadstairs,Kent.

3235TaylorTitch-A. Docherty,3WhittonGrove. Stillington,Cleveland

3236TaylorTitch--A.A. O'Mara,64FromeHouse. RyeHillPark,London.

3508Tailwind- -A.Whiting,Wheeldale,Carlton Thirsk,N.Yorks.

3607PazmanyPL.2--AI. Sutherland,TheBungalow. Kindeace,Delny,Ross-Shire.

7029EvansVP1-D.J.Park. 5MonaAvenue.Chedale.Cheshire.

7031EvansVP1- R.Perrin.SandfordSt.Martin, MiddleBarton,Oxon.

7032EvansVP1-C.El Bestwick,60LilacGrove, BeestonRyland.Notts.

7033EvansVP1-A.I Sutherland,TheBungalow. KindeaceDelny,Ross-Shire.

7216EvansVP2- -J.Cater,7PittsLane,Earley, Reading.Berks.

7217EvansVP2--R. North.50LongstantonRoad, Oakington.Cambs.

7218EvansVP2—D. T.P.Heatley.2Birchwood Drive.Worsley,Manchester.

7219EvansVP2—K.L. Wiseman,5FurlandRoad, Milton,Weston-super-Mare.

7220EvansVP2-P. W.G.Fade,5EdgewoodCourt. HillbrowLiss,Hants.

7221EvansVP2 -F.GMorris,8KittyleaRoad. Armagh,Co.Armagh,N.I.

7222EvansVP2 -G.Adams.41FarloughRoad. Dungannon,Co.Tyrone.N.I.

7223EvansVP2--A. A.Coppen,22NorthTown Moor,Maidenhead,Berks.

FromP.F.A. Engineering

MINCERSOFUSINGMO1ORGASOIINE

Enginecertificationdependsontheuseofappro ed fuels,anditismandatorythatonlysuchapproved fuels,andnotmotorgasoline,areused.Thereare differencesbetweenthepropertiesandcompositionof motorandaviationgasolinewhichmaketheformer unsuitableforuseinaircraftengines.Motorgasoline isdeficientinthefollowingmainrespects:-Ithasawiderdistillationrangethanaviation gasoline,andthiscanpromoteunevendistribution oftheanti-knockcomponentsofthefuelinthe inductionmanifold.

Theknockratingofmotorandaviationfuelsare notdirectlycomparablebecauseofthedifferent methodsusedtodeterminetheknockigitingsof thetwotypesoffuel.Thisresultsinanappreciabledifferenceinactualdetonationcharacteristicsoftwofuelswhichareostensiblyofthesame knockrating.Thisdifferencecouldleadto destructivepit-ignitionordetonation.

Itismorevolatileandhasahighervapour pressurewhichcanleadto"vapourlock-occurring,particularlyataltitude.

(cl)Comparedwithaviationgasoline,whichcontains onlythechemicallycorrectamountofbromine. thetetraethylleadadditiveinmotorgasoline containsanexcessofchlorineandbiomine.The chlorineisverycorrosiveandundersevereconditionscanleadtoexhaustvalvefailures.

(e)

Itislessstablethanaviationgasolineandcan l'ormgumdepositswhichcanresult in ialve sticking_

(f)Ithassolventcharacteristicswhichmaynotbe suitableforairciaftengines.Seals,gasketsand flexiblefuellinesaresusceptibletoattack.

qoItisnothandledorcontrolledinaccordancewith thesamerigidproceduresasisthecasewith aviationgasoline.

Someofthelocalyoungsterswouldliketotake upyourhobby...Passiton.

andsupervisingyoungmenof around131Ato17172inyourhobby, aswellastherestoftheaircadet activities.

Ifyougetalotofenjoyment andinterestfromyourhobby,why notshareitwithsomeoftheboys inyourneighbourhood'?

Becomeacivilianinstructor atyourlocalAirTrainingCorps.

There'snoneedtohave previousexperienceorspeciahsed knowledgeoftheAirTraining Corps,justakeeninterestin youthworkandthetimetodevote afewhoursaweektoencouraging

Inreturnyou'llhavethe opportunitytofly,tovisitRAF stationsonspecialistcoursesat ourexpense,andtotakepartinan annualcamponanRAFstation eitherinthiscountryorabroad. Ifyou'dliketoshareyour hobbywithsomeofthelocal youngsters,wecanprovide equipmentandmaterials.

Butweneedyoutoprovide yourknowledgeandyourtime_ Whynotfindoutmore?

Eithercutoutthecouponor ringyournearestRAFCareers InformationOffice(addressin phonebook)toobtainyourfree book"jointheTeamatyourlocal AirTrainingCorps'i

Aloe

AScarletStory

OntheWirralagentleheathazehungoverthehole airfieldatHootonParkwheretheComperAircraft Companyemployed110menbusilyengagedin buildingsmall,fast,shoulderwMgmonoplanesknown astheC.L.A.7Swift.Poweredbya75hp.Polljoy sevencylinderradialengine,thediminutivesingle seatersDidbeenbreakingrecordsthroughoutthe preyiousyearwhenCA.ButlerhadflownhisSwift frontU.K.toSydney.AustraliainjustONerninedays andanothersimilarmachinehadcompletedadouble crossingoftheIsAwn.Andesmountains.I3v1932. followingthreeyearsofdevelopment,theproduction linewasMfullswingandcompleting.oilaverage.one newancrafteverytwenty-sixdays.Itwasmid-August whenairframenumber532/9waslittedNNithPoMov engineNo.108andpaintedwiththeIndianregistration VT-ADO.Finishedinthestandardpillar-hosredand whirecolourschemethelittleaircraftwastestflown byitscreator,Flt,LICower,beforebeingdismantled cratedandshippedbyseatoIndia.Threemonthslater ithadbeenre-assembledatCalcutta'sDumDuntairportbythegroundengineeroftheBengalFlyingClub andwastestflownbytheclub'sC.F.I.Laterthesame davitsproudnewowner.anEastBengalGONernment officer.Mr.AlbanAliflewherforthefirsttime. pronouncingher'assensitiveasagalvanometer'and namingherhis'Scarlet lherefolloweda riotous'christening'ceremonywhichinvolvedseme lovelyyoungladies.champagneandadentedspinner beforeAlidepartedforSilcharinEastBengaltoresume hisollicialworkofinspectingteaplantationsandusing theaircraftforcommunicationduties.Sincethere werefe•airlieldsinregularuseatthattime.Aligained muchexperienceduringthecool.dryseasonlanding titpolofieldsand',madegrounds,Bymid-I933he tookhisannualleaseandsetoutforDelhiandthe Viceroy'sCupeventwhereheachievedonaverage

VINTAGE NEWS

CamperSiridt FT - T DO oil thetarmacornum1)unc unpart.ColcuicaIn /932. Thisphotogamesli.anc fascinatinghookohocahistral'clsintheCanniermu/ entitled"TheScarletAngerThe(chetahinthehockground 117L1thescheduledK.L.:11.service, (Phaw:courlesyofthe'Slotesmonn

Thelineupof.S'iciltsenOldWardenpriorcotheir formationlakc-olkTheSenile(Angelisintheforeamunel ,

speedof124.3mph.andwasplacedsixth.VT-ADO hadbeenbuiltwithextrafueltankagcforlongdistance DyingandAliplannedtoflyfromIndiatoEnglandin companywithasimilarmachinewhentheracewas over.Allwentwellalongthemostdifficultpattofthe journeyaroundtheGulfandacrossthedesertsablaze withsummerheat.Towardssunsetonthefourthday increasingoilconsumptiondictatedaprecautionary landinglustshortofCairoatAbuSmilerinEgypt.The landingwasperfectbutfailinglightobscuredan irrigationsandbankwhichdamagedtheundercarriage beyondimmediaterepair.PoorAlicompletedtherest ofhisjourneytoU.K.byseaandsoldtheScarlet AngeltoMr.GeorgeErrington,aComperAircraft Companyinspector,whointurnhadthedismantled componentsfreightedfrontCairotohishome. Followingacompleterebuild.Errington.wholater becomechieftestpilotofAirspeeds,registeredthe machineasG-ACTFandflewheruntil1938before sellinghertoPortsmouthANiationwhereshewas impoundedattheoutbreakofhostilities.Duringthe WartheScarletAngelwasmodifiedtotakeastandard size parachuteseatandpaintedinnight-tightermatt blackwithR.A.F.roundels.Between1942-44shewas flownonwhatofficiallywere-communicationsduties.

AkertheWarherracingcareerbeganinearnest whenshewasboughtbyAirspeedtestpilm.Mr. RonaldClearwhocarefullyoverhauledandtimedthe Pobjoyengine.Fairingthestrutroots,fittinglong chordspotsontheundercarriage,andanenclosed streamlinebubblecanopyallhelpedtoraisethetop

PopularFlying,March-April, 1976

(Photo:A.Cholklgr,

speedto140mph.whichbronchisuccessinthe - DailyExpress!'triangularairracewithanover-all averagespeedof132.5mph.Therefollowedaperiod ofslowdeclineinthefortunesoftheaeroplaneuntil. severalownerslater,itwasacquiredbyformer HawkerSiddelyproductionmanagerMr.BillWoodhamsin1965.Adetailedsurveywasmadeofthewhole aircraftfromwhichitwasdecidedtoreconstructthe wholefuselagewithnewtimberforwardofthewings andtore-gluetherestoftheairframe.Tldsjobtook threeyearsofpart-timeworkduringwhichthe original"R-enginewasreplacedwithalaterPobjoy 'Niagara'.Whentheaircraftflewagainin1968there wasgreatexcitementamongvintageaircraftand preservationsocietycircleswhereBillWoodhamswas alsotheChairmanofthethenVintageAircraftGroup. Returnedtoheroriginalredand•hitecoloursthe littlemachineattractedmuchpublicityfromaviation magazinesandtheRoyalAeronauticalSociety'declaredherasan'historicaeroplane'.Despiteiecurring problemswiththeNiacaraengine,Billmanagedto gettomostofthevintageairshowsandononememorableoccassionatOldWardenin1971threeSwifts tookoffinformation,theothersbeingG-ABUS (S32/4)flownbyJohnRamshaw,andG-ABUU (S32/5)flownbyJohnPothecary.Earlierthatyearall fourairworthyU.K.basedCompel-Swiftsattended theP.F.A.FasterRallyatBlackbushebutdidnot managetogetintotheairat(hesametime,theother SwiftbeingG-ABTC(S32/1).theoldestoftheroar

TenYearsbetweenmajoroverhaulsforawire bracedwoodenairframeisalongtime.especiallywhen itwaslustbuiltin1932.HenceG-ACTI7isoncemore undergoingacompleteinspectionandoverhaulinthe carefulandcapablehandsofMr.JoeAustinasaspare timeprojectathishomeinBerkshire.Thecritical metalfittingsofthefuselage,wingandempennageale onceagainbeingremovedforinspection,repairand protectionbefcrebeingrefittedtothecarefullyinspectedwoodenmembers.WorkingatPersonalPlane ServicesatWycombeAirPark.JoehasbeeniesponsiblefertherebuildingoftheYaktrainer,the Vdmabiplaneandisnowjustcompletinghisbiggest taskofall,theWestlandLysanderofMr.PhillipMann (PopularFlying,August1975).Forseveralmonthshc hasbeeninvolvedwithfilmingof"AcesHigh-which commissionedDoug.BianchiofP.P.S.toconvertfour StampestolooklikeWorldWarOneS.E.5afighters. Havingcompletedthefalseworkrequiredforthebiplanes,Joeandhisassistantbecamecompletelyenmeshedwithallthemanyflyingsequencesinthefilm involving.astheydid,muchuseofsmokeandpyrotechnics.ForsomescenesJoeevenfoundhimselfin thetrenchesinacorporal'suniformwithasquadof extrasathiscommandtohandle'downed'machines. Followingthisexcitement,hisworkontheScarlet Angelwillprobablyhe,bycomparison,quiterelaxing.

LeatherFlyingJackets

Anyonewhohasflowninanopencockpitaeroplane willrealisehowimportantitistokeepwarm.Thefur linedbutsuppleleatherjackets of thepre-warR.A.F. daysarenolongeravailableandtheremainingones aregettinaabittatty.ftistruethattherearesome reasonableimitationsonthemarketmadeforthe motorcycleenthusiastsbutcloserinspectionshows thatquitealotofplasticmaterialgoesintotheir constructionmakingthemanythingbutsupple.

Havingobtainedacompletelyunused1938R.A.F. issueleatherjacketasapattern.CarlButlerhas approachedaleather-waretailorwhoclaimsthat exactreplicascanbemadeinanygivensize.andthat thepricewillbearound£50eachAtthisstageCarl ouldliketo knowjust him,manypilotsand CI'ew wouldbeinterestedinthisproject_Writetohimc/o VintageAircraftClubandmentionthiscolumn.

