bearhawkproject.com Matt Kunkel's Bearhawk Build Log

Began Fabricating Floor Inspection Covers

I started on the fabrication of inspection covers for the floor area around the control sticks and flap handle.  There are many cutouts to size and fit, so I'm only about half done with the covers now.  It's pretty challenging to get something that will slip into place without removing the flap handle or sticks and still seal up tight to the tubing and fittings in the area.  I've already ruined one cover and had to start over.

Made Templates for floor Inspection Panels

I used poster-board to create templates for some inspection covers that go under the flap handle and over the shock struts.

Deburred Custom Floor Panels

I used a scotchbrite grinder wheel and fine emery cloth to debur the edges of all custom floorboards.

More Floor Trimming

Trimmed Custom Floor Panels

I used files, snips, and a belt sander to trim the custom panels I made.  Small amounts of trimming were needed to get proper clearance and fit.

Rough Cut Panel under Rudder Pedals

I began to rough cut the cutouts for a panel under the rudder pedals.  The factory panel end aft of the pedals and I'm making one to go under and forward of that area.  There are many small cutouts to get located correctly with the aid of a pattern and then trim to fit.

Rough Cut new Floor Panels

I began making new floor panels for the area around the control sticks.  The avipro panel that comes with the kit is a single panel for the area, with a generious area cutout for an inspection panel around the flap handle.  I wanted to be able to remove the whole floor board for annual inspection.  The single piece panel couldn't be removed without pulling the control sticks also so I decided to split the panel.  I sheared some panels at my neighbor's shop and today I begin to rough cut the cutout areas with a scroll saw and band saw.

Floorboards/ Rudder guards

I went to a friends sheet metal shop to shear and bend up some floor panels and rudder guards.  I used flashing to make a brake shoe and that worked out quite well.

Disassembled Shock Struts, Installed Fairleads

I disassembled my shock struts so that I can make a slight modification to them to plug them off (so the rod end isn't the thing capping them).  Also, I used a rotoray tool to grind off some of the weld flash on the fairlead brackets.