1968 Citabria 7ECA Rescue/Rebuild Thread

[Norm]

A gentleman called me up not long ago and knowing I was in the market for a Citabria he offered me his "project". A project was the very last thing I wanted but as soon as I saw the old dusty 7ECA I got Citabria drunk and handed over my money. I have decided instead of starting a new thread every time I have a question, I would simply start an official rebuild thread as others have done before. I often find these type of threads very helpful while researching my build.
The airplane is a 1968 Champion Citabria 7ECA with approx 2000 hrs total time, the engine (a Lycoming O-235-C2C) has 1000 hrs SMOH. According to the logbooks her last fabric recover was in 1997. At that time she received two new metal spar factory wings from American Champion. As far as I can tell all SB's and AD's were up to date as of the time it was removed from service due to an incident. The airplane has sat untouched for the past 5 or so years until most recently June 2021 when I took over ownership. I simply do not have the budget to immediately sink the large quantities of cash straight into this project, so progress going forth will be slow but steady.
The first few photos are from how I found the airplane dissembled in a back shed for some years.

 

[Norm]

I purchased a trailer and moved the plane to a local hangar. I strongly recommend not using a tarp when transporting an airplane in such a manner. Once safely in the hangar I was able to remove the engine and crate. I then built some wing cradles and picked them up a few weeks later.

 

[Bob Turner]

Steel gear legs. Good plan. Low time, with new metal spar wings. Double good plan. Yeah, the tarp will beat it senseless, and possibly do thousands of dollars worth of structural damage.

Do check carefully all the ADs and bulletins on metal spar wings, and replace the lift strut fittings as soon as you can. The rest is bulletproof. Hopefully heel brakes?

 

[Norm]

Continuing with the disassembly... All parts have been labeled and I've taken hundreds of photos to aid in the the rebuild. Fabric has been cut off in sections to be used as template for inspection panels and drains. I had considered not removing the fabric from the fuselage as I did not expect the repairs to require it, however I certainly am glad I did after finding half the pulleys with missing cotter pins, some minor corrosion on the lower tubes and a few rather shady repairs occurring somewhere along the planes 53 year history.

 

[Norm]

Removing the rear windows was a pain, heavy use of silicon is a recurring theme on this airplane. The rear right passenger window cracked straight down the middle while I was trying to delicately scrap off the sealant to free it from the fuselage. When you are on a budget, destroying a $300 window is a heart felt affair. I identified some rather minor damage from the incident which left this airplane grounded some years ago and after a few emails and a lot of patience from Chad at ACA my first parts order was made (greenhouse frame, various odds and ends etc.) The bulkheads are pretty manky looking and I think I will replace them with Rainbow Aviations kit. Why they weren't replaced on the last rebuild stumps me for what they cost. The stringers were replaced for all but one as far as I can tell, the one original has a crack and I'll need to source a new one. How to get a stringer shipped to Northern Canada safely and economically is a future me problem.

 

[Norm]

Onto rebuilding and overhauling... starting with the seats. I removed the moldy Airtex interior and shampooed all the fabric, then left to air dry for a few days. The seat frames were a disgrace with multiple layers of old paints. They were stripped, primed and repainted black. Far from an Oshkosh champion standard but much better than before. Note the airplane has seats with a provisions for seat pack parachutes.

 

[Norm]

Next the rivets holding the windshield retainer were drilled out. Hands down grinding, centre punching and drilling solid core pop rivets is a PITA! The boot cowl and components were then stripped and sanded lightly with 320 grit. I made a few small patches that will be riveted just above the gear legs on the boot cowl as the screw mounting locations were an elongated mess from years of abuse. The patches will need to be trimmed as I've noticed the fuselage frame tubing will interfere if they are left at current length.

 

[Norm]

I then dissembled the firewall, stripping off a mess of old spilled primer and then polishing it for 6 hrs with Mothers Metal polish. It's approx 50% better than what it was but I'm still not happy with the shine. I may go at it again another day. I removed superficial corrosion from all solenoids and fuel strainer bowl by brushing them gently with a scotch bright pad.

 

[Norm]

The propeller took a hit, so I packaged it up and it has been sent to a reputable overhaul facility for a good inspection and straighten.

