Category Archives: Flight

P-leads and wires

The only finished project of the weekend is the installation of new P-leads to replace the original ones, which were well beyond ratty and were starting to fail (one of them had to be spliced recently).  P-leads are like ignition cables for a car, but in reverse in that the magnetos are designed to produce a spark unless the rotor is grounded to itself.  The P-lead is a wire running from the magneto rotor to the switch (where it is grounded when the switch is offed).  Since there’s huge voltage spikes in the magneto (the sparks…), there’s lots of noise in the P-lead, so it’s shielded wire (which was part of what was failing).  Anyway, the new cables look halfway decent…

IMG_0251I started running all the data wires for the EDM-900 (there’s a crapload of them).  It looks like everything is going to fit, although I’m still not entirely sure how I’m going to setup the fuel flow sensor.  I need to get some smaller hose clamps to secure the oil pressure and fuel pressure sensors and put some more holes in the firewall.

 

Hydraulics!

The hydraulic powerpak arrived from its overhaul today, all nice and shiny.  Installation went much more smoothly than removal, probably because I khow everything fit together.  I was able to pressure check the flaps and the gear down lines and everything checked out ok.  I need to put the plane up on jacks next weekend and hook up a mule (electric hydraulic pump) to swing the gear and work all the air out of the system.  Thus far, no leaks!  Once the gear is swung, I’ll be able to remove the straps securing the gear and move the airplane around, which will be helpful when it’s time to paint the flaps and ailerons.

IMG_0238

I finished drilling out the holes for the circuit breakers from the new support panel and made sure everything fit.  It all looks good, although I need to make up some new labels, as I decided to move the landing/taxi and navigation light fuses to the bottom row and move the transponder and autopilot from the bottom row to the middle row so everything on the avionics bus is in the middle row, making the bus bars a bit easier to run.  I’ll strip everything back apart this weekend and paint everything before putting it all back together again.  Sigh.

IMG_0239

 

Service Letter 66 Completion

Finally completed something on the annual tonight!  I reconnected the T connections for the main fuel tanks, which took a bit of convincing as adel clamps and I do not get along.   With that, the changes recommended in Service Letter 66 to raise the fuel drains level with the bottom of the fuselage is complete.  Woo!

OLYMPUS DIGITAL CAMERAI also stripped the circuit breaker panel so it’s ready to be painted and built a backing plate for the panel since some of the old breakers had a larger neck than the Klixon breakers I’m installing.  The reducing plates and the cover plate came yesterday, so I prepped those for paint and painted the reducing plate where the autopilot selector will sit.  I still have to find a gray paint that matches the engine instrument section of the panel.

 

Varnish and Circuit Breakers

Tonight I applied the second coat of varnish on the flaps and ailerons.  Assuming the replacement bolts for the attach brackets arrive tomorrow, I should be able to set up the fabric this weekend.  Some repairs were required, in particular some reinforcing around the leading edge where the control attaches on the ailerons and a new stringer on the left flap (the flaps have a bend, which is a stress point on the trailing edge material).

OLYMPUS DIGITAL CAMERAI also removed the circuit breaker panel tonight (the hard part was labeling all the cables before removing them).  The breakers are all getting replaced with modern Klixon breakers (which are pullable, yay!).  I was originally not going to replace the 35A battery breaker, but the old one shattered during removal, so I guess I’m replacing that as well.  Unfortunately, over the years the circuit breakers have been replaced, sometimes requiring larger holes, sometimes not drilled in a straight line.  So I have a bit of work to do figuring out how to support the new breakers and get them straight enough to attach to a bus bar.  Again, things to do this weekend…

OLYMPUS DIGITAL CAMERA

 

The worlds longest annual begins…

So what might end up being the world’s largest annual has begun. Thankfully, the IA (aircraft mechanic) who works on my airplane is great about letting me do a bunch of the labor. Thankfully, I enjoy working on the airplane, but I do tend to spend a lot of time in the hangar during annual inspection season. This year, I’m trying to catch up on a number of little things:

