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Tucano Replica: If You Can’T Own an Original, It’S the Next Best Thing

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Tucano Replica: If You Can’T Own an Original, It’S the Next Best Thing ® MAY 2016 www.kitplanes.com IN A CASSUTT L Valve Sealant Sticking a Right for The Counterbores In theShop: • Fix • • T O PIL O anger UT eview R R A Replica Tucano Tucano AR E AL AL C MI herwood adios in O S R C A UD AND CL L nexpensive and Effective nexpensive T Com BUILT IN BRITAIN BUILT Lo I ECO-N Best Thing The Next The ERROR CHAIN:ERROR OF CONTRO LOSS KITPLANES MAY 2016 Tucano Replica • Sherwood Ranger • Com Radio Guide • ECO Autopilot • Firewall Layout • Sealants • Error Chain—LOC • LED Taxi Lights • Oil Systems • Prop Blades BELVOIR PUBLICATIONS May 2016 | Volume 33, Number 5 Flight Review 6 FLYING LEGEND’S TUCANO REPLICA: If you can’t own an original, it’s the next best thing. By Luca “Luke” Perazzolli. Builder Spotlight 12 BUILT IN BRITAIN: The Light Aircraft Company’s Sherwood Ranger. By Geoff Jones. 18 ECO-NOMICAL AUTOPILOT: And now for an autopilot that’s completely different. By Paul Dye. 32 StAND-ALONE VHF RADIOS: Our market scan reveals plenty 44 of models with advanced feature sets and space-saving designs. By Larry Anglisano. 44 ErrOR ChAIN: Expectations—You don’t know what you don’t know. By Dave Holmgren. 50 ENGINE THEORY: Oil system design—Exploring the components that keep your engine alive. By Tom Wilson. 67 COMPLETIONS: Builders share their successes. 74 ASK thE DAR: Converting a Taylorcraft to E/A-B, rebuilding and modifying a Rans S-9. By Mel Asberry. Shop Talk 24 FIXING A StICKING VALVE: It may not be overly complicated, but it’s not for the faint at heart. By Mike Bullock. 38 FIREWALL LAYOUT: The chess game. By Paul Dye. 56 BEST PrACTICES: Choosing the right sealant. By Dave Prizio. 62 HOME ShOP MACHINIST: Counterbores. By Bob Hadley. 78 AERO ’LECtrICS: Call me a taxi (light). By Jim Weir. Shop Tip 55 RIGht-ANGLE DEBUrrING TOOL: By Larry Larson. Designer’s Notebook 75 WIND TUNNEL: A bit about blades. By Barnaby Wainfan. 6 Exploring 2 EDITOR’S LOG: On with the shows! By Paul Dye. 64 ChECKPOINTS: Back courses and billy goats. By Vic Syracuse. Kit Bits 4 LEttERS 69 LIST OF ADVErtISERS 70 BUILDERS’ MARKETPLACE 80 KIT StUFF: Drawing on experience. By cartoonist Robrucha. 12 On the cover: From Italy, Flying Legend’s retractable-gear Tucano replica soars through clear blue skies. Photographed by Edwin Borremans. For subscription information, contact KITPLANES® at 800/622-1065 or visit www.kitplanes.com/cs. KITPLANES May 2016 1 EDITOR’S LOG On with the shows! Spring is here (or will be when you aviation with those who may very well reaching children with clueless parents read this) and with it comes the “flying become our future. who indulge their kid’s wishes to make season”—at least for those in the north- The big shows, like Sun ’n Fun or footprints on the wings of the nearest ern climes whose hangar doors have AirVenture, are a great place for people airplane, hang on props, or kick away at been frozen shut for several months. Of to mingle with airplanes. This is, admit- wheelpants to see if they are solid. course, those who live in places where tedly, both good and bad. First, the Public events are a double-edge sword the seasons never change have been good: We have all seen the fascinated for aviation—a great way to bring in the burning everyone else’s share of avgas stare in a young child’s eyes as they new, yet possibly dangerous to people all winter long. But statistically, spring look at the gleaming airplane and see already involved. The important thing is is when pilots start shaking off the rust the handsome pilot who has recently that we have control over how we react and getting out more—and that means stared death in the face while dogfight- to, and interact with, that public. I have going to fly-ins and the big shows to ing with the clouds. Seriously, though, met many a homebuilder who says, “I will mingle with others of their kind, as well many of them just have that fascination never go to a public fly-in event again. as the general public. Sometimes the with airplanes that makes them want to The last time, I had to yell at those little destination isn’t a formal event, just a reach out and touch them. And equally kids who wanted to touch my airplane bunch of different airplanes converging seriously, this is a golden moment to and get them back behind the ropes or on a favorite lunch spot or fly-in break- grow