'68 Citabria 7ECA Milman Spar Conversion

[Clifford Daly]

@Bartman i used the original brass fittings that were in the tank. Brass fittings do not go bad... I don’t see why you would have to replace them. If it didn’t leak before I’d be weary to change anything. But in the end he has to sign it off!

 

[MA Cantin]

I’m the other project going on. I have the 67 citabria thread! But yes I took a time lapse of the entire process of changing the spars from taking the fabric off to putting the fabric on. I have quick videos on the airplanes Instagram (oldtimeaviation) but can post the longer ones here to show more.

What group? I’d be interested in joining

Just search aeronca interest group on FaceBook. You should find it there. I’ll look on my daughter’s Instagram. I don’t have it. Thanks!

 

[Bartman]

There was a strip of aluminum angle under the upper contour of the leading edge aluminum, probably to stiffen up the surface of the leading edge aluminum. Someone thought it was a good idea to attach it with duct tape way back when so the well aged residue had to be removed today. I used MEK and kept two additional rags soaking on the ribs while working on the third. It went pretty quickly and everything is set now to attach the new Milman leading edges.

The aluminum of the Milman leading edges is not quite as soft as the factory material so the stiffener strip doesn't have to be reinstalled the new panels.

 

[MA Cantin]

They came out looking like new! Good job!

 

[MA Cantin]

After inspecting the root fitting, we’ve noticed that the welds on it seem different from the other three fittings. Since our airframe has a high total time, we suspect that the fitting was repaired (re-welded) in the past. Spoke to Mike from Milman and he suggested to get a new fitting. We’ve got one on order from Aircraft Spruce. I’ll try to let you know how it goes with the new fitting once it’s in.

Ended up getting a new fitting from Univair and it fit like a glove!

 

[Bartman]

Ended up getting a new fitting from Univair and it fit like a glove!

Glad to see it worked out for you guys.

 

[Bartman]

latest update is that the left wing is almost done, the first leading edge section is in place and i'm planning to keep going so it will be done done in the next week or so.

A big change to my plans is that I have a local legend, Cub restorer Bob Hunt will be applying the fabric to my wings after which I'll seal and paint them. I'm running out of time if I want to be done before it gets cold again. Having to heat the garage so I can paint would be a huuuuuuuggggeee pain in the butt so Bob will do the fabric, I'll paint, and then the local shop will rig everything and then complete the annual. If everything goes according to plan I'll be flying again by the end of October.

Stay tuned!

 

[MA Cantin]

That’s great! You’re coming along well!

 

[Bartman]

Thanks! Dropped off the first wing at Bob's house today and he's already working on it. Now to finish the second wing so it'll be ready when the first one is ready for paint. And I asked the local shop to pencil me in for the third week in October so now we've got something of a goal to work towards! Woo hoo! lol

 

[MA Cantin]

Awsome! Wishing you succes with your goal!

What kind of set up do you have for painting?

 

[Bartman]

Had a small compressor and some old guns that I never used before the project. Figured it was time for an upgrade so bought a 60gal compressor and the paint gun that Stewart Systems recommends, Devilbiss Finish Line for water based paints, a new regulator/filter/dryer, and a new hose.

It's been a huge difference just in making my little blaster box more useful so looking forward to finally trying out the paint gun.

 

[Clifford Daly]

Had a small compressor and some old guns that I never used before the project. Figured it was time for an upgrade so bought a 60gal compressor and the paint gun that Stewart Systems recommends, Devilbiss Finish Line for water based paints, a new regulator/filter/dryer, and a new hose.

It's been a huge difference just in making my little blaster box more useful so looking forward to finally trying out the paint gun.

Just a thought from my experience. I used the poly fiber system and spraying the poly brush (sealer) and the poly spray (silver coat) let me practice with the gun and learn a nice technique to spray the color on the wings to wear it really matters keeping a wet line and whatnot. If you had the fabric work done up to the point of spraying whatever the Stewart’s system calls for I think you’ll love the practice especially because it’s pretty hard to mess it up

 

[Bartman]

The day is quickly approaching where I'll have to face my new equipment and figure it out! Our two car garage is too congested on one side and my current shop is on the other side so when the second wing is done (soon, hopefully), the bench will be broken down and I'll have room to get the gun figured out. I'm going to do the struts, ailerons, and spades first and some practice with something else first but I'll look into spraying the different layers before the top coat goes on, that's a good idea.

 

[MA Cantin]

that’s great advice! Thanks for sharing! The thing is for my Dad’s project, he is thinking of putting Oratex fabric on. So there’s only the metal parts that will need spraying. I probably wouldn’t have the chance to practice on sealer and silver coats. You guys are getting me thinking here! Lol! My Dad and I will have to debate on this step of the project.

I realy like this forum!

Have a good one!

 

[Bartman]

Well hellllllllloooooooooo there fellow Champ, Citabria, and Decathalists!

It's been a while since I've posted an update because I've been working too damn much and trying to make progress on my project! Good news though, in the last three weeks the second wing was finished and sent off for fabric, the garage was converted to a paint booth, and today I managed to get the first couple of layers of fill sprayed onto the right wing.

I'm using the Stewart Systems system and their first layer after attaching the fabric is called EkoFill, it's the UV protection and weave filler before primer and paint.

I've been taking photos so I'll try to fill in the blanks and also update the leading edges thread. There should also be a Stewart Systems thread for questions and stuff to be discussed. The fabric process seems so confusing but now that I'm pretty far along with it it makes a lot more sense.

Will update again during my trip this week, have to run to pick up more sandpaper and then get to bed early tonight.

 

[flyingdakota]

@Bartman Nice looking progress! Congrats! I know how it feels! I have been up to my armpits with crocodiles and alligators trying to get a customers J-3 done. We haven't had any movement on the 06S but will soon after I get the J-3 done. Excited to see the pictures of the MM spars! That will help us a lot! Stay steady and committed but don't get committed! lol!
Cheers!
Tim

 

[Clifford Daly]

Well hellllllllloooooooooo there fellow Champ, Citabria, and Decathalists!

It's been a while since I've posted an update because I've been working too damn much and trying to make progress on my project! Good news though, in the last three weeks the second wing was finished and sent off for fabric, the garage was converted to a paint booth, and today I managed to get the first couple of layers of fill sprayed onto the right wing.

I'm using the Stewart Systems system and their first layer after attaching the fabric is called EkoFill, it's the UV protection and weave filler before primer and paint.

I've been taking photos so I'll try to fill in the blanks and also update the leading edges thread. There should also be a Stewart Systems thread for questions and stuff to be discussed. The fabric process seems so confusing but now that I'm pretty far along with it it makes a lot more sense.

Will update again during my trip this week, have to run to pick up more sandpaper and then get to bed early tonight.

I like the idea of a Stewart’s system thread. If you started a section on that I will definitely add a poly fiber section to talk about my experience with that process. It would be an awesome resource to get some other systems as well..

 

[Bartman]

I like the idea of a Stewart’s system thread. If you started a section on that I will definitely add a poly fiber section to talk about my experience with that process. It would be an awesome resource to get some other systems as well..

Just did the Stewart thread. If you want to start the Poly Fiber thread just copy what I did and that ought to get the ball rolling.

 

[Bartman]

Pics that were just posted to the Stewart Systems sub forum about trim lines. First wing is done, will be trying to get the second one done ASAP.

 

[Bartman]

The saga continues! The finish is like a fine grit sandpaper while the fog coats are going on and the final coat is applied more heavily to get the smooth glossy finish.