  • Recovering the flaps and ailerons. The flaps take a lot of abuse because they sit so close to the ground during landing. One of the ailerons was slightly twisted, likely because someone wasn’t careful during the fabric shrink last time they were recovered, so fixing that should help in getting the airplane close to rigged correctly.
  • Sending the hydraulic powerpack (the thing that makes the gear and flaps go up and down) out for overhaul. It was seeping a little bit of hydraulic fluid out of the flap pressure adjustment, so it was time to send it out. Unfortunately, getting it out from under the front seats is a bit of a pain since it just barely fit in the first place.
  • Installing the service kits for a couple of old service letters that raised the fuel drains flush with the bottom of the airplane so that they wouldn’t get ripped off in the event of a gear up landing.
  • Replacing all the engine gauges (which needed overhaul) with a JPI EDM-900, which will free up some much needed panel space and give me exhaust gas and cylinder head temps for all 6 cylinders. The EDM-900 also gives fuel flow and fuel totalizer, meaning that I’ll be able to be much more precise in fuel management.
  • With the engine gauges by the left seat pilot removed, there’s space for the autopilot out of the way so that radio bay where it lives now is available for, well, radios. At the same time, since I had to remove a bunch of wiring to get the EDM-900 installed (and the old stuff out), I’m going to wire the nav input for the autopilot to include a selector for both nav radios. When we installed the radios a couple years ago, we only wired the autopilot to the VAL nav unit because the other unit was a King KX-145, which wouldn’t drive the autopilot. It’s since been replaced with a Narco Mk-12D, which is both a better receiver than the VAL and can drive the autopilot. So more wiring fun…
  • Since I’ve got most of the wiring bundles ripped apart to clean up the EDM-900, I’m also taking this opportunity to replace the 53 year old circuit breakers with modern breakers. In addition to being calibrated properly, they’ll all be pullable so equipment can be disabled in flight. The main bus was a poor design, so that will get updated as well. Once it’s done, the main bus should be able to handle 60 amps (it was originally designed for 35 amps) when I replace the generator with an alternator in the future.
  • If we’re not horribly behind come April (when I hope to do the annual inspection), I’m also going to try to deal with the fact that the horizontal stabilizer and elevators aren’t quite rigged correctly.

Obviously, quite a list. I started a couple weeks ago with the removal of the flaps and ailerons. They’ve now been stripped of fabric, sanded, repaired (the trailing edge of one of the flaps had some corrosion), and now varnished. I still have a coat of varnish to apply, hopefully on Wednesday. This weekend will start the actual covering process. Hopefully I’ll be able to get the fabric glued down and the first shrink done so that I can start stitching the following weekend.

On the EDM front, the panel’s stripped as far as needed and I’ve started pulling the wires that are no longer needed. The alarm light is installed, just so that I could claim I’ve installed something :). I’ve generally figured out where I’m going to put all the sensors and wire bundles, but it’s going to take a little while to get everything in place. Currently, the panel looks a little rough:

Empty panel

2012 Flying in Review

A winter storm is (literally) blowing through central New Mexico tomorrow, so it looks like my flying is done for 2012. It’s been an interesting flying year, with 37.7 hours and 46 takeoffs and landings through the year. The year started with a fun trip to Crested Butte to visit Pete, which involved some nice winter flying in the Colorado Rockies. Flying a pattern in Gunnison involves a downwind right up against the mountains, which was really cool. After some pretty serious engine work, I took the Bellanca to South Bend in July, got weathered out of flying to OSH, had a blast at OSH, and spent 9.5 hours dodging thunderstorms, bumps, and headwinds in one day flying home. The fall saw me buying my partner out of the Bellanca, so it’s all mine now :).

The start of 2013 brings a lot of work on the Bellanca. I’ve wanted a full engine monitor for some time, but panel space is a major problem. So after trying a lot of mock-ups, I’m going to install an EDM-900 primary, which will replace a lot of the aging instruments in the plane. The flaps and ailerons were painted with Emron before the Stits STC changed and the paint on the flaps has taken some abuse over the years. Combined with a bent aileron and it’s time to recover the wing control surfaces. Finally, the hydraulic powerpack is off to overhaul. So it will be a busy spring with maintenance, but hopefully some good flying time later in the year. The EDM-900 should also help run the airplane much more efficiently than I can with the single EGT/CHT today.

106.8 hours in the Bellanca

After a long hiatus, I’ve decided it’s time to resurrect the blog.

A little under 3 years ago, I bought a Bellanca Cruisemaster 260 with a neighbor. The Cruisemaster 260 is the last of the Cruisemaster line, also known as the Cardboard Connie due to its triple-tail configuration. The Wikipedia Page has more information about the Cruisemaster line (although not much). The short description: fast, fun, good capacity, plenty of power.

We decided to take the plane to Airventure this year, and I flew the plane out to South Bend for the month of July to deal with some midwest travel for work and see the ‘rents. We ended up not flying to Oshkosh due to weather, but it was still fun to fly out to the midwest and stretch the plane’s legs a bit. The flight home was a bit of a disaster, taking 9.5 hours of flying over 14 hours of daylight, most of it in bumps of nasty headwinds. But it ended with me crossing the 100 hour mark in the Bellanca. I almost know what I’m doing in the plane these days!

Rusty Blindness

After the 6 weeks in Bloomington and Canada, I needed to do a currency flight at the Aero Club. I went up with Mike on Wednesday after work. On the way home, I did some hood time and tried to shoot an ILS approach. Unfortunately, they were using 26 & 30, so the tower said no to the approach. But I did spend 30 minutes or so under the hood. I was a bit rusty, but not nearly as bad I was afraid I would be. Really need to find a safety pilot and get my currency up again. Oh, and I won a free hour of flight time from the club at the safety meeting. Woo!