our community—by giving them a the fence!” OK, I understand that need fast. But either way, it is not uncommon chance to have a friendly and fascinating to protect the airplane. But let’s put our- for those on the other side of the airport interaction with something that could selves into the mind of that kid. We have fence to be interested in our planes, and take over their lives and set them on a been taken by our parents to see some- this gives us an opportunity to share path to the sky. However, there is a bad: thing that they tell us will be really neat. Big shows, like Sun ’n Fun or AirVenture, are a great place for people to mingle with airplanes. Paul Dye retired as a Lead Flight Director for NASA’s Human Space Flight program, with 40 years of aerospace experience on everything from Cubs to the space shuttle. An avid homebuilder, he began flying and working on airplanes as a teen, and has experience with a wide range of construction techniques and materials. He flies an RV-8 that he built in 2005, and an RV-3 that he built with his pilot wife. Currently, they are building a Xenos Paul Dye motorglider. A commercially licensed pilot, Paul has logged over 4800 hours in many different types of aircraft and is an EAA tech counselor, flight advisor, and member of the Homebuilder’s Council. He consults and collaborates in aerospace operations and flight-testing projects across the country. 2 KITPLANES May 2016 www.kitplanes.com & www.facebook.com/kitplanes We see bright, shiny, inviting things, and those interested, and if they have fur- we reach out to touch them—only to be ther questions or interest, they can get yelled at and threatened by a complete in touch with you. stranger—an adult stranger who makes (Oh—the key to good behavior by us feel really bad. The young mind asso- children is in their parents’ hands. Most ciates punishment, abuse, and embar- kids are wide-eyed sponges, willing and rassment with aviation, and we have lost waiting to learn. They don’t know how to that person to our community forever. behave, so they follow their elders’ lead. Certainly, our airplanes need to be If you see a kid behaving badly, don’t just protected, and if you find yourself at a yell at them; interact with the parents, and crowded field with a reaching public, get them to keep the kids under control. you have two choices: Stay with your It’s often the parents who have encour- plane and interact with the crowds in a aged the bad behavior in the first place, way that answers their questions, gives so reprimand the responsible party.) them safe access, and has them leaving Let’s encourage new starts—not make with a positive experience. Or get in the aviation unfriendly and unwelcoming. airplane and leave so that you don’t have We don’t want to be the last generation to interact. Either works to protect your that knows the joy and excitement of airplane, and frankly, leaving might be personal aviation. We have a responsi- better for our community than interact- bility to the future to turn the sparkle in ing in a negative way. Some of us just a child’s eye into a set of wings and the aren’t people persons—and that’s OK, rapture of flight. so long as we recognize it. But let’s face it—every indication is that the pilot pop- Respect Each Other ulation is shrinking, there are few new Oh yes—while we’re on the topic of starts, and we are aging rapidly out of airshows and fly-ins, here’s something the cockpit. We need to grow this com- to remember about helping out your munity, not shrink it by turning people fellow aviators. When someone lands away. Yes, part of the allure of aviation is and taxies in at a fly-in event, it is not its exclusivity, but we will go extinct if we uncommon for them to have a crowd don’t let new blood into the game. gather outside the airplane even before We need to be encouraging, wel- they shut down. I can’t tell you how coming, and nurturing when it comes many times I have taxied to a tie-down to those interested in joining this and then had the greeter try and talk to remarkable community of aviation. me through the closed canopy while I Homebuilders play a big part in being am still trying to shut down the avion- ambassadors for the breed. Let’s face ics and record the flight time on my it—we have cool airplanes, and we love kneeboard or airplane log. Usually, they to show off our work! The key is to show are saying, “Welcome to the show!” But them off not just to community mem- that welcome is lost in the distraction.
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