July - August 2014

publication agreement number 40050880 July - August 2014 Recreational Aircraft Association Canada www.raa.ca The Voice of Canadian Amateur Aircraft Builders $6.95 From The President’s Desk features Gary Wolf RAA 7379 Prop Man When you can't find the one you want, make it / by Mike Shave and Gary Wolf ......................................4 Foo Foo and Me ANOTHER WINNIPEG CHAPTER in Canada by Toronto Aerosport at been sold but the sewing operations Memories in a C-152 / by Barry Meek ....................................................................................................8 PLANE Baldwin Ontario. They have pro- are available to someone who would Jill Oakes of Winnipeg has really vided supporting documentation to like to continue manufacturing their Getting It Straight started something. She donated a Transport Canada for inclusion in the aircraft covers and interiors. Tips on wheel alignment / by Wayne Hadath ........................................................................................10 Cessna 150 to be used by RAA mem- Advanced UL category. Gross weight bers for flight instruction and $20/ is 499 kg with Jabiru or Aerovee 80 SAM aircraft, a Quebec manufacturer D-Motor Comes To Canada hr rentals, sparking a large increase hp, and 521 kg with Jabiru 120 hp. of light sport and AULA aircraft has A new flat-head engine for builders / by Dave Hertner ..........................................................................14 in chapter and national membership. completed their development pro- Now they have had a donation of a Bushcaddy was bought by Tony gram and is offering the company to Winnipeg to Oshkosh Piper PA-28 from Bill Vandenberg and Wilkins several years ago and shortly someone who would like to continue The Lyncrest chapter flies to the Big One / by Jill Oakes .........................................................................19 Ken and Jerry Pennington. Members relocated to Cornwall Ontario. with marketing their aircraft. may use this 4 seat aircraft for $40/ Tony has lately sold Bushcaddy to a First Class Seating hr dry. To become a member contact Chinese company and now has a con- HKS 700E engines are again in Ivan Kristensen builds an immaculate RV-10 ........................................................................................22 [email protected]. tract to set up manufacturing in that production, now distributed world- These are both certified aircraft, country. wide by two companies, Green as required for flight examinations. Sky Adventures in Florida and First step is to get people licensed, The rights to the Beaver and Quicksilver Aircraft Northeast in and then they can look at building Chinook ultralights have been sold New York. Both companies will carry an airplane with help and encourage- to Aeroplane Manufactory in Texas. parts and handle service for these ment of the RAA Winnipeg members. As yet they do not appear to be in engines. This will be a relief to owners columns Congratulations to Jill and members production, but they have some parts of aircraft powered by these light and for what they are accomplishing in available from the inventory that efficient 4 stroke engines. From the President's Desk / by Gary Wolf ......................................................................................2 Winnipeg! came from ASAP in Vernon BC. At Classified ....................................................................................................................................38 this writing they are not listed as sup- GROSS WEIGHT Across Canada: Chapters in Action ..............................................................................................40 INDUSTRY CHANGES porting the aircraft for the Advanced In the Amateur Built category there Lately we reported that Dave Hertner UL category, so it appears that there is no upper limit to gross weight of London has taken over the opera- is no one to supply the required except that specified by the designer tions of Fisher Flying Products. He Advanced UL documentation. or manufacturer. Owners may apply has also now become the Canadian for an increase if they supply accept- distributor for D-Motor engines, and Turbulence Aviation, longtime able data to show that the completed an article is in this issue. Quebec manufacturer of accessories aircraft will still be safe to fly. for Challenger ultralights, is selling At the other end of the spectrum, Sonex aircraft are now represented its operations. The ski business has continued on page 30 The Recreational Aircraft George Gregory at [email protected] of the magazine is to promote education Association Canada and safety through its members to the Waterloo Airport, Breslau ON The Recreational Flyer is published general public. Opinions expressed in N0B 1M0 bi-monthly by the Recreational Aircraft articles and letters do not necessarily Telephone: 519-648-3030 Association Publishing Company, reflect those of the Recreational Aircraft Member's Toll Free line: 1-800-387-1028 