SuperAcevictorfox

WerecentlyhadtheprivilegetomeetPaulLonghorpewhoisrebuildingChrisleaSuperAceG-AKYF athishomeinMaidenhead,Berkshire.Thefuselageis nownearlycompletefollowingayearofhardwork thathasrequiredPaultobuild all newcomponentsfor thefronthalfofthemachinewhichsufferedinacrash aLShoreham in1972.Workingwithveryfeworiginal drawingsbutusingCarlButler'sC.H.3SuperAce G-AKIJWfuselagecomponentsasapattern,thesteel tubingframehasgraduallybeenre-manufactured piecebypiece a ridnowawaitstheCeconitecovering. Lookingatphotographstakenjustafterhepurchased thewreckagewemarvelledattheprogressthathad beenmadethusfarandatInsmethodicalapproachto theworkwithallcomponentsneatlylabelledand stored.Welookforwardtodoingamorecomplete articleonthismachinewhenthefuselageisrolledout andsomephotographscanbetaken.

VINTAGECLUBCALENDAR

2ndMay GeminiPatrol—Finmere

Anotherchanceforairtoairphotography usingoneoftheclubaircraftasthe cameraplane.Nowisthetimetoget somedecentairbornepicturesofyour valuablemachine.

29/31May BattonRally—Boston, Lines. Aspringcampingweekendonthislovely flatgrassairfieldinsightofthefamous 'Stump'.Afullprogramofflyingewnts hasbeenorganisedincludingpassenger flyingforVintageClubmembers.

13thJune ThruxtonRally

P.F.A.StruteventDetailstobeannounced.

2/5July Sywell'76

PFAInternationalannualRally.Sayno more,seeyouthere!

28/30Aug. Suninier Camp

T.B.N.

19thSept. TeaPatrol—Fimnere.

17thOct. SpotLandings—OldWarden.

DON'TFORGETSYWELL1976

July2nd,3rd,4th,5th

JoeAustinatworkonG-ACTFwiththeJutselageonce agaMstrippedfinaeletailedinspection.

(Photo:courtesyW.A.Austin)

AircraftCoveringMaterialsbm y u Chrisorris

Theusualnaturalfibresusedforaircraftarethe cottonsandlinens,thecottonsbeingmadapolanthe finest,throughDTD575,to5F8beingtheEnglish ones,toGrade'A',theheaviest,beingtheAmerican fabric.IrishLinen,7F1/SC,istheheavyweightBritish fabric,andprobablythemostwidelyused.Life expectancyvariesfromabout2yearsfortheDTD 575intheworstcasesofsun,acid,saltandmoisture, to15-20yearsperhapsforIrishLineninanideal climate.Madapolanisrarelyusedasanunsupported coveringmaterial,andismostwidely.usedonplywood, togiveitprotection,strengthandfinish.Fairly recently,becauseofthedifficultyofobtainingnatural fabrics,andoftheirlowlifeexpectancyinuntavourableconditions,man-madefibresarebeingmadeand used.Theyareofthepolyesterandterylenetypes, whichcanbeheatshrunk,andoftheglassfilament types,whichaleinerttoheat.TheseaiOficialfabrics, althoughmostofthemhavebeenaroundforlessthan 20years,showgreatpromiseinoutlastingthetraditionaltypes,becauseoftheirchemicaliesistaneeto sulphurousfumes(whichactuallystrengthensome types),rotandmildew,andtotheirresistancetosunlight.However,theydohavesnags,twomajorones comingtomind.Althoughtheyarecheaperthanthe cottonsandlinenstheydonothavetheirhairy texture,whichmeansthatdopewillnotadherequite soreadilytothefibres.Therearewaysofpartiallv overcomingthis,discussedlater,butexperimentingis stillintheearlystages.Secondly,althoughthefabric mightlastfor20yearsormore,thestructureunderneathcertainlywon't.TigerMothsandwoodenribbedaircraftareprimeexamples.Extrudedaluminiumsparsandpressedsheetalyribsarealsonot exemptfroma6-10yearrecoverandinspection. Buildinginmoreinspectionpanelsandwoodframes helpsofcourse.Wheretheartificialfabricsscoreisfor agriculturaloperations,andwheretheinternal structurerepeatedlyoutlaststhecovering.

Belowissetout,inafaircomparison,mostorallof thefabricsthatcanbeobtained,giventime,inthis country.Notesareadded,wheretheauthorhasfirst handexperienceorreliableinformationsources.They arenotexhaustive,butitisbelievedthatthisisthe firsttimeallthisinformation,withpriceswhere known,hasbeengroupedtogether.

(I)IrishLinen

Specification 7F1/5c. Type Irishlinen,unbleached.

Cosr: 38"—E2•58/yd.for80yds.48"— 29/yd.54"—±13.70/yd.VAT extra.Delivery6/8weeks.

Tapes: 2",3",4",6"pinked.

Weight: 4-2oz.max.persq.yd.

Strength: 901bs./inch(mM.)warpandweft.

Availability Becomingdifficult,38"and48"in stock,54"atleast12months.

Stockist: D.E.Pickles,69PainesLane, Pinner,Middlesex,HAS3BX.

MethodofApplication: Checkwithdrawings,or useTitamineadhesiveAafteradequateprotection ofstructureswithdope-proofpaintandSellotape Canbewatershrunkwithdistilledordemineralisedwater.Whenabsolutelydry(48hours)brush 10%thinnednitrateorButyrate,withquick,full brushstrokes.Sandlightly,spray(orbrush) nitrateorButyrate50/50fortherequiredfinish. Don'tleavethe.surfacetapestoofarbehind. preferablydostringingandtapingaftersecond coatdope.

Advantages: Knownlonglife.Relativelyrotproof,eitherbywaterorsun.Mustheusedfor authenticrebuilds,e.g.Tigers.Gooddopeadhesion,becauseofclose,hairyweave.Easilyfitted andsewn.

Disadvantages: Becomingincreasinglydifficult andmorecostlytoobtain.Doesn'treadilylay backonitselfwhendopingserratedtapes,especiallycreasedtapes.Burnsreadily,especially withnitratedope.

Approval: CAAandFAAapproval,all relevantstructures.

General: Themostwell-known,popularand acceptedcoveringmaterial.Probablymore pleasanttoworkwiththanGradeA.Themost resistantmaterialtopuncturingandtearingwhen doped.

GradeA

Specification T30-05. Type: AmericanCotton.

Cost: About90%ofIrishlinen.

Tapes: AsIrishlinen.60"widthwith selvedgemostcommon. 4ozs./sq.yd.

Strength: BetterthanIrishlinenandSF& stillusedonproductionailcraftin theStates.

Stockist: VanDusen'satBicester,CSEat Oxford.

Application tea/Inoue: AsforIrishlinen.

Advantages: Probablymorereadilyavailable thanIrishlinen.Easilysewn.

Disadvantages. •Notquitethelonglifeoflinen,or therotresistance,butisusualto treatwithafungicide.

Approval: CAAandFAAonalmostall structures.

General: AswellknownintheStatesas Lrishlinenishere.

Ceconite

Specification Ceconite101,102or103.

Type: Polyester

Cost: 101-50inch-1:1.88/yd.(April'75).

Tapes: 2"—£4.I3,3"--E.5.63perI00yds.

Widths: 50inch,60inch.

Weights: 101-3.5ozs.,102-2.8ozs.,103— 1•7ozs./sq.yd.

Availability: Good,except102atthemoment.

Stockist: R.F.Saywell,ShorehamAirport.

Applicationtechnique: Cannotbereadilysewn. AdhesiveAtowell-preparedstructure(willallthe enclosedlastatleast10years?).Heatshrunk carefullytocomprehensiveinstructionswith domesticirontorequiredtautness,untilapenny justbounces.Usemoderatelyfullbrushof10% thinneddope,presswithbrushtoforcedope throughweavetillafingerrunonthebackwillbe moistened(bestsetupatestpanelfirst).Formsa goodmechanicalbondthisway.Carefulnotto getrunningdopeotherside.Thenbuildupto requiredfinishbybrushorspray.Tapesafterfirst brushcoat.

Advantages: Morereadilyavailablethannatural fabrics,andapproximatelyhalftheprice.Heat shrinkingaboon,especiallyondoublecurvatures atthcbaseofthefinandontapesroundthe empennageedges.Relativelyfineweaveforrapid dopefill.Strengthactuallyincreasedinanindustrialareaatmosphere.

PopularFlying,March-April.1976

Disadvantages: Dopebondacknowledgednotas goodasonmaterialfibres.Experimentinginprogress.Mustnotbeheatshrunktoomuchforthe structure,hencethepennydroptest,otherwisea 2/3scalewarpedaircraftwillresult.especially CubsandAeroncas.NotclearedbyCAAforall structures,notadvisedbyauthorforTigers.Not tooeasytoworkwith,norsuitableforproduction run a ircraft.

General: Althoughman-made.uneonfirmedreportsstatethatmoisturerottinghasoccurredon DecathlonsandPittsSpecialsafter5-10yearsin theStates.Eseasilyrepaired,withdopedoradhesiveApatches,heatshrunkforthelargerones. Ceconite102(formax.wingloading9p.s.f.,Vne 160mph)looksidealforPiperCubsandthelike. Authorinvestigating.

(4)Razorback

Specification: Razorback.

Type: TreatedGlassClothforCABdope only.

Cost: 72"—El-90/yd44"-tI30/yd.

Tapes: 2"--U•50(50yds4"—EI-20/50 yds.All1973prices

Widths: Cloth:72",5I",44".

Finishingtapes:6",4,3",2",I".

Reinforcingtapes:",",

Weight: 3-92ozs/sq.yd. vailability. FromStates.

Agent: PossiblyVanD LIsen.

Strength: Greatertbannaturallibres Relativelypoorpuncturing resistance.

Applicationtechnique: Theclothischemically treatedforButyratedopeonly.Usefull-bodied dopetoadheretopreparedstructure,notlightly, butsnug.Sprayonly.Startwithlightcoats50/50, don'tblowthroughweave.Asweaveslowlyfills, increaseweightofspray.Verylightrubbingdown betweencoatswhendry'.Applytapesandstringingearlyon.Noedgeorballoonseamsnecessary. A2"lappedjointwithdopehas100Ibs/inch tensilestrength.

Approlvl: FAAmoststructures.Apply toCAAforothers.

Advantages:lnert toheat—glosslikeanincandescentgasmantlewithtorchonit,anddoesn't losestrength.Adubiousadvantage.Adhesionof dopegood,forman-madefibres.Cutswellwith plainscissors,don'tusepinkingtypes.Laysdown onitselfwellduringcover,especiallytapesround corners.Twoinchdopelappedjoint(e.g.repairs) almostasstrongasitself.Nosilvercoatreally necessary,exceptforuseaswitnessduringfinal sanding.Indestructibleregardsmoisture,heat, sunandchemicals.

Disadvantages: Weaveofclothcoarseandvery slowtofill,andthereforeslowtotauten.Final weightcanbehigherthanIrishlinenforsame finish.BecauseofextraButyraterequired,can damagefrailstructureafterseveralyears.Cannot besewnforedging,repairsorballoonseams(a disadvantage?).

General: Pleasantandquicktolay,clothwide enoughtogotiptotip.Repairseasyusinglap technique.Cangivedoubtstosomebodyusingit forthefirsttimewithregardstoitsslownessto tauten.(Authornoted11coatswithsmallspray guntilltaut.22coatstotalforglassfinishonJ3 Cub.Withastandardindustrialspraygun,5-10 coatswoulddoalmostthe sa mejob).Probably hasindefinitelife.

(5)DTD575

Specification: Asabove.

7lupe: ScoredcottonFtbric.

Cost:

Strength:

501bsdinchwarp,401bs.linch weft.

Weight: 3ozsdsq.yd.

Widths: 53"and64".

.4inliry: Towardsendofyearonsome widths.

Stockist: A.H.Vane, Va neHouse.SodreyStreet,London,SEIIPF

Applicationtechnique: Sewn,stitched,balloon seamedorAdhesiveAasperdrawingorinspector/LAE.NitrateorButyrate,brushed.Tapes believedtobe5F8.

.Advantages: DevelopedduringwarforAusters, andusedeversince.Light-weight,strong,little dopeneeded.NowusedonseveralBritishhomebuiltlightaircraftaswell.

Disadvantages: Littleresistancetomildew,sunlightorindustrialatmosphere.Beconnngincreasinglydifficulttoobtain.

5F8

Specification. Asabove.

Type: Mercerisedcotton.

Cost: Approx.Irishlinen.

Strength 80Ibs./inch.

Weight: 4- 25ozsfschyd.

Widths: Cloth,38"and48".

Tapes: AsforIrishlinen.

Aiailahilitv AsforDTD575.

Stockist: AsforDTD575.

Application teclmique: Similarinallrespects to GradeA,butrefertodrawings.

.4drantages: Costmainly.

Disadvantages: Notthechemical,sunlightor rot-resistanceofIrishlinen.

General: DevelopedforHorsaglidersandused oncertaincomponents or Dakotas,soisamply strongenoughforallstructures.Canbeused insteadofIrishlinenonanystructures,butthe samelifespancannotbeexpected.

