78 SuperD Restoration in RI

[VIPirate]

Started restoration Oct 28 2022. Just about stripped fuselage down to bare frame today.

 

[Big Ed]

Moving fast!

 

[VIPirate]

Ok second installment of 100 photos …

 

[VIPirate]

If you look at the full-size image in that second installment, look at the nosecone sitting on the table. When I went off the bathroom, my IA pulled out the battery. I came back and the airplane was sitting tail-high on its nosecone. Well, let’s not dwell on that too much! We also cracked both the greenhouse glass and windscreen glass taking them out. Oh well.

 

[Big Ed]

If you look at the full-size image in that second installment, look at the nosecone sitting on the table. When I went off the bathroom, my IA pulled out the battery. I came back and the airplane was sitting tail-high on its nosecone. Well, let’s not dwell on that too much! We also cracked both the greenhouse glass and windscreen glass taking them out. Oh well.

Don't feel too bad. I cracked my greenhouse glaas literally by picking it up.

Great pics!

 

[VIPirate]

Ok a little more background on this aircraft N5024R. I bought it out of Denver, CO in May, 2021 from Barnstormers. It had 1720 original hours on the engine airframe, and was owned by a retired UAL check airmain / instructor. He was in his 90’s and lost his medical due to dementia. Prior to completing the sale, I trained in a Dcat at a few places including Patty Wagstaffs, I brought it back solo to RI, a 12 hr trip. I flew it for a year and a half, and 160 hrs later it is time for an airframe overhaul.

Backing up a little more, I had a BE55 Baron that I flew for 20 years that was end of life that I sold to a maintenance school in Canada. I used the money from the Baron sale to purchase the Decathalon. Before I sold the Baron, I used that plane to get my MEI. Then I used the Decathalon to get my single-engine CFI.

Most of my flying so far has been solo light aerobatics, spins and tailwheel experience. Also did a couple of BFRs, putting my CFI to work. My goal with the restoration is to go through the entire aircraft, clean out all the dust, install some new Hooker harnesses and chutes. Then hit the acro hard. When I first bought the airplane, I opened the vents and this black dust flew all over the place. Then when I rolled it, I got showered with the black insulation dust, as well as various washers and spare parts. Going thru the airplane, I will of course clean all that out to get to a clean sterile acro machine.

Another thing I am going to do when I recover the plane is to change the tail number. Something with my initials.

 

[VIPirate]

PS engine is still running good, so I am going to hold off on the engine overhaul for another year or so

 

[VIPirate]

Planned airframe welding additions:
1) Baggage door
2) Truss in rear spar carry-thru for Y-harness
3) Second lug for lap belt anchors
4) Larger gear hoops to support future aluminum gear
5) Larger tab for mixture vernier

 

[Big Ed]

Planned airframe welding additions:
1) Baggage door
2) Truss in rear spar carry-thru for Y-harness
3) Second lug for lap belt anchors
4) Larger gear hoops to support future aluminum gear
5) Larger tab for mixture vernier

Looks like a pretty good list. That would be my top 5. You might consider the windshield brackets. It is a more sturdy design than the original trim strips. Also, there is a lug for the rear shoulder harness Y as well.

 

[Big Ed]

Yeah, that black dust is some foul stuff. The really aggravating thing is that the factory still uses the same product, and I can't find an appealing alternative to line the boot cowl.

 

[VIPirate]

Yeah, that black dust is some foul stuff. The really aggravating thing is that the factory still uses the same product, and I can't find an appealing alternative to line the boot cowl.

Shouldnt need insulation in FL?

 

[Big Ed]

Shouldnt need insulation in FL?

Agreed, but cosmetic covering of bare aluminum is somewhat desirable. Plus, my life plans may see me spending part of the future in the Colorado mountains.

 

[VIPirate]

Removed front and rear pedals today. So easy. Dont think I can post a video

 

[VIPirate]

Agreed, but cosmetic covering of bare aluminum is somewhat desirable. Plus, my life plans may see me spending part of the future in the Colorado mountains.

Ed what about this?

Fiberglass Insulation | Aircraft Spruce ®

Fiberglass Insulation Ultra-light FAA compliant Thermal/Acoustic Insulation by the foot.

www.aircraftspruce.com

 

[Big Ed]

Ed what about this?

Fiberglass Insulation | Aircraft Spruce ®

Fiberglass Insulation Ultra-light FAA compliant Thermal/Acoustic Insulation by the foot.

www.aircraftspruce.com

Looks interesting. Something like that with a cosmetic liner on one side might be a good option.

 

[Bartman]

Planned airframe welding additions:
1) Baggage door
2) Truss in rear spar carry-thru for Y-harness
3) Second lug for lap belt anchors
4) Larger gear hoops to support future aluminum gear
5) Larger tab for mixture vernier

How's the project coming along? There's a different mounting tab for the fuel shut off valve if you find you need to replace the one you had, fwiw.

Bart

 

[VIPirate]

How's the project coming along? There's a different mounting tab for the fuel shut off valve if you find you need to replace the one you had, fwiw.

Bart

Looking for a qualified vendor with an 18’ oven that can do soda blasting of frame and eventually powder coat per factory spec
Waiting for factory quote on welding mods to frame including baggage door, harness modifications, mixture vernier and gear lugs.
Going to replace wings with new factory wings with metal spar. My wings are trash (see my FB post). 10-month lead time on factory wings

 

[Bartman]

If you think the factory guys might do the mods, you can also have them powder coat your frame so it'll be ready to go when you get home. They'll media blast it, inspect it, get it ready for the jigs and then do all the welding before getting it coated and ready for pick-up. Doing mine that way worked out great and they filed the paperwork as well. I'm expecting to drop mine off for final assembly and new wings in a couple of months.

 

[Bartman]

and we'll expect to see you when we eventually have a northeast meetup!

 

[Bartman]

My wings are trash (see my FB post). 10-month lead time on factory wings

That would make you Bill. Nice to meet you Bill!