Waterloo Airport, Breslau, ON N0B Association Canada. Accuracy of Emails can be sent to President Gary 1M0. The Recreational Flyer is devoted the material presented is solely the Wolf at: [email protected] and to the aerospace sciences. The intention responsibility of the author or contributor. George Gregory A cabin Waco, Arlington 2014. On the cover: Ivan Kristensen's gorgeous RV-10. the X-axis, and a carriage rides on that is adjustable for height, with a these ways. The carriage provides skateboard wheel bearing mounted in Prop Man the transverse Y-axis, and the vertical a slot at the bottom. The 3/4”diameter Prop too heavy? Make your own Z-axis is accomplished with swing of the bearing is marginally larger by Gary Wolf and Mike Shave arm pivoting from the Y axis. The than that of the router bit. swing arm holds a follower to trace On the table are two machined the pattern, and in parallel a router aluminum plates drilled in the pattern with a round cutter. of the prop hub to locate the pattern To keep everything in line there and the prop blank. The conven- must be a firm foundation, and for tion is to have two opposite holes this Mike made a miniature wing positioned along the longitudinal building table from dimensional centerline. Placement of the locating lumber in a grid pattern, with ply- plates requires accuracy, especially wood glued and screwed top and the lateral positioning. They must bottom. This produced a machine be directly under the centres of the base with good beam stiffness and cutter and the stylus respectively, great torsional rigidity. Mike’s table otherwise the prop blade will not is approximately 2 ft. by 5 ft., wide be laterally centered on the hub. On enough to accommodate both the Mike’s machine the lateral spacing is pattern and the prop blank, and some- an accurate 7 inches. what longer than half the length of the Laminating and drilling will be longest prop anticipated. dealt with in a separate article but Mike made his set of ways from once it has been done the blank is 2 lengths of heavy wall 1-1/4” steel drilled for a centre hole and posi- tube. The key to accuracy is to have tioned on the table, parallel to the them mounted parallel in all axes. prop being traced. For the roughing Mike has a bench top mill-drill so he cuts Mike begins with the stylus posi- was able to bore and face lengths of tioned lower than the cutter to leave square tubing accurately to become ~1/4” of extra material on the blank. MIKE SHAVE IS A RETIRED high school important there is no material better the weight of its propeller and most end supports for the tubes. Builders It would be possible to use the router industrial arts teacher who frequently than wood, and many of the “carbon of the commercially manufactured without this equipment could make to rough the entire blank but Mike brought his students into contact with fibre” props are really a wood prop ground adjustable props are just them from milled hardwood or MDF has a shortcut. He does roughing cuts aviation, to show them the technolo- with a carbon fibre exterior. Even the too heavy to be safe. A conventional and shim if necessary to get all to the chordwise every inch and then uses a gies used in this discipline. Aviation, certified prop on a diamond DA40 is wood prop is the only economical same height. chisel to pop off the excess material. especially amateur aviation, is unique made this way, which Mike discov- way to stay within the limits of the The carriages are assembled from The extra ¼” of material and the close in that it always very concerned with ered when one ran off the end of the crankshaft, but if the builder is also aluminum square tube extrusions pitch of the cuts ensure that the mate- maximum strength with minimum runway and Mike later found one of in a quest for modifications that will bolted together. The rollers are off the rial being chiseled off will never get weight, and this must be accompanied the blades in the cornfield. The carbon produce more power this is going shelf 6-series bearings set at 30 degree below the finished dimension. Next by a high degree of accuracy with an fibre provides a hard exterior to resist to mean buying a lot of fixed pitch angles to the ways. The blocks are alu- Mike raises the stylus to the height of From top down: A pair of ways, a carriage, and a swing arm appropriate level of affordable tech- weathering, but the strength of the propellers. For Mike the choice was minum but could just as easily have the cutter and machines off all but the combine to make a prop duplicator; Each bearing is set at 30 nology. Materials must be employed blade is its wood core. For most of us simple – he would make his own pro- been wood or MDF, cut to the angle last 1/16” of the material, leaving a degrees off vertical to ride the 1-1/4" ways; and the stylus' in a way that exploits their benefits a wood prop without the carbon will peller duplicator, and prop changes on a mitre saw.

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