Vadene

Specification: None.

Type: BritishTerylenecontinuous filament.

Cost: El•88/yd.-60"(In'75).

Tapes: 2'orcuttoorder.Heatsealed selvedge.

Wklths: 48",60",orcuttoorder.

Strength: 2001bsdinchwarp,l701bs./ weft.Goodresistancetosharp edgedinstrument.

ChrisMorris'CubatGroveTann,Notfolk.withsomeoftheairfieldmaintenanceequipment.

Weight: 3.9ozs./sq.yd. Good—demandwillencourageproduction.

Stockist: A.H.Vane.

Applicationtechniques: Maybeusedinexactlythe samewayaslinenfabric,exceptthatitcannotbe sewn.NormaltouseAdhesiveAtowell-prepared structure.Heatshrinkifrequired(pennydrop test).Runironoverfabricatabout5"/second,a biteachsideatatime.Firstandsecondcoat1/3 dope,2/3thinners,rest50/50.(Authorexperimentingwith25%AdhesiveA,75%butyrate,as the1/3,plus2/3butyratethinners).Allsprayed, asbrushapplicationnotsuccessful.Tapes(flat andcurvedsurface)ironed,afterdopingcentre only,andallowingtodry.Fullbodieddope brushedontapes.Cutbackwellwith220wet/dry.

Approval: CAAapprovalpending.

Advantages: Britishandrelativelycheap.Good heatshrinkingproperties(upto10%)with domesticironsetto"cotton".Relativelyquickto 1111weave(3coats50/50).Virtuallyrot-proof. Readilyavailable,stockistwillcuttoorder. Doesn'tflare,onlyburnsifheatapplied,especially withbutyrate.

Disadvantages: Probablypooradhesiondueto singlestrandfilamentlibre—i.e.nothairy.(Experimentinginprogress).Fairlycoarseweave. butnotascoarseasRazorback.Heatsealed selvedgeanuisanceontapes,fairamountof cuttingbackrequired.(AdviseusingCeconite 101tapes).

General: British!Hascostandavailabilityadvantages.Probablyhasbetteradhesionthanthe finerCeconitefabrics,becauseoftheeaseof forcingthedopethroughtheweavetototally encapsulateit,foragoodmechanicalbond.

CommercialDacron

Cost: 39"wide--El88/metre.(VAT extra).

TIPe: Polyester

Approval: Notreleased.

Agents: LondonSailPlanes,Dunstable,Luton,Beds. Weights,Application, etc.,asforCeconiteprocess. Readilyavailableinthisonesizeonly.

Madapolan

Specification: El14/343/4A.

Type: Lightcottonfabric.

Cost: 40"-85p./yd.48"--E1.04/yd. for100yds.(VATextra). April1975.

Tapes: None?

Strength: 301bs./inch.

Weight: Viozs./sq.yd. Instock.

Stockist: D.E.Pickles.

General: Exceptinthegliderworld,notnormally usedasanunsupportedfabric.Whencovering plywoodandproperlydoped,willoutlastthe woodunderneath.Probablynoman-madereplacementrequired.

Thereyouhaveit.Incompletemaybe,butastart. Withthenaturalfibres,youpaysyourmoneyand takesyourchoice."Which?"wouldhaveajobpicking outthebestbuy.Foranauthenticre-buildthereis littlechoice,exceptbetween5F8and7F1,andIdo believe,thatalthoughoneishalfthepriceoftheother italsohashalfthelife,andwithallthatdope,effort andenergy,IknowwhichIwouldchoose.Foranew aircraftofthePFAtype,575mightseemthenatural choice,tillyoureaditssectionabove.Supportedsurfaces(fuselages,plywoodwingsandempennage) couldnotbebettercoveredthanwithmadapolan. Wherethere'shalfandhalf,it'sabitmoredifficult.

Man-madefibrescansolvemostproblems,andthey aredecidedlyeasytouse—butfirstgetthepermission ofthePFAand/oryourinspectorbeforecovering. Andreadtheinstructionswell.

Aquickwordondopes.Thephysicsofdope tauteningisfairlysimple.Thefabricisthemediumfor takingthetauteningdope,and as thedopedries,i.e. asthesolventsevaporate,thecellulosedopesolids graduallycontract,givingthetauteningprocess.With thecoarserweaves(Razorbacks,Varlene),thefull tauteningwillnotappeartillalmostalltheweaveis filled.Themoredopethatisapplied,thetighterwill bethefinish,dependingonthemechanicalstrength thedope.Atthisstage,thefabricisdoingnothing whennoloadsarebeingapplied;i.c.thetautdopeis takingalltheload.(Heat-shrunkfabricswilbedoing somework).Asthedopeage-hardens,especiallynitrate,itcracksandpassessomeoftheloadtothefabric. Thesheerforcebetweenthefirstcoatofdopeandthe fabriccausesthepeelingandringing,dependingon thekeyorbonding.ftlooksasifthebestmethod wouldbetouseaheat-shrunkfabric(Varlene. Ceconite)andusenon-tauteningdope,preferably butyrate.Itwouldbetemptingtouseepoxypaints, polyeurethanesoroil-basedenamels.Undoubtedly. theiradhesionandlastingpropertiesareasgoodasor betterthancellulosedopes,butthedifficultyofcompletingasatisfactory,quickandneatrepairunfortunatelyrulesthiscaseout.

Thebestsequenceofdopeapplicationistouseone coatofnitrate(red,orTSM)dopefirst,asithasshown togiveabetterbondtobothtypesoffabric,andthen tofollowupwithbutyrate.Theymustneverbeused atanystagetheotherwayround,asthebutyrateshave ahigherorderofsolventsthanthenitrates.Thisis probablytheonlyadvantageofnitrateoverbutyrate, exceptperhaps,cost(aboutEl0/gall.now)andwhatevertheengineer/inspectorrequires.Butyrateremains moreflexiblewithage,ismorefire-retardent(useful whenironingtapes),andabsorbslessmoisture,either directontothelastcoatofdope,orgeneralmoisture intheatmosphere.Followupeachcoatofdopeas soonasthelastcoatisdryandallsandingand finishingcompleted,toaffordthebestpossiblemelt andkey,especiallywiththesilvercoatsHowmany timeshaveyoupeeledoffacolourtofindsilverunderneath?Ifthesilverhasbeenonsometime,sprayona lightcoatofthinnerstosoftenitabit.Donotusetoo muchsilver,3coatsareampleonnaturalfabrics,and preferablysandlightlytoaffordabetterkeystill.Use aslittledopeaspossibletoobtainthefinishrequired; trynottouseanyformoffillerfortheweave,asitadds weightandcracks,justuseplentyoffinewet/dry,preferablywet,andelbowgrease.Thethinnerthedope thickness,thelightertheaircraft,andthelesslikelyit istocrack.(Tip-waxthefinishregularlyto"feed"the paintandusecarshampoo.Snag—difficulttoremove waxforfabricrepair).Forthefinalcolourcoat,trynot touseasyntheticpaint(asmentionedbefore),asapart fromthedifficultyinpicklingitofftocarryouta satisfactoryfabricrepairandthenpaintingitupagain, syntheticsformapoorkeytodopes,anditsplasticizersmigrate,preventingapropercurefortheenamel. Also,syntheticscannotberejuvenated.

Finally,torecapbeforebuyinganyotherfabricthan usuallyusedforthejobinhand,checkwiththepowers thatwillsignoutyouraircraft.Also,checkthatifa lighterman-madefabricistobeused,itwillnotupset thebalanceandflutterofcertaincontrolsurfaces.

N.B.

Don'tbetemptedtobuyout-of-dateorsurplus dopesandthinners,astheygoacidwithage. ThehigherrateofVATdoesnotapplytodopes, fabrics,etc.

IREMEMBERCONSTRUCTINGTHEKIWI

Itisnoteasytowriteastorythesedaysonwhatwas lacedduringthebuildingofyetanotherhomebuilt aircraft.Aquicklookatanyaviationmagazinewill producethestory,withvariationsaccordingtothe typeconstructed.Weallforonereasonoranother selectthetypetosuitourpockets,ambitionsorexperience.WhowouldbelievemethereforeifIwereto projectmyinnerfeelingsrelatingtomywonderful littleflyingmachine.Iwanttoskipthetrialsand tribulations,Idon'twanttomentionthemistakes,latc deliveries,powerfailures,lousydopingweather barkedknuckles,thevoiceoftheMissusblasting acrossthegapbetweenhouseandshed....'YER FLAMIN'TEA'SCOLDNOW.No,Twouldrather relyonthehappymomentsinanefforttogetaway fromthestereotypearticle.Iwillinfactputmy memoryintoneutralandselectafewofthemost memorablemomentsastheycoastby.

TheHawkerFuryhasalwaysbeenformethe ultimateaeroplane,theywerethein-thingwhen r was averylittleboyandlaterinlilylifefwasabletobuild Ilyingmodels.Controllinefirst,thenfreenight. finallyafour-channelproportionalradioyersion. fmaginemyreactionthen,whenin1963flearntthat a7/10thyersionoftheIThryhadbeendesignedby JohnIsaacsandwasflyinginEngland.Ibeganover thenexttenyearstogatheralltheinformationIcould onIsaacsFury'andresolvedonedaytohuildit.

Thefirstofinvhappymomentsthereforeoccurred whentherealizationstruckinNovember1972thatI couldnowjustaffordtobeginmyproject.Myfirst 'DearJohn'letterwasdispatchedwiththeorderfor thecompletesetofdrawings.Irememberafterwaiting aweek,beltingouttotheletterboxeverydaythereaftertomeetthepostie.Thepoorblokedidatone stageconfidethathehadwonderedwhathehaddone todeservethesightofan18011).Kiwiboundingup thepathtomeethinteachday.

1rememberthedaytheyarrived.Irememberthe sheerpleasureinunfoldingeachsheetforthefirst timeandstudyingeverydetaillikeachildtryingto dissolvealollyslowly HI hismouth,beforeunwrapping thenextone.ManytimeswasItorepeatthisprocess. untilfinallytherelationshipofeverypartofmydream wasarrangedinmymindinthecorrectorderand firmlylockedintomymemorybanks.Thispractice paidoff,for,inanytimesmyworkwouldbehalted byasignalfrommybrainpromptingamorepractical approach,oranotherstagefirst

Irememberthethrillofliftingmyfirstwingribfrom thejigIrememberthepridewithinmeasIgazed uponthegreatstackofcompletedribsallsportingthe inspector'sstamp.Again,likeachild,fwouldplay withmythirty-nineribssettingthemuponthework bench,correctlyspaced,thenallowingmyimaginationtoputinthespars,wingtipbows,etc.Irememberthechallengeindrillinganaccurateholeinthe rightplaceandthereliefwhenfhaddoneso!I_willnot forgetthevalueofmanyyearsofaeromodellingthat taughtmeplanreading,patienceandaboveall,the needtobeweight-consciousfronttheverybeginning ofanystructuredesignedforflight.Imustnot forgettothankmybibleformanyyears—The'Aeromodeller'—forteachingmemanyofmyskills,for encouragingmetogoastepfurtherandforintroducingmetoIsaacsFurywithinitspages.

Irememberhowmywifeandfamilywouldoccasionallycomplainaboutmylonghoursintheshed, yetifthingsgottouchormyspiritssagged,therethey were,rightbesideme,givingthesupportweallneed frontourkinatsuchtimes.

IrememberthedayFenteredtheshedtoworkasI haddoneoverthepastcoupleofyears.onmydream,

byBARRYTHOMPSON

whenastrangefeelingstruckmeasIstoodadmiring myhandiwork.Icouldnotidentifythesensation immediately;asIstoodtheretherealizationeventually filteredthroughtomybrainthattheaeroplanewas finished!Thereisnothinglefttodo.Barry,relaxand savouryoUrreward

Iwillneverforgetthedaysoftransportingallthe bitsouttotheairfield,therigging,theinspections. theweighing,thecheckingandre-checking,the tension,thecontinuousstreamofspectatorsall waitingformycreationtoburstfromitshangarwomh andbehorn,byflight.Thesedays,thoughfraught withhardworkandworry,willalwaysremainin 111> memoryasthemostrewardingandhappy,alongwith thosespentontheactualconstruction or theaeroplane

Thefirstflight—Oh.whatamemory!Mywife. fathei,brother.sister,relationsfromallcorners.m threeboysanddaughterallwithlumpsinourthroats asZK-DMNflewpastforthefirsttime.TheFuryhad becomeoneofthefamily,it \VaS oneofourchildren •hohadjuststeppedintolifequalified,graduated withthe!Ugliesthonour-Flight.Weallwhohad nurturedthischildhadearnedthelumpsinour throats!