200.7 hours in the air

Since I’m going to be in B’ton for the month of august, I got checked out in BMG’s Cessna 172SPs this morning. Did the usual slow flight, stalls, steep turns and all to get used to the plane. Then did the landings, which were a bit rough but workable. The plane wanted to float a lot more than either the T-41 or the XL2 does, so that took some getting used to. The flight also crosses the 200 hour total time mark for me — woo. Now to find some clouds while I’m out here to get the instrument ticket wet.

Flying Updates

Ok, I’ve been lame again. Perhaps busy is a better description.

June 1st, I got my instrument rating in Alamosa, CO. The flight was long and painful (it was 90+ degrees and the Liberty XL2 is not good with two people and high density altitude). We started with the ILS 2 approach from the DME arc, which would cover both the precision approach and the DME arc requirements. Flew the arc perfectly, despite some monster up and down drafts. Turned onto final approach, went to verify the approach signal and got silence. The ILS was out, which would be a problem, as a precision approach is a requirement for the checkride. We switched to a partial panel GPS 2 approach to cover the partial panel requirement, and I nailed that approach, went missed, and setup for the VOR-A approach, to cover the circling approach requirement. While we were climbing up to 10,000′ to start the approach, Jim (my examiner) called the airport manager on unicom and he agreed to go try to reset the ILS (it’s old and if it gets wet, apparently it sometimes trips a breaker). While on the outbound portion of the procedure turn, we caught a strong downdraft that had me at Vx (best angle of climb speed) and still losing altitude. I got out of that, made the turn, got caught in an updraft, was nose down, power back, and climbing. I didn’t really want to give that altitude away, so delayed my descent until I was sure I wouldn’t catch the previously mentioned downdraft. I crossed the VOR at about 9800′, despite a minimum crossing altitude of 9300′. I then made a stable, 800 fpm descent, hit minimum descent altitude before the missed approach point, and made a perfect pattern to land. We went missed and headed to the east to do some unusual attitude recoveries, during which we got news the ILS was back up and running. The examiner also expressed concern that the crossing of the VOR high was a failure situation, but agreed to continue the exam to completion. I then flew a very solid ILS approach to decision height and made a descent landing.

The FAA has some interesting rules on exams. The examiner has two options if the examinee does something that results in a failure — he can either continue the exam or end it right there. At the examiner’s discretion, he is only required to retest the part the examinee failed (and not everything else). Also, the retest can occur immediately (it used to be 30 days), as long as the instructor provides instruction in the areas of deficiency. We got on the ground, and had a fairly intense discussion about the situation. My position was that the altitude is a minimum, and as long as I made a stable descent, I was ok. His position was that it’s an assigned altitude to guarantee you make a stable descent. I was at 9800′ at 3:36 from the MAP and MDA is 8020. So I had to lose 1780′ in about 3.5 minutes (approach was flown at 90 knots), which is just a bit under 510 fpm. Recommended stable descent altitude is 800 fpm. Now, if I was a jet, I’d need to be much closer to 9300′ at the VOR, but I also wouldn’t be fighting the turbulence quite so much because I’d be in a properly powered Jet instead of an underpowered XL2.

Long and short, I had two choices. Appeal the examiner’s opinion to the FAA or agree to take the fail and retest. The examiner said he’d retest immediately, so I took that approach. The 45 minute discussion about whether I passed or failed was proof to both the examiner and my instructor that I understood the issues and both were equally unsure about the rules, so we all felt that the remedial training had occured. Anyway, I knew I could nail the approach, so I just took the retest option. Flew a single, picture perfect VOR-A approach to a landing. I was now an instrument pilot.

Yesterday I finally dealt with the fact that I had let my T-41C currency at the aero club expire. Flew down towards Belen, did a practice emergency landing down to 100′ or so at Mid-Valley (can’t actually land there due to aero club rules), did 2 landings at Belen, then went back to the Sunport. Uneventful, beautiful flight. It was good to fly after almost 6 weeks on the ground. When the instructor was filling out my logbook, he asked about the fail. I explained, he looked at the chart, and said “that’s a minimum, not an assigned altitude. You were fine as long as you made a stable approach.” Another instructor hanging around the office said the same thing. So I feel better that I was right after all.

As of yesterday, I have 197.4 hours total time, an instrument rating, and T-41C currency. I’m thinking about getting checked out in either the C-182 or C-182RG (retractable gear), as they’re a bit more roomy for taking people up (but also a bit more expensive). The RG would require a complex endorsement, which would take 5 hours or so of time.