 

[Norm]

Steel gear legs. Good plan. Low time, with new metal spar wings. Double good plan. Yeah, the tarp will beat it senseless, and possibly do thousands of dollars worth of structural damage.

Do check carefully all the ADs and bulletins on metal spar wings, and replace the lift strut fittings as soon as you can. The rest is bulletproof. Hopefully heel brakes?

Yes heel brakes with no intentions of changing them over to toe brakes.

 

[Norm]

I noticed the control sticks were out of alignment by a few degrees. Upon closer inspection I believe the forward mounting holes on the torque tube were drilled off center. The tube rolls true and smooth on a flat surface which leads me to believe it isn't twisted or warped. Has anyone else experienced this with an old Citabria? I am a little concerned it will drive me nuts having the front stick slightly off center in flight once completed.
The bushings were removed and everything went for a dip in the parts cleaner. Next the old primers were scuffed and a new coat of zinc chromate applied. The control sticks will be stripped soon and primed. Paint to follow, thinking simple Tremclad white.

*Note another thread mentioned there should be needle bearings on the torque tubes where they mount into the phenolic bearing blocks. I was curious about this as there were no bearings on my tubes and I could not make reference to them in the IPC. I determined the needle bearings seem to be specific to the 8KCAB and not the 7 series (these are just my observations and may or may not be accurate).

 

[Norm]

Debating on how to proceed with the panel, the original has been gutted and modified over the life history of the plane. I do not really care for the layouts current state (preferring the 6 pack to be centered). Owners and pilots out there with high panels how do you find them for visibility? I am looking at replacing it with a Wag Aero low panel but I'll loose one of my instruments due to space.

The fuselage has had every component removed and is ready to be stripped of primer and corrosion. I am thinking of zinc chromate priming it and then painting it with a two part epoxy paint white. I am looking for a nice glossy smooth finish as opposed to the the scaly rough mess it is now. I would guess it was not prepped well during its last rebuild (good from far in the pics, far from good in reality).

Worth noting I could not figure out how to remove the main fuel line running along the fuselage left side without cutting the flared ends and removing the fitting. Seemed like more work than it was worth so I left it and I'll just have to manage around it during the fuselage overhaul.

 

[Norm]

I noticed one of the stringer guides on the belly was damaged, probably would be fine but I'll be pricing up a replacement since it's all apart anyhow.

 

[Bob Turner]

I have a high panel in my Decathlon, and I love it. I am 6’, and can see over the panel. I still do S-turns out of habit, but they are not required. I think there is a photo in the gallery somewhere.

 

[Bartman]

Debating on how to proceed with the panel, the original has been gutted and modified over the life history of the plane. I do not really care for the layouts current state (preferring the 6 pack to be centered). Owners and pilots out there with high panels how do you find them for visibility? I am looking at replacing it with a Wag Aero low panel but I'll loose one of my instruments due to space.

The fuselage has had every component removed and is ready to be stripped of primer and corrosion. I am thinking of zinc chromate priming it and then painting it with a two part epoxy paint white. I am looking for a nice glossy smooth finish as opposed to the the scaly rough mess it is now. I would guess it was not prepped well during its last rebuild (good from far in the pics, far from good in reality).

Worth noting I could not figure out how to remove the main fuel line running along the fuselage left side without cutting the flared ends and removing the fitting. Seemed like more work than it was worth so I left it and I'll just have to manage around it during the fuselage overhaul.

Norm, the low panel is pretty low but there's a mid height panel that offers more room than the low panel without being awkwardly high like that high panel you've got.

Try Chad in the parts dept at ACA for info/pricing

 

[Big Ed]

I think I have the mid. I dunno. It's about right for me.

 

[Hiperbiper]

I noticed one of the stringer guides on the belly was damaged, probably would be fine but I'll be pricing up a replacement since it's all apart anyhow.

And this is how it always starts...

 

[Bob Turner]

Tough to find my photos - found them on page 3 or so of "new member intros". Something in there hints that we have a photo gallery somewhere.

Here is my obviously very high panel. Again, easy for me to see over, and I use it (VFR, with a check pilot) to maintain instrument currency.

 

[Norm]

Does anyone know the price of an ACA former set? I feel I've hounded their parts guy enough lately. Poor fella, just when I think I have it under control and my order finalized I find more things incorrect or broken on the plane.

 

[Big Ed]

Bah, that's job security for Chad!