IrememberlilyfirstHight!ThiswasthefirsttimeI hadbeensentoffinanewtypewithoutaninstructor atmyside.ThereIwas,allaloneexceptforthe0/235 Lycomingchuffingawayinfrontandtheoddpop andcracklethroughtheheadphones,linedupawaiting clearancetotakeoff.Thenitcame,'DeltaMike Novemberclearedfortakeoff'.AssoonasI.openedthe throttleI_feltathonle.gonewerethedoubts,forI knewthatthisaeroplaneunderstoodmebetterthan1 didandwouldlookafterme.Andsoitdid.ftfairly leaptoffthegroundandclimbed,frantieffike,intothe sky,140Oftperminute,fullpowerand55kn.Ispent ISminutesflyingthroughthemostaccuratesteep turnsIhadeverdone,stalling,gliding.slippMg,all thetimewide-eyedinwonderattherealsensationof MNIKUMflightandinrapturecomplete!

I couldgoon,butwhatisthepoint'?Thoseofmy fellowconstructorsworld-wideknowwhatIamtrying tosay!Iantpleasedtohavesharedinthewonderful adventure,andwouldliketoclosebyofferingthanks toallthosewhopavedtheroadsforme.Themenwho yearspastfoughtonmybehalftowintheplacethe ultralightmovementenjoystoday.Tothosewho showedmehowwiththewrittenword,tothosewho generatedwiththeirenthusiasmthesourcesofsupply. AveryspecialthankstoJohn0.Isaacswhoproduced suchfinedrawingsanddesignedsuchawonderful flyingmachine.Tothosewhomaystillhearmy thanks,pleaseacceptthem.Tothosewhohavepassed. Ireserveaspecialplaceinmymemory.

WELDING

Weldedsubassembliesmadetoyourplans. Fuselagesreadywelded.

Sendplansforquote.Alllettersanswered. Wecanofferyouagoodhonestservice.We alsoarehomebuildersandunderstandyour problems.

AgentsforASH360VHF.

JYROJOTTINGS

fromPeteLovegrove

Pre-spin MechanismsforultralightGyroplanes—continuedfrom PopularFlyingVol.20No.1.

Powertransmissions

WhatevertypeofpowerLike-offyoumayhaveat attheengine,youaregoingtoneedsomeformof transmissiontogetthatpoweruptothehead.This willalmostcertainlybeoneoftwoforms.viz:-rigid driveorflexibledrive.Idonotevenconsiderelectrical. pneumaticorhydraulicsystemsworththetroubleof discussion,asIMasamateursareconcerned.Cometo thinkofit.theyhaveseldomprovedworththetrouble evenforprofessionaldesigners!Letusconcentrate thenonrigid-shaftandflexible-driveschemes,taking thelatterfirst.

Flexibledrivesareusuallyaformofmulti-layer cable,builtuplikealargeBowdencable,withthe variouslayerswoundinoppositedirections.Thecable ishousedinaveryrobustcasing.Specialendfittings allowattachmentstothedrivecablewhilstleavingthe casingstatiomuy.

Thebiggestproblemwithflexibledrivesistheir limitedabilityto transmit torque.Ifyoutrytopush toomuchpowerthroughthem,atlowrpm,they simply'windup'andshearoff.Thewaytoprevent thisistorunthemathighrpm.Thctorque.foragiven horsepower,isthenatamiiiimtuii.andthesmaller drivesareOK.Forourpurposes,wemighthaveto limitourselvestoa;1"drive.becauseoftheveryhigh weightoftheseunits.fnordertogetareasonable amountofhorsepowerthroughthedrive,itwouldbe necessarytorunitatthehighestspeeditwilltolerate. say.intherange4to8000rpm.

Thisgenerallytakesyououtsidethemanufacturer's ratingsandyou can forgetanyguaranteestheyusually make.Butremember,theratingstheyquotearefor industrialapplications,wherereliableperformance overalongperiodisimportant,oftenunderconditionsofcontinuoususe.Bycomparison,weonly usethedriveforafewminutesinadayandforavery fewdaysayear.Sowecanaffordtoexceedthemanufacturer'slimits,providedwedoitsensiblyanddon't expecttoscreamatthem if wemakeamistakeandthe shaftfails.

Lookingatthequestionofhighdrive-rpm,fromthe view-pointofthecompletesystem,thefollowingpoints becomeapparent:—

Wherethepowerisdrawnfromtheengine,weneed agearing-up.Forexample,iftheprop-flangecarriesa 6inchroller,gearorpulley,weshouldfita31-to5 inchroller,gearorpulleytothedriveinput.A4inch driveNwheelwouldbemychoicefora6inchdriveR. At3000rpmontheengine,thedrivewouldthensee about4500rpm.ffarollerpick-upisused,itmust havea'tread'widthofabout2inches.

Rememberthattheoverallreduction,fromengine torotor-head,needstobearound10:1or12:1,sothe totalreductionyoumusthave,intherotor-head mechanism,is10:1or12:1,multipliedbythegear-up ratiousedatthedriveinput.Witha6:4drivecombinationasIhavesuggested.theheadreductionmust be10,,6/4--15:1,or12/4

Theseareratherlargereductions,toomuchfor acceptably-smallgearUnitswithonlytwogears.This iswhymachinessuchastheWallisandtheTervamaki hadcompoundsystems usingplanetary gear-boxes andtwo-gearreductionsinseries.Butdon'tbetoo despondentAmodifiedthree-speedhubBoina bicycle (anee( one,please?)andapairofhardened MulTettgearswilldothejob,suitablyinstalled.Do

notforget,thesystemspendsmostofitslifestationary,unlessyouarrangethatitisusedintheover-run mode,sosimpledevices can hesatisfactory.

Onemoreproblemwiththeflexibledriveisthatthe lubricationtendstobepoorerincoldweatherandthe shaftmay he limitedinitsthroughput.comparedwith itswarm-weatherperformance.

FlexibledrivesaremadebyMorrisflex,whodoa largerangeofhand-operatedtoolswhichuscthem,as wellassomefinerubber-tyredrollersadaptablefor ourpurposes.AnotherfirmisPennwaltSS.Whitein Bletchley.

Nowletusconsidertherigid-shafttransmissions. Basically,theseuseapowertake-offfromtheengine. justaswiththeflex-drive,butherethedrivegoesinto agear-box.which(Urns the transmissionthrough90. Theoutputfromthisgearboxgoesuptotheheadreductiongearsorbeltsystem.Asliding,splinedshaft isnecessary,Mordertoallowtheheadtoriseandfall duringcontrolmovements.Universaljointsatthetop andbottomoftheverticalshafttakecareofallmisalignmentswhichmayarise(Fig.5).

Again,asmallshaftmaybemadetotransmitmore powerbyusinghigherrpm,aswiththeIlex-drive,but onehastobecarefulthattheshaftcannotreach whirlingspeedorthepilotmayfindhimselfbeing beatenabouttheheadwith,itsbrokenend!Iwould suggestthatthedrivetake-offfromtheenginebemade about3:2or6:5,i.e..youlita6inchwheelorpulley totheengineanda5or4inchwheelorpuoleytothe gear-boxinputshaft,foraflex-drive.Forarigid-shaft. reversethepulleys,i.e..putthe smaller onc onthe engineshaft.

Severalsmallgear-boxesareavailableandusually havethecapabilityofbeingoperatedasareduction gearof11:1or2:I.Eitherissatisfactory.MotorGear ofEssex.OppermanofNewburyandVaratioof Sloughallmakesuitablegear-boxes,althoughIwould selecttheVaratioasbeingperhapsthemostusefulto us.

Ifyouuseapulleysystemfromtheenginetothe spin-updrive.Iwouldrecommendthe'Picador' pulleysfor-;"beltsand'Pelikan'onesfori"belts. H. AldridgeofReadingaregoodstockistsofsuch items.Beltscanalsobeobtainedfromthem.

Withanengine-to-drivereductionof3:2anda gear-boxreductionof3:2theremainingstep-down mustbecarriedoutinthcheadmechanism.Foratotal dropinrpmof 10:1 weshallneedaratiooflOxixin 4=,1approximately.IfweuseaVee-beltandpulleys onthehead,asontheCricket,wcwillselecta2inch anda9inchpairofpulleys,ora 2J inchandanII inch.(Fig.6).

Operatingcables

Oneoftheirritatingandoftenperplexingjobs,in settingupaspin-upsystem,isgettingasuitablecable arrangementtofunction.Ifyourchosenschemehasa BendixgearoraTorringtonclutchattherotor-head end,thenitisself-engagingandyouneedonlyprovide asinglepullonthebeltorrollerpick-upattheengine end.Thiscanbeachievedwithsomethingverysmiliar tothethrottlemechanism,

ff,however,youhavegearswhichswingintomesh ortffeslidaxiallyintomesh,onthehead,thenyou musthaveacablesystemwhichfirmlyengagesthese beforecausingtheenginepick-upto he activited.On onemachine,Isolvedthiswiththeschemeshownin

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Te ,Fn5g4E „ ir-CCEA/TgiC#1156C5 6'c..ua )eire:g-915eCelarr61‘54”VGS .S5,2/VS(R5LC .5cco9FT gammds

Pia. 7 5.6494072"#e?0,0-(Rait- ,gEvahve- CMS dcs. 8.Hee,-Gemewin,/ E/YaRarlienr-rHY

wasallIcouldcomeupwithatthetimeatshort notice.However,itdoesservetodemonstratethe principle.Justrememberthatyoucannotproperly engageapairofgearsattherotor-headifoneofthem isspinningfuriouslybecausetheenginepick-upis alreadyengaged.

Suggestedsystem

Toforestalltheobviousquestion,hereisthebasic sortofarrangementwhich I wouldrecommendas givingagoodperformance.Unfortunately,itisnot thesimplest,cheapestorlightest.

Iwouldsuggesta5inchpulleyontheengineshaft anda4inchpulleyontheinputshaftofa2:1Varatio Anglegear.Ontheoutputshaftofthegearbox,now rotatingat5/4x1—ofenginespeed,Iwouldfita heavy-dutyuniversaljointsuchasaMotorGearand EngineeringLtd."Hi-Tore"coupling,probablythe 9/16inchboreversion.Totheoutputendofthis coupling,wouldbeattachedalengthofsplinedsteel, say,about4or5incheslongandinchesoutside diameteronthesplines.(Remember,itmustnotpull outofengagementastheheadmovesforflight

PopularFlying,March-April,1976

control).Thelatterwouldengageinafemalemember weldedorbrazedtothelowerextremityofainch diametertubeofT45steel.Apluginthetopofthis tubewouldfitintothelowerhalfofanotheruniversal coupling,thetopofwhichwouldconnecttothe bottomofashaftcarryinga14inchPCD,12DPgear or,possibly,a11PCDgear.This,andthemaingear, wouldbecase-hardenedaftermachiningtosize.

Themaingearwouldbean8or9inchPCD,12DP gear,dependingonthesizeofdriveRselected.The smallgearwouldbeswungintoengagementwiththis largeonebysupportingitsshaftinaneccentric housingwithanappropriateoperatingarm.Figure8.

Asanalternativetothetwogearsswinginginto mesh,theinputuniversalcouplingcouldbeconnected toashaftcarryingamodifiedBendixcoupling;(make sureyouhavethecorrectrotation:therearetwosorts). Thereturnspringwillhavetobeconsiderably lightenedforourpurposes.Selectaspringofthesame lengthanddiameterwhichcompresseshalfitslength withaloadofoneounce.Also,theshaftwillhaveto besupportedatitsupperend.Thisbringsmetomy finaltopic,practicaloperationofaspin-up.

Fieldoperationofspin-ups

Fortheuninitiated,itisaverysimplematterto wreckaspin-upsystem.Thecommonestfaultis applyingavigorousinputtoRtuefromtheengine pick-upwhentherotoristotallyatrest.Underthese circumstances,thetorqueloadingsseenbytheparts ofthetransmissionarecolossalandtheleastthatcan beexpectedisasheareduniversalcoupling.Thetorque mu.s1beappliedverygentlyindeed,intheearlystages ofTinningup.And,evenmoreimportant,it-atall possible,therotorshouldbegivenapushtogetit rotatinginthecorrectdirection.ftdoesnotreally matterhowfastitismoving,justsolongasitisnot stationary.Thereductioninstresslevelinthetransmission,asaresultofthislittlebitofmotion,isvery large.

Settheenginerpmtoafasttick-over,around1500 foraMcCullochand1000-1200foraVWand,with therotorgentlyswanninground,pullthespin-up engagementlevertolockintheheadconnection-if youusedone—andthen,eversocarefully.carryon pullingtobringintheenginepick-up.Takeyour timeand,ifitlooksnecessary,progressivelybringin thepick-upastherotorgathers,say,100to150rpm. Thereisnoneedtohurryandeverythingisgoing-to lastlongerifyoutreatitsensibly(yo LI canforgetabout enginepick-up,sincethesystemissolittleused).

Oncethepickupisfullyengagedandtherotorhas eqtnlibratedattherpmcorrespondingtotheengine

speedmultipliedbythereductiongearratio,youcan begintoopenthethrottlesmoothly.Forexample,if yourengine,nowundertheloadofthespinningrotor, hasdroppeditsrpmfrom1200to1000andstabilised atthat,andthe10:1spin-upaearisfullyengaged,the rotorshouldbedoing1000•:1/io—100rpm.

Graduallyraisetheenginespeed.allthetimegiving thehighinertiaoftherotoranadequateperiodto follow,untilyoureachthedesiredmaximum.The lattermaybedictatedbyanyofseveralfactors,such as:--Thetorqueloadingontheenginepick-upmay becometoogreatanditmayslip,thepropellormay bethrustingsomuchatthehighenginerpmthatthe brakeswillnotholdtheaircraftortheairframemay beprotestingatthehightorquesappliedtoit,by twistingthemastorsomesuchhorridoecurence!

Atthistoprotor-speed,releasethebrakesandpush thethrottlesmoothlytomaximumopeningandaway yougo.fftherotorrpmwerearound2/3to3/4of flyingrpm,youcangoolTwiththesticknotveryfar backfromneutral,thatis,inthetake-offattitude.If therpmwereinuchlower,itwouldbenecessaryto holdthestickwellbackuntilthenose-wheelbecomes light,thentoeasethestickforwardtowardsneutral forthetake-olf.

Toansweronelastquestion,"DoI have tolit a spin-up?",no,youdonot.ftyouhavealargeairfield or alongstripandonlylikeflyingaroundthepatch, soyouarenotgoingtogetinatrafficstreamatthe runway'send,forgetit,itisjustdeadweight!

AircraftfortheHomeBuilder

No.6 OFASERIES

JUNGSTER

TheJungsterisascaled-downversion or the WickerBO133Jungmeister.Theaircraftwasdesigned in1959andflewforthefirstdineinOctober1962.Itis asinglescatsportingaircraftstressedto=9G-6G andconsequentlyisfullyaerobatic.Thedesigner,Rim Kaminskas,isaprofessionalaeronauticalengineeron thewestcoastoftheU.S.A.

Description

Abracedbiplanewithtwoparallelinterplanestruts eachside.Thewingisallwood,two-spar,with optionalmarineplyribs.WoodenFriseaileronsare fittedtoallfourwings.WingsectionisNACA4413.

Thefuselageisallwood,trusstype,fabriccovered. Tailplaneisbracedwoodstructure,rudderand elevatorfabriccovered,fixedsurfacescoveredwith plywood.

ThelandinggearisPiperCubstyleweldedsteel tubewithrubberbungeeshockabsorption.

AnypowerplantfromC-85,C-90,0-200upto0-320 isquotedasbeingsuitable.

Leadingparticulars

Span —16ft.8in.

Wingchord—2ft.8in.

Length •—16ft.0in.

Tailplanespan—6ft.8in.

Wingarea(gross)--80sq.ft.

Emptyweight 606lb.

T-0weight—850lb.acrobatic

Maximumweight—1000lb.

Performancedependsonthetypeofenginefitted, butthefollowingfiguresarequotedfortheLycoming 100hp.0-235.

Maxlevelspeed

Maxcruisespeed

Stall

Rateofclimb

T-0run

Landingrun

Thedesignrightsarenowownedby: K&SAircraftSupply, 4623FortuneRoad.SE, Calgary,Alberta,Canada. Thepriceoftheplansisaround880.

RobinOwen's STRUTNEWS

amwritingthisinthefirstweekof1976reflecting upontheremarkablesummeiof1975whichIthinkis theusualthingtodoatthistimeoftheyear.Strut activitywasquiteintenselastyear.nolessthaneight newstrutswereformed,althoughsoniewerefcrmed fromoneverylargeStrutinEastAnglia.Iwouldbe ertsurprisedtoseesuchdevelopmentin1976but neverthelessthereisstillplentyofspaceontheStrut mapfornewStruts.

Strutsfallintotwoquitedistinctcategories.The hugerStrutsarexeryactive:theysendadelegateto thequarterlycouncilmeetings.publisharegularnewsletter.stagearally:fly-inandholdregularmeetings TheyconstituteabouthalfthetotalnumberofStruts. Theotherhalfarelessactiveforthefollowingreasons: theyareinadecline,orparadoxicallyhavejust startedorgeographicallytherearefewermembersin thearea.TheseStrutstendtoholdrandommeetings. donotpublishanewsletteranddonotheldarally.I thinkthattheirprimarynewyear'sresolutionwould hetosendadelegatetothenextcouncilmeeting.

However,toreportontheStruts,Iwillstartwith themostrecentbformed,theLUTONANDDUNSTABLE.Sevenmembersattendedtheinaugural meetinginNotember.hichwasheldatRobin King'shouse.Members'projectsareasIbllows:Tom.. Francis.completedflyingIsaacsFury:RonBeecham. RobinKing,Fury:Piper,Nipper:RonJones. Sonerai:MickJohnson,VP2.PEAmembersinthe areaareintitedtotelephoneRobinatDunstable 64924forinformationabouttheStrut.

TheGLOUCESTER/CHELIENHANIStrutnow hasnewmanagement.BernieBaumanhasproduceda newsletteronbehalfoftheChairman.HB.Yardlex, 135LansdownRoad.GloucesterGE_I3JE.TheStrut meetingatStokeOrchardinNovemberattracted23

enthusiastsThemeetingwascentredarounda virtuallycompleteCavalierprojectonthewartime airfield,inaworkshop,Ihastentoadd!Strutmeetings arenowheldonthefirstThursdayoreachmonth. StokeOrchardisthepermanentvenue.

WenowmoverapidlyeastwardstotheNORTH WESTNORFOLKSTRUT.JohnFellreportsthat duringthesummerof75theStrutmetatLittle .Snoring(McAullyGroup)onthefirstandfourth Tuesdaynenings.Mostmembersflewuntildarkand thenretiredtothelocalpubinFakenhamcalledthe Crown.wherenoteswerediscussedoveraverypleasant drink.TheStrutwillholdameetinginMarchtodiscussfuturesummeractivities.

TheEASTMIDLANDStrut'sJanuarynewsletter reportsonlastseason'sactivitiesincludingtheirtwodayrally.unfortunatelymarredbypoorweather.The StrutplayedalargepartatSywellbyprovidingCourse judgesandanexcellentstandintheMarquee.The 1976RallydateissetforMay30th:31st.

Averysuccessfulbreakfastpatrolwasheldbythe REDHILLSTRUTatRedhillaerodromeonDecember28th.Iheardthatabout70aircraftarrivedand only7or8breakfastswerewon.

TheSOUTHERNSTRUTnowonlyissuesnewsletterstothosememberswhohavepaidtheirpound. ThelastmeetingwasheldatShorehaminthemiddle orahealingfailure.Anearlyadjournmentw,as necessaryduetotheintensecold,severalfilmsere shownatthismeeting.

Ihatehadnonewsl'orseteralmonthsfromthe YorkshireareaandcanonlyassumethatallStrut activitieshateceased.TherearealotofPEAmembersinYorkshireandroompossiblyfortwoStruts. I anymembersarekeentostartStrutsperhapstheywill getintouchwithHeadOffice.

CAVALIERSQUADRONNEWS

IhefirstIlightofaCavalierintheUK.tookplace on6-12-75-thiswasmyownaircraft.G-AZJIH.At thetimeofwritingthetestschedulehasbeencompletedandtheCofAisnowawaited.

ThefirstfightoftheKen Cm illiam:AndtMills projectisalsoimminent.andwillprobablyhavetaken placebythetimeyoureadthis_

Arisingoutor(heverythoroughinvestigationolthe U.K.prototypeCavalierbyP.F.A.EngineeringexecutiveMr.Walker,thereareanumberofpointsof interesttootherbuildets_

'Hieshoulderharnessattachmentsshouldbecarried afttodielongerons.prelerablybymeansolcablesto astrongpointonthelongerons.

Theelevatorpushrodshouldbeliltedwithasteady bearingtopreventvibrationduetoexcitationfrom theengineand/orvibrationsfromthespringsteel landinggear.Asketchofthismod.willbesenttoall bonafidebuildersonreceipt or astampedselfaddressedenvelope.quotingplansserialnumber.

Whentiptanksonlyareusedanadequatefuel punipisamustl'orsafeoperation.

Whilstonthesubjectoftiptanks.Ifoundit preferabletousethealternatesingletankoutletto avoidhavingunuseablefuel,especiallyathighangles ofincidence.Alltanksshouldhaveoutletfiltersand waterdrains,andausefuladditionwouldbeanonreturnvalveineachfuellineoracombinedfilterivalve intheramairventtoeliminatethepossibilityof cross-feeding.

Toallowfullaileronmovementitisnecessarytolit aself-aligningbearingatbothendsofthefront PopularFlying,March-April,1976

byDavidBuckle

tile\atorpushrod.1heFafnirRli4NI6bearingatthe tubetorqueendhasinsufficientmovementandshould liefittedwithathinlocknuttopreventrotationofthe threads.Asimilarbearingcanlieusedattherearend ordiepushrod,or,withtheoriginal'Minicab'type duralbellcrank.thepushrodcanhaveaforkend. withaself-aligningbearingfittedinthebeficrank.

Thecontrolcolumntorquetubeshouldbeassenibled onthebenchusingablockofwoodtosimulatethe mainspar.Clearancesandmovementscanthenhe checkedbeforelinalinstallation.Careshouldbetaken toensureadequateclearancebetweenthesparthrough boltsandtheaileron!everBEFOREtheaileronlever attachmentboltholesaredrilled.

most or theCavalieraircraftwiderconstructionin theU.K.appeartobecomingoutheavierthanthe designersweightestimate,particularlywhenthebig Lvcomingengineswithelectricstartingareused.Itis thereforeessentialthatcarefulthoughtshouldbe giventoeachitemolequipmentandthetemptationto addthingsorto'beefup'thebasicstructureshogldbe stronglyresisted.ltisnicetoaddalotoftwiddlyknobs andgadgets,butyouwillloseoutonperformanceIn particular,takeoffdistanceandrateofclimbwillsuffer noticeablywhenyouarecarryingexcessweight.

Finally,thosebuilderswhoseprojectsaregoing throughastickypatchwillbepleasedtoknowthatthe finishedaircraftiswortheverybitofeffortit'srather likegettingintoanL-typeafteryouhavedrivenaFord Popularforyears.

VINTAGENEWS

DearSir, Ihaveenclosedaphotographwhichmaybeof interesttothe'VintageNews'editor.IhavejustreturnedfromavisittoSouthAfrica,andvisitedquite afewairfieldsintheJo'burgarea.Imustsaythatthe enthusiasmtowardsflyingandolderaircraftisvery high.TheTigershownwasoneof 10 whichwereat Baragwanath,andImustsayIhavenotseensuch beautifullykeptaircraftanywhereinthe U.K.. possiblyduetothefactthatKarlFrank'Bok'Strecker rebuildsthem,heisagentlemanofaboutseventy yearsofageand'Tigers'arehislife.Iwonderwhether perhapsanybodyintheAssociationmaybeableto helpwithaproblem—thatis—PropsforTigersare veryhardtoacquireandtheywouldliketoknowif theycangetholdofany,oranyother'spares'.Their addressis:'TigerMothClub'.P.O.Box9266,Johannesburg2000,SouthAfrica.

DearSirs,

A1RBUGGYDELIVERY

Youmaybeinterestedtonotethatthefirst'AIRBUGGY'AUTOGYROtobesoldinEnglandwas purchasedrecentlybyW.HenryBeeversofYapham Mill,Pocklington,Yorkshire.Thebuilder,BillEkin ofCrumfin,N.Ireland,broughtthemachineto Pocklingtonfordemonstrationpurposesduringthe beginningofOctober1975.Inspiteoftheverywindy conditions,3or4dozengyroenthusiastsarrivednot onlybycarbutbyfixed-wingandrotary-wingaircraft. Perhapsthemostenterprisingvisitorintheconditions prevailing,wasGroupCaptainKenHayi,the CommandingOfficerofR.A.F.Binbrook,whoflew the120mileroundtripinaCampbellCricketbelongingtoFlightLieutenantErnieSimmons.Itmust havebeenalotslowerthantheHarriersthatGroup CaptainHayrnormallyflies.AlsopresentwereYorkshiretelevisionwhosefilmreportwasshownnextday ontheirprogrammecalled'Calendar'.Mr.Beevers andhissonDavidhadpreviouslybuiltaBensen B-8Mwhichtheyhadsuccessfullylearnedtofly.Since Mr.BeevershadbeenanenginefitterwiththeR.A.F., hewasnotconvincedthattheex-droneenginewhich wasfittedtotheBensenB-8Mcouldeverbemadeas reliableasamass-produced,air-cooledcarengine. Thiswasperhapsthemainreasonforswitchingtothe 'AIRBUGGY'whichemploystheVW1600ccengine.

OnavisittotheE.A.A.conventionatWelkom someverynicehomebuiltswereseen,includingafew TurbulentsandanEAABiplane.AtDurbanVirginia AirporttherewerethreeLutonBetas,oneflyableand theothertwounderconstruction.ItseemsthathomebuiltsarebecomingquitepopularinSouthAfricaand couldprovetobeinthefutureoneofthelargest countriesoutsidethcU.S.A.tohavesomany.

Yoursfaithfully, ALANC.BUSHELL

10BARLF,ECRESCENT, COWLEY,UXBRIDGE, MIDDLESEX,UB82EX

FRENCHCONNECTION

A10Vee-beltreductiondrivebetweentheVW engineandthepropellerisusedtooffsetthemuch inferiorpowertoweightratiooftheVWcomparedto theex-droneengine.SinceMr.Beeversreportsthat therateofclimbinthe'AlRBUGGY'seemstobe betterthaninhispreviousmachine,itwouldappear thatthereductiondriveispayingforitsextracostand complication.

Trainingofautogyropilotshasalwaysbeena problem,butFlt.Lt.Simmonsisnowratedtotrain pilotsinbothCampbell'Crickets'andEkin'AIRBUGGYS'.However,traineesmustprovidetheirown machines.Thecostperhourisabout£2and10hours arerequiredtoconvertaP.P.L.(Fixed-wing)pilotto anautogyropilot.Aphotographisenclosedshowing WilliamH.EkinhandingtheCertificateofAirworthiness(SpecialCategory)toW.HenryBeevers. Yoursfaithfully.

W.H.EKIN

TIIEPARK, 12NUTTSCORNERROAD, CRUNILIN, CO.ANTRIM

DearSir,

TheThionvilleAero-Clubispreparingahistoryof theiractivitiessincetheirinceptionandtothisend haveaskedmeifIcouldobtaindetailsoftwooftheir formerclubaircraftwhichweresoldintheU.K.in 1972.

TheyareparticularlyinterestedtoknowtheBritish registrationandpresentwhereaboutsofthesemachines togetherwithanyitemsofinterestregardingtheir operation,possibleprangs,etc.

TheaircraftinquestionaretheJodelD112.formerly F-BIQQandJodelD9.formerlyF-PHFC.

Iwouldbemostobligedit-youcouldpublishthis letterinthehopethatthepresentownerswillkindly letmehavethedesireddetails.

Yourssincerely, J.PluirPs

9RUEAuxFOILLONS, 78650.BEYNLS, FRANCE

Inthismodernageofcommunications,itiseasyto takeforgrantedthefactthatjustanythingcanbe convenientlypostedtoanywhere.even,youmight think,aparachute,whichmakesaprettyordinary parcelbyPostOfficestandards.Myexperience,however,isastudycfabsurditytowhichoccasionthe Britishwayofliferoseadmirably

ItbeganwiththepurchaseofaD.H.TigerNlothai anobscuregrassairfieldintheSouthofFrance.ata realisticprice,andafterconsiderablehagglingabout theeffectsoftheBritishdevaluationofthetime.I spentsonie15airhoursen-routeFortheUK.,sitting onaparachutewhichwasapparentlyinwiththedeal. Isatonitmostlybecausetherewasnowhereelseto putit,notenaccountofanyobviouslife-savingmerit whichitmighthavehad.Infact.itwasverywellused, wasoftheexactpatternfrequentlyseenin1TheadventuresofTintin',andonfurtherinvestigation provedtohave18gores,beingmadeofsilkin1947. Itsrecordcardshowedsomepassingattentionsonic 10yearsbeforeandsuchwasmyopinionofitthatI promptlygaveittotheAirCadetwhocameonthe triptomanagetheaircraftontheground.e.g..held wingswhentaxi-ingonconcreteorinstrongwinds

Onlyshortlyafterwards,anirateletterfromFrance askedurgentlyforthereturnofthe"irreplaceableparachute.saidtobelongtosomeotherparty.Iexchangedthetired'VtypeIhavekeptintheloftfor severalyearswithmycadet'srecentacquisitionand setaboutpackingsameforreturntoitsallegedowner. ItwasdulyweighedandinsuredatthePostOfficeand sentonitsway.Afewdaysafter,however,anote arrived,summoningmebacktotheP.O.andthere wasmyparcel,accusedofnon-regulationpacking.I hadtogotoW.H.Smith,returningwithsealingwax. morestring,stickytapeandinparticular,aseal, uniquetomyselfforimpressioninthewax.Anew customsdeclarationtookintoaccountitsnewdimensionsandweight.Justaweeklater,theparcelwas solemnlydeliveredtomyaddress,withmoneyback. beingnowmarginallyoverthemax.permittedweight. TheP.O.washedtheirhandsofit.

Nothingdaunted,IresortedtodearoldBritish Rail.Myneareststationturnedouttobeuntraceable inthe'phonedirectory.soIwentinperson,tobe greetedbyapoliteIndiangentlemanwhopointed forlornlytothepatchonthewallwherethetelephone hadpreviouslybeen.Allhisbusinesshadbeentaken overbythedreadedLondonTransport,whohadleft himforbiddentoissuetickets,andworse,devoidof allauthorityrelatingtoparcels.Needlesstosay, LondonTransportwerenotinterestedinmyprobleins either.

ThenearestparcelsofficewasatHayes.soIdrove there,aheadlateremergingfromaslidingwindow. saying"Yus.MatenFormswereshovedthrough theapertureandItilledindestination,contentsand allthat.ire,thisisforeign Yes,itwas Foreign....-Can'tgofrom'ere-.Iaskedwhat.. differenceitmadewhetheritwasforeignornot.but thesystemdecreedthat.1mustgotoaContinental ParcelsOffice,therecommendedonebeingatVictoriaJusteyerythingisgoing'continental'nowand aftervoicingmyviewsonthistrend.IwasadYised thatImightgetsonieconsiderationatSlough,wffich hasbeenknowntoexportsmallaiticlesfromits tradingestate.AtrainleftforSloughinoneminute ilndIwasonitbyanarrowmargin.heavilyladenwith myburden.

l'opalurFlying,March-April.1976

Sloughboastedaperiodparcelsofficeintrue Victorianstyleandonmakingmyselfknown,the oraclewasconsulted.Itconfirmed thatthere wasno reasonwhymyparcelhadnotbeenacceptedatHayes, whichwasontheapprovedlist.Ifumed.askinghow muchallthiswaseventually going tocost.Thebook said£513s.4d.toSt.Raphael.S.N.C.F.bypassenger trainThisseemedprettysteepandIventuredthatI vyasn'tworriedwhatsortcftrainitwentby,aslong asitwent,sowhataboutgoodstrains?Theoraclethis timeprovedtobeatBroadStreet,aYailahiebytelephoneanditmentioned£2Ws.withalittleextrafor insurance.Isettledforthat.

1- Course,we can't dothat'ere.:Ayetotakeit dafintheGoodsYard...T.TheGoodsYardproved tobequiteremovedfromthestation,andwasreached viamuchofthetown.I came totheweighbridgeand ollice."Not'ere,Mate.dahntheotherend...".

Atthe-otherend'myparcelwasacceptedwith some confusionIhavetheimpressionthatnoU.K.citizen haseyersentaparachutetotheSouthofFrance previously,andastrenuousdebateensuedregarding itsclassification.BroadStreetwasagainconsultedand OfficestaffproducedDickensianpublicationswhich setouttheproceduretobeadopted

Itwasofficiallyweighedandvaluedat£110for insurancepurposes,sinceIpreferredgoodcover againstfuturedisappearanceinthehandsofB.R. Theyconfirmedthatthiswasadistinctpossibility. Forsomeobscurereason,thevaluehadtobeconverted intoGOLDFRANC'S,acurrencyhithertounheard of_Thi5wasachievedviaadecayingsetoftablesand areceiptdulyissued.

TimewentbyandlongbeforeIhadanyindication ofarrivalinFrance,thefirstcomputerisedinvoice arrivedfromB.R.AccountingOfficeinCroydonThey hayebeenarrivingprettywelleversince.withexhortationstopavuporbesuhjecttothe-usualprocedure-, latelydefinedaslegalaction.ofcourse.Ihavewritten repeatedlyquotingthenumberofmyreceipt,etc.,ad inlinitum.andofcourseitispointlesswritingtoa computer,whichisneve]preparedtoallowthatit mightbemisinformed.

Theparceldideventuallyarrive,takingapprox.10 weeks,andIhavenoideawhattheparachutewas subsequentlyusedfor.IhaveoftenwonderedifperhapssonieFrenchmanisreadytoplacehislifeinthe handsofthe1947silkrelicIdismissedsoreadily.

TheTigerMothwassuitablyequippedwithapair ofIrvinScatType'chutesforaerobaticsandproved tobeanexcellentplatformforexitwithfree-fallrigs. Agoodinnovation.Ifound,wastoweartheMilitary patternflyinghelmetandbone-dome,withbffilt-in intercom.Thisway,aparachutistcouldstandcomfortablyonthewing,talkingwhennecessarytohispilot, withoutrisk or beingmisunderstood.Attheopportune moment,asafety-quick-releaseplugisdisconnected andawaygoestheparachute_Thiseffectivelyavoids theneedtoshout,wavearmsorreachovertotap shoulders.wffilsthangingonlikegrimdeathtostruts withtheotherhand,amuchmorecomfortable arrangement.

IhavesometimeswonderediftherewasanyadvantageinflyingmyparachutetoLeTouquetfor postingtherePerhapsIshallneyeiknow.Onething isclear,however.civilisationisnotyetsufficiently advancedtoacceptparachutesintransit.withoutsome indigestionwithinthemachine,

Building"Sprite"-Part 2

byBarry

lnthisdescriptionofthemainsparandundercarriagemanufacture,Iwilldescribehowwedidthings alittledifferentlyfromthebuildbookinstructions. Firstlythewingismadeupofthree8'sections,withthe centlepartboltedpermanentlytothefuselage.This sectioncarriestheundercarriage,theouterwing panelsareremovableforstorageandtowingpurposes.

OurfirstdepartureFromtheinstructionbookwas touse'CELLOSEELjointingcompoundforthewet assemblyofthespar.insteadofthequoted'Bostik', whichweconsideredverymessytoapplyanda terriblesubstanceforpickingupeverypiece of dirt andswarlthathappenedtohearound,also,any surplusjointingcompoundcanbeeasilywashedoff thesurfaceofthefinishedcomponent.CELLOSEEL ismadebyPinchin&JohnsonPaintsLtd.,andis manufacturedtoD.T.D.900%4549.costtodayahout CI•30pertin.

Thesecondthingwasachangeofundercarriage fromtherubberincompressiontypeoflegasdrawn, toa'CESSNAspringsteeltypeundercarriagewhich wehadpurchasedsecond-hand,andcompletewith axlesfromWestairFlyingServicesatBlackpoolAirportfor£25.Ourreasonfordoingthiswasanattempi tomakeitlookbetter,alsotherewouldbenomaintenancetocontendwith.Thespecifiedlandinggear appeatedtobealotofworktoproduce,withextensiveamountsofmachiningrequired.whichwe •erenotinapositiontodo.HavingmadethedecisiontofitthislegIdidn'tknowwhatIwasletting myselfinfor,lotiLtookme19monthsofhardWork tocompletetheinstallation,andattheendofitallI hadaccumulatedthemostassortedselection or short drillsandreamerswithturneddownshankstoenable themtobefittedintospecialtools.withoutwhichit wouldhavebeenimpossibletocompletethetask.

Thirdly,wecarriedoutsomerathersophisticated toolingfordrillingofthemainsparouterwingpickup pointswhichwillbethesubjectofaparagraphlater inthisseries or articles.

Tobeginwiththemainsparisalaminatedaffair madeup or fiyestrips8'••1 or L73lOswgand backedbyanextrudedsectionIt"9ofL65dural. thetopanobottomsparboomsarethenjoinedtogetherwithasparweb7'deepmadeof18swg1.72.The worstpartofbuildingupthespariscleaningoutall theguillotinemarksfromthelOswgstrips,brought aboutduringtheinitialcutting—thisisalong. laboriousjoboffilingwhichwealltookahandin,an operationImightadd.Iwouldnotliketorepeat today.Iamsureitmusthavebeensheerenthusiasm

.5pretraig Viscosity

Dest. B..c.('oplf4 ctRel. ReducerorThinner CalourCotoft.si

EtchYellow Primer SI.. 4853

Parkinson

or thosefar-offdaysthatcarriedusthroughtothe completionofthisparticulartaskasthereisabout 200ft,ofthisstripthatrequirescleaningupalongthe edges.Oncetheabovetaskhadbeencompletedthe wholethingwasclampedtogethercompletewiththe webpla1eandtheboltholespilotdrilled,thiswasheld togetherwithslavemetalthreadscrews,nutsandfibre washers.Theseareverycheaptobuyatanylocal ironmongers.Wefittedthesescrewsinroughlyevery otherholeandthenopenedupthewholelottothe correctsizesubstitutingtheoneswiththemetalthread screwsfittedforthecorrectboltsasrequired.

NMI:Ausefullittlebookletonmetalstructures especiallyforbeginners,isPopularFlying PracticalNotesNo.2.-Preparationand Assembly or RivetedStructures-

Afterthedrillingandreamingoftheholeshadbeen completedthesparwasdismantled,atthesametime carewastakentokeepeverythinginitscorrectorder sothatreassemblywouldnotheaproblem.Allthe holeswerede-burredusingasuitablygrotmdj-1"drill, whichinturnisfittedintoalifehandle.

ThistoolisinvaluableformetalaircraftconstructionandLshouldthinkforanyhomebuilder needingtode-burrhole,onmetalcomponents.It mustheemphasisedthatonamulti-laminatedspar suchasthis,cleanliness,deburringofholes,and removalofswarfmusthcconscientiouslycarriedout inordertoacliIcveitgoodboltedjoint.

BeforegoinganyfurtherwiththisarticleIthinka wordortwoabouttreatments of metalsbeforefinal assemblywouldnotgoamiss.IdeallyduralcomponentsshouldheAnodisedbeforeprimerpaint treatmentsareapplied,thisgives;Igoodbondforthe differingtypesofpaintprimersusedintheindustrx today.butforobviousreasonsthissortoftreatment cannotbepursuedbythehomehuildertherefore,we havetoturntoapainttreatmentknownas'Self EtchingPrimer'asourmeansofcorrosiveprotection, thistogetherwithacoatingofthepreviouslytalked about'CILLOSEEL'atthefacestobejoinedtogetherwillprovideadequateprotectionfromthe elementsasrequiredbythehomebuilder.including theoperationofaircraftinasaltairenvironment. EtchingPrimerisonceagainsuppliedbyPinchin& JohnsonPaints.TransportDivision,P.O.Box359, BoltonParkStreet,Birmingham16.Thisprimerisa two-partmixconsistingofaprimerbase.SL4853,and asprayreducer.T.S.L.4854.theseshouldbemixed thoroughlyinequalvolumesabout30minuteshefore application.

A A.I).

Pol-Life interval(wince ofmixed overcoming nuarrials 65-70F Spec or 65-70F Prepaimion(18 -21 0RemarkS Approval

8hrs.Degreasing1hourMaybeDTD onlystowedfor827,899, 5io10mins911,5555A at250FBSX77 (121C)28,29,30 and31

Thinner TDXL ifneccessary

Mixed1:120-22 byvolumeseconds with SprayingAddupto Reducer10"„by TSL4854volume

Aquantityofthinnermaybeaddedtogiveagood sprayingviscosity,thetypetobeusedisknownas ThinnerTDXL.Itcanbeappliedbyconventional sprayingequipment.andrapidlyairdries,italsogives excellentadhesionandprotectiontoawiderangeof metalssuchasaluminiumanditsalloys,ferrous metals,zincandgalvanisedsurfaces,brass,copper, tinplate,cadmiumandmagnesium.Becarefulwhen mixingyourprimeronlytomixamountsasrequired, asthe'PotLife'aftermixingis8hoursat70-T. (21C.).Beforeapplyingthisprimerallthatisre-

quiredisathoroughdegreasingofthesurfacestobe treated.

Whenapplieditwillprovideaprotectivefilmwhich actuallykeysintothemetalsurfaceandatthesame timeprovidingaprotectivefilmcapableofpreventing corrosion.Thisalsoprovidesanexcellentfoundation forsubsequentfinishingcoats.

Tocontinue,thesparlaminateswerethencoated liberallywith'CELLOSEEL'jointingcompoundand assembledwith,inourcase,'HI-SHEARpins.These areaclosetolerancesteelpinwhichdemandareamed

SKINS P(ALP BEIWEEN at0CK3 Or 3" Ar•ioTOLREbOVER

LaV ILLJkLLDL,MEL:Y

AIREyfriv(1.4311-5±D e' 71fr-

7AOLEoP k/f/he A30RIP OlTD1/18EkANDC-/TTAD1PS,AND [Rs N214)(Sc SOAP/I3133APIC7)

BYtiEPkE55iomisErmiRi‘i

pi-Ro-1-”Y -isck

b.3.3i'L

FIG2

4.33 LOAFFo

3"33"6.30c.K.5 ofATI&E.1-1,515rco Vo niS FLATTOA1Fouil2FLE rrin445 Arta7,y/so,

FIG. HI-SHEARPIN AA, D COLLAR..

3AoovY o CANA): Re,-, /N3 [33/

ANTL-AANAAAEO

P/3/.333.6327-E33,30h3333- (sunk'3NA/coovTA/ 11/oFEARsErA,b DILL:A-INSAARAPPLIED

IDIVEIFINgDvARTS-DoLLAK

3_33.LE3501..3,5;maY. 3%NKr., AD CLAILFI'EL

7-HE SgibO335rEt3 bud-/TOF-OrLf-1 E Lxy SKIMSHAPE

holeTheyorelockedwithanaluminiumcollarwhich isset to itspermanentlockedshapebyaspecialsetting tool(Fig.I)Agoodpointinfavouroftheuseofthis typeofattachmentisthattheyarere-usable,thelockingcollarbeingeasilycutawaybytheuseofismall shay chiselintheabsenceofthespecialtoolneeded forremoval.

Intheabsenceoftheabovepins,boltscanhesubstitutedattheexpenseofasmallweightincrease,but alltheserequirepeeningtolockTheuseofboltsand plainnutspeenedtolockasspecifiedalloverthis aircraftis.Ipersonallyconsider,averypoorwayof goingaboutthelockingofbolts.Inthisso-called advancedtechnologicaleraof1975.tothinkthatwe takeahammerandchisel,orcentrepunch,orbluntendedtoolandproceedtodeformtheendofthebolt threadsasameansoflockingis.Ithink,archaic,to saytheleast.Thenutandboltisrendereduselessafter thistreatmenttogetherwithresultantdamagetothe holecausedbyburredthreadspassingthroughwhen theneedforreinovaloftheboltoccurs.

Icannotseewhystiffnutsusedinnumbersof3and upwardsfortheattachmentolcomponentscannot constituteaclassonelock.Inmilitaryaircraftdesign areasthereisnowadefiniterethinktakingplace regardinglockingofcomponents,andtheremovalof wirelockingandsplitpinningfromcertaincomponent partsandfittingswhereverpossibleisnowtheorderof theday,andnotbeforetimeasIseeit.Eachcomponentshouldbetreatedonitsindivudualmerits frontthesafetycriticalpointofviewinsteadof applyingthistotalblanketofclassonelockingright acrosstheboardfoieverythingfittedtotheaircraft asinthecaseof"SPRITE.

Therearesomanynewandexcellenttypesof fastenersonthemarketwhichareextremely'reliable andhaveverygoodreusahlecharacteristics,far superiortoearliertypesbothingrippingqualitiesand fromthesizeandweightpointofviewalso.Itherefore thinkconsiderationshouldhegiventotheirmore liberaluseasameansofattachingandlockingcomponents,butthcargumentssurroundingthissubject areinanyandthisarticleisreallyabouthuilding 'SPRITE'andhowthingsarcdoneonthataircraft Tocontinue,afterassemblyofthesparwascomplete,alltheribs%sereattachedforwardandaftofthe spar.andthcrivetholesintheribandsparflanges pitchedundpilot Pilotdrillingallowsfor any'minormovementtakingplaceaftertheskinsare subsequentlyremovedandmadereadyforfinal rivetting.Thisgivesyouthechanceolpickingupthe holesagainafterrefittingtheskinstotheribstructure astheyrequireopeninguptoI"beforerivetling,and believeme,withoutexpensivejiggingthingsdoshit( aboutabit.

PreformingtheLiEdgeskinswasajobthat perhapsdeservesawordortwo,forthetaskwasquite asimpleoneandthereispossiblysomefall-outfrom theexercisethatotherhomebuilderscouldmakeuse ofOriginallyI.thoughtweweregoingtoruninto difficultiesandmaybewewouldhavetorecruitsome outsideassistanceinordertoproducethem,butthis wasnotthecase.Firstly.agoodwoodenflatworking topisrequired.inourcaseanoldchestofdrawers.To makethetaskeasierweformedtheskinsin4'lengths tomakethemeasiertohandle,inordertoachievethe correctskinsizewemeasuredfromtheskinoverlap ofthespartopflange,totheskinoverlapofthebottom

SpriteIllidyr

lilttoright'Royfasker

BarryParktoson.PeterBaklantandFronkNaylor, PopularFlying,March-April,1976

flange,andthenwecuttheskinsaccordingly.The wholelotwasproducedatonego.oncewehad acquiredtheknowhow.Stripsofmetalabout14"wide werecutastestpiecesuntilwehadacquiredthe necessaryshape.Whenthesehadbeenformedthey weretriedontotheleadingedgeribstoseeifwehad compressedthemenoughtogiveusthecorrectshape needed.SeeFig.2.

Thetopandbottomaftwingskinspresentno problemstofit,thesepulldownandintoplacequite easilyByworkingtheskinsintoposition,starting atthesparandworkingalltowardsthetrailingedge, securewithskinclipstemporarilyateveryotherhole Adoptingthismethodshouldnotpresentanyproblems astheynaturallytakeuptheshapeofthewingribsas theyaredrilledon-.

Toconcludeparttwoofthesearticlestheinstallation ofthe'CESSNA'springsteelgearwas,anduptothe presenttimehasbeen,themostdifficultpieceof

engineeringontheaircraft.Thedifficultieswerecause mainlybyalackofspacetowork.Ididnotrealiseat thetimetheproblemssurroundingthefittingofthis typeofleg,involvingusinthemanufactureand fittingofaFalsesparandadditionalribs,togetherwith stiffenedexistingstructure.Insomeplacestheextra ribsareasclosetogetherasoneinch.Thisiswhere thetroubleoccurred.asa90anglewindydrillwas anabsolutemusttodrillholesinsuchconfinedspaces, inadditiontowhichthewholelotwaspracticallya completeboltedandreamedassembly,Infairnessto thedesignersoftheaircraft,Imustpointoutthatall theseproblemswerebroughtaboutbyourown making,asitwasourchoicetolitthistypeofLanding Gearandnotthedesigners.Sufficetosay,thatweare pleasedwiththeendresultandtheaestheticsofthe installationwethinkaregood,butcarryingoutthe operationwasanabsoluteB

BookReview

TheProfessions—CivilAviation:FlightCrews. A.S.Jackson.

ThisbookiswrittenbyaBritishAirwaysVCI0 Captainandcoversingreatdetailthecompleteworkinglifeandenvironmentoftheairlinepilot.

Thebookopenswithanaccountofareturnflight acrosstheAtlantic.Themanyfacetsoftheairline pilotstaskinflyingamodernairlinerinconjunction withhisothercrewmembersarcdiscussed.Animportantchapterisdevotedtotheinitialqualifications, selectionandsubsequenttrainingofpilotsatthecivil airtrainingschools.Theauthorthentellshowthenew pilotconvertstotypeintheairlineandthenpasses throughsuccessivestagesofcontinuationtraining.

Alltheotheraspectsofoperatingamodernairline areconsideredindetailDifferencesbetweentypes, methodsofnavigation,radioaids,instruments. operatingtechniques,safetyaspects.crewfatigue.and aviationlawareincluded.

Someoftheinformation.particularlyintheappendicesisslightlydatedandthebookverysurprisingly hasnophotographs.Apitythis.

Thebookisadelinitemustforanyyoungman interestedinflyingasacareer.laisalsorecommended aseasyreadingforanyoneinterestedinthisfascinatingsubject.

PopularFlying.March-April,1976

"BRITISHHONIE13LilurAIRCRAFTSINCE1920"

RecentlypublishedbytheMerseysideSocietyof AviationEnthusiasts,thisYolumeis of greatinterestto PFAmembers.IncludedintheonebookletarecompletedetailsofallhomebffiltaircraftofBritishand ForeignoriginstoappearintheUnitedKingdom sincejustaftertheFirstWorldWarTheworkisthe resultofmanyyearsofpainstakingresearchintothe subjectbyPEAmemberKenEllis.whoincidentally, generouslyacknowledgesmuchhelpgiveninits preparationbyfellowmembers.

RatherthanduplicatinginformationalreadypublishedinthePFA'sownbooklet-theConstructors' List-wefeelthatthisvolumeinmanywaysis complementary.Aswellasanalphabeticalsurvey typebytypeaallhomebuiltssince1920.othersectionsdealwithhomebuiltgliders.balloons,andeven man-poweredcraft.Oneofthemostinterestingparls ofthewholebookisthedetailedsectiondescribing thehistoryofthePou-du-Cielor"FlyingFlea.'ofthe 1930's.Therearenearly120photosofalltypesof homebuiltfromtheU.K.andabroad,andanumberof appendices.

Allinallthisisanexcellent.well-producedbook. providingmuchfascinatingreadingand,mostimportant.good alueatonlyEl.40.incl.postageand packing.ItcanheobtainedfromMerseysideAviation Society.4WillowGreen.LiverpoolL25JRR.

POPULARFLYINGispublishedin Januaryandthereafterinalternate months.Alladvertisementstobesent to:AdvertisementManager,Popular FlyingAssociation,TerminalBuilding, ShorehamAirport,Shoreham-by-Sea. Sussex.

Semi-displaypercolumninch£300. Lineage(minimumthreelines)perline 44p.Discounts:seriesofthree5"o. Seriesofsix10%.Agencies102,.

FREE!

MembersarenowentitledtoFourFree Adverts.peryear,subjecttobeingofnon-businessnature andtospacebeingavailable. QuoteMembershipNo.

FolLI.50wewillincludeaphoto ofAeroplanesforSale.

ThePEAdoesnotnecessarily guaranteeorendorseanyproduct offeredthroughouradvertising.

Members'atteniionisparticularly drawntobuiltandpartly-builtAircraft.Theyshouldsatisfythemselves thatthemachinehasbeenclearedto P.E.A.standardsiftheysubsequently intendtooperateitthroughthe PILA.Airworthinessfacilities

WOODENAIRCRAFT PROPELLERS

Availabletosuitawiderange includingVW.Continental.Lycoming andDeHavillandengines u/so

Gyrocopter,Airboatand AirCushionVehiclePropellers

Availableinavarietyof LeadingEdgeSheathingsand finishes

Comae,:

HAWKERDEHAVILLAND AUSTRALIAPTY. um. P.O.Box30Bankstown.2200

Telephone:Mr.IanHart--770111

PFAAPPROVED PROPELLERS

VW1200 £77-00

VW1400 £78-00

VW1500 £84-00

VW15003Bladed £145-00

VW1609 £89410

VW16003Bladed £148-00

ContinentalC90 £132-00

ContinentalA65. £105-00

MikronItI. £105-00

9'DiameterAluminiumSpinners BackPlates&FrontPlates

VWCylinderHeadMachiningService £18-50including10minPlugsand LongSockei

R.WATL1NG-GREENWOOD Ridgewood.Uckfield.Sussex Tel,:Uckfield3242

FABULOUSFRED

STOLperformanceonVWorLawranceengines.De-rigsand rigsaseasilyasaglider.Roadable.Plansincluderoadfittings. Easytofly.Cheaptobuild.Longestsinglecomponent12'9' long.Plansconsistof25highlydetailedsheets.

PerSet—E15.00

Informationsheet,3viewdrawing.photograph— 75p. ERICCLUTTON,92NEWLANDSSTREET,SHELTON, STOKE-ON-TRENT,STAFFORDSHIRE,ENGLAND

MERSFYSIDEAVIAIIONSOCIEI1' Lio_ 'BRITISHHOMEBUILT AIRCRAFTSINCE1920'

Thisisthclatestandmostcompre hensiveguidetotheseaircrafiever published.Inover100pagesarefull detailsonhomebuildsfromFlying FleastoMicros,HeathParasolsto DykeDeltas,manpoweredtoekctricpowered.Fullyindexedand cross-referenced.Over100illustrationsAMUSTforanyonewith aninterestinBritishLightAviation. AtCI.40,postageincluded.itis availablefrom:

MerseysideAviationSociety

Co4WillowGreen.Liverpool

1.254RR

SILVERWINGSBADGE

TheCommitteearepleasedto informyouthatanalternativequali ticationhasbeenintroducedfor applicantsforthePFaCsSilver Wings.Badge,

A person who hasbuilthirhero•n aeroplaneandhasflownthataenk planesately/Or 50 boorsemitina mannerwhichI.,acredittothe Associationshallheconsideredft». mown/pfiheSilver If lugs.

STOCKLIST

FrenchAircraft

JODEL

Ailerons..t10-00ca.

Tailplane.1.25

RudderCables.ElevatorCables, EngineMount,Canopy,LUCLegs.

EMERAULD

EngineMountIC90)..:130.00

SIPAWings €150•00

TailplaneandElevators£50.00

MINICAB

Cowlings.suitPiperCub£40.00

EnglishAircraft

TIGERMOTHFuelTanks

SPITFIRE

TailWheelswithTyres1,20.00

AUSTER

R.P.M.Drives.. £9•00

RudderCableMod.KitsL10-00

BrakeCables.. £400

OilTemp.Gauge £9•00

TailWeights.. £5•00

TailSprings

13.00

BendixMag.ISF4LN-8£30.00

LucasMag. 1:30.00

MESSENGER

MainLECIcomplete.MetalProp, Mess.2CirrusMajor3),Engine Mount._01500thelot

TURBULENT

Tailplane.Rudder.SternpoiL.Elevators,Ailerons.OuterWings.

Props:

Drg.No.DEI5178(2forDEI(t0Li orDIA60N1

Drg,No.D15258TY3.slightdarn.

General

CurryWotPlans€20•00(ono)

CiipsyMajorHandbooks€5.00 35yds.DTD575Fabric05-00

SmallamountofS51412swg.

CornpressorUnitplus

RENEGADE VWpoweredlands50mph,tops150. Plans&workinstructionsLI6.Also FormulaOnemodelforRollsRoyce ILI6.BrochureonbothLI.

SouthernAeronauticalCorp.. 14100LakeCandlewood, MiamiLakes,Fla.33014,USA

TankplusGun tibn

KLGRE41I4mmPlugs:50

ManyAusterandChipmunk SparesandInstruments

Pricesdonotintimate(hyoid,. Wherenomice.makeemafter.

BILLOVERY FOIKESTONE76976

TYPE LowWingAcrobaticMonoplane

CONIERE:CIIONWoodandFabric

PERFORMANCEStall(withflap)50m.p.11Cruise-155m.p_11.

SPAN-18'9"Length-16'II"

REMARKS:SIRhrbleforracingintheformulaoneclass.Notan aeroplaneforthenovice.Pilotstressedto9G.

Brochure45p lop P/ons £16-sr35p P&P.

TAYLORMONOPLANE

TYPE LowWingMonoplane

CONFRUCTIONAllWoodandFabrie

ENGINEVWContinentalA40

PERFORMANCEStall30(withflaps)Cruise80kts

SPAN-21'Length15'

REMARKS:Specificallydesignedforbuildinginthcminimumof space.

Brocluoo 35pE10p. Plansfrom £12+35p P&P.

Froln Mns.J.TAYLOR,25ChesterfieldCrescent. Leigh-on-Sea,Essex.

FORSALE.1Engine-drivenGenerator-Rotax29V17.5AMP,overhauled. Magneto—BendixScintillaSF4LN8M, overhauled.1DirectionalIndicator,6A/ 1298—servicable.IDirectionalIndicator 6AI666—overhauled.1P12Compass5— goodorder.1P12CompassS—good order,lessmirror1EngineSpeedIndicator,Smiths82RV—overhauled.Very reasonablypricedtoPFAmembers.R.R. Lockwood,TheBungalow,HighStreet, Thorndon,Eye.Suffolk1P347LX.Tel. Occold378.

TOURINGBritainortheContinentthis year?ThenhirealuxuryBroadstone MotorCaravanandenjoythesatisfaction ourpersonalservicewillbringyou.For detailswriteto:NickCranfield,BroadstoneMotorCaravans,BroadstoneFarm, ForestRow,Sussex,England.

FORSALE.JodelDI17AirframeSpares. Allfuselagefittingsavailable,fuelsystem, controlcables,ailerons,elevators,rudder, tailwheel,canopy,undercarriageand wheels,rudderbar,stick,andmanymore items.Tel.016540898

WANTEDFORBETA.Componentsor completeitems,Wings,Ailerons,Aileron fittings,C90Engine,Mount,Cowlings, largeFuelTank,EngineControls,Propellorandex-BeaglePupBrakes.Details toT.MartinJones,38SouthAvenue. Chellaston,Derby.Tel033270112/7.

WANTED.TwoseatSpecialCategory aircraftsuitableforshortfieldoperation. Cub,Champ,DI17orMinicabwould suit.W.R.Prescott,Drumhoe,Warrenpoint,Co.Down,NT.Tel.Warrenport 2204.

FORSALE.AusterAutocratG-AHAU. New2-yearG.P.C.ofA.Sept.1975. Goodfabric.D.1.andCirrusMinor2 enginehas550hrs.torunanduses412gals perhour.£1600.H.Butt.Tel.Benington 668.

VOLKSWAGEN

AIRCRAFTENGINEPLANS forAmateurConstructors

30sq.ft.ofdrawingsanda15,000-wordmanual providedesignsandinformationenablingonetoconvert anyV.W.engineupto1600ccs.Fullyapprovedfor amateur-builtaircraft,theseplansareofferedwithlifetimefreeadviceforonly£9.50postpaid.

DonaldG.Peacock, MeadowCottage,Ardle:ghHeath,Colchester,C077QB Tel.Colchester230446

WANTED.BendixNav'Com.typeCNS 220orsimilar.Wouldacceptinrepairable condition.R.Harper.111.Lymm2796.

SYWELL1976.Thefollowingcharges havebeenagreedforcampersatthisyear's Rally:Caravans70ppernight.Tents70p pernight(for2persons,Speachpernight foradditionalpersons).Reservationsto Mr.M.E.Robinson,6WhitefieldRoad. Dunston,Northampton.Tel.0604-55094. StatingName,CarNo.,CaravanorTent No.ofPersons,DateofArrival,and whethermilkisrequiredandforwhich days.

WANTEDURGENTLY.5,10andI5cwt. WireStrainersorTurnbuckles,any quantity,urgentlyrequiredforSopwith replica.D.M.Caslimore.Tel.Blidworth 2622.

WANTED.WorkshoporGaragetorent intheGlasgowAnportareaforcompletionofSiroccoproject.TerryDuhig, 14StrathdonAvenue,Paisley.Tel_041889-9629.

FORSALE.E.A.A.Biplane.Fuselage complete,WingRibs,TimberforSpats, GRPNoseCowl.£150ono.AlsoVP-2 Plans,unused,£15ono.R.Webster,454 HinckleyRoad,Leicester.Tel.858038.

WANTED.RadiosuitableforNipperaircraft.AnyNo.ofchannelsconsidered.C. Wilkinson,13RainbowWay,Colne Engaine,Colchester.Tel.EarlsColne 2931.

WANTED.GoodJodelDI12/117series. DetailsandpricetoC.A.Parker,10 TarrantWay,Moulton,Northampton. Tel.44287.

FORSALE.360-channelSKY505Transreceiverjustoverhauledandcompletewith harnessforJodelD117plustestharness andmanual.£170ono.DM.Caslimore. Tel.Blidworth2622.

NewPFALapelBadge inblueenamel, *60p±Spp.&p.* FromthePFAOffice

FROMTHEP.F.A.OFFICE...

JUSTINSTOCKFROMTHEU.S.A.

"TheLightPlaneSince1909" byUnderwoodandCollinge

Fullyillustrated £3.00±30pp.&p.

"AerobaticsInTheSky" byJ.Underwood

Fullyillustrated. £2.50±30Pp.&P.

"TheVintage&VeteranAircraft Guide"byJ.Underwood

Fullyillustrated. £2.50-F30pp.&p.

"ThePL4aExplodedViewManual" £645+3OPP.&P.

WANTED.Hasanyoneapartsheetof L73,10swg.whichtheyarepreparedto sell?Noamounttoosmall.H.Beckingham,7GraftonAvenue,Hurstwood Estate,Felpham,SussexTel.Middleton onSea3840.

TIPSYNIPPER.Forinformation,spares. plans,etc.,pleasecontactNipperKits& ComponentsLtd.,IRidgewayDrive. Bromley,Kent,BR15DG.Tel.01-8577821.

Tel.—Dunstable62068

OPENMONDAYTOSATURDAY-9A.M.TO6P.M.

StocksofmostmaterialsfrytheHomeBuilder

Fabric,343,575,Linen7F1/5CandDacron

Dope(ClearandColour),PinchinJohnson, TitanineandRhodius

Spruce,PolishPineandAsh

ControlCablesmadeuptoorder

Adhesives,AeroliteandAerodux

Fibreglass,ResinandMicroballoons

SteelTube,SheetandRod

GL1AircraftPlyfrom0.8mm.to3.0mm.thick

Widerangeofinstrumentsinstock

C.A.A.welding.Machiningandre-sprays

Sends.a.e.forpricelist

Doncaster Sailplane Services for

HOMEBUILDERSSUPPLIES

G.L.I aircraftbirchply0.8mmto5mm. Fabric-2weightsforsupported and unsupported areas.

Dope—tauteningandcolouretc.

Jointingcompound—for wood/metal.

Spruce,DouglasFir,WhitcPine,Ash,gradeA.

A.S.I.V.S.1.compassesetc.etc.

S.514andS.510steelsheetandT45tubes. Controlcablemadeuptoorder.

V.P.I. Cavaliermaterials.

Cavalierplansandallrawmaterialtobuild. Fibreglassandresin,releaseagent,pigmentetc.

Sends.a.e.forpricelist