7AC rebuild and covering

[Big Ed]

Odyssey 680 is intriguing. How much weight do you save over a Concorde 25R? Any reduction in cranking power?

 

[Bartman]

I finally got my 2 STC's from Bill Pancake. The first allows for fabric rivets to be used in place of the stock pk screws and washers. The second is for installing the C85-12 into the Champ airframe. It also allows installation of the Odyssey 680 battery either under the front seat, the front of the firewall or (as I've done) behind the rear seat. Big or small tail your choice. Short or long engine mount your choice. Cessna 150, Hanlon Wilson or stock exhaust your choice. And last but not least, gross weight increase to 1320 lbs.!
My M12 rivet puller arrived this afternoon so tomorrow it's pop rivets and taping the wings...
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Chris

Very nice to see you moving along with it Chris. You'll be flying it in no time.

 

[aftCG]

I finally got my 2 STC's from Bill Pancake. The first allows for fabric rivets to be used in place of the stock pk screws and washers. The second is for installing the C85-12 into the Champ airframe. It also allows installation of the Odyssey 680 battery either under the front seat, the front of the firewall or (as I've done) behind the rear seat. Big or small tail your choice. Short or long engine mount your choice. Cessna 150, Hanlon Wilson or stock exhaust your choice. And last but not least, gross weight increase to 1320 lbs.!
My M12 rivet puller arrived this afternoon so tomorrow it's pop rivets and taping the wings...
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Chris

So far I have pulled hundreds of stainless steel rivets on my Kitfox using a Milwaukee M12 rivet gun. Sometimes it is 120 in a single build session. It works fantastic. I can only imagine my forearms and wrists if I had to do that with a manual pop rivet tool. And yes I've used air operated rivet guns. The M12 holds its own and might even be slightly less bulky.

 

[Hiperbiper]

Odyssey 680 is intriguing. How much weight do you save over a Concorde 25R? Any reduction in cranking power?

Odyssey 680 weighs a little over 8 lbs lighter than a Concorde 25.
It spins my 200 hp lycoming better than the Concorde 25 xc it replaced. Better still is the fact that the Odyssey maintains it's charge MUCH longer than the Concorde and much much longer than a Gill ...
I like 'em.
Chris

 

[Hiperbiper]

So far I have pulled hundreds of stainless steel rivets on my Kitfox using a Milwaukee M12 rivet gun. Sometimes it is 120 in a single build session. It works fantastic. I can only imagine my forearms and wrists if I had to do that with a manual pop rivet tool. And yes I've used air operated rivet guns. The M12 holds its own and might even be slightly less bulky.

I LOVE my M12 rivet puller...
My pneumatic puller works great on metal birds but due to the fact it puffs out oily exhaust onto the fabric with every trigger pull I decided (based on the glowing reviews here) to get the M12.
I had the right wing ready to start attaching the fabric this afternoon. Placed all the rivets on the bottom side...20 minutes later it was ready for taping...
It would have taken hours to do the washer/pk screw attachment and then you have the problem of them coming loose from the rib.

An Aeronca porcupine.

20 minutes later.

Rivets taped...

Chris

 

[Hiperbiper]

A quick update. All the covering is on, still have the tailfeathers and ailerons to tape and polybrush.
The fuse is in the booth getting all the openings sealed up (hopefully) and is first in line for Polybrush spray coats, Polyspray spray coats and then a coat of white Polytone as a base for the red Aerothane.
Between all that spraying I'll be priming the landing gear parts, the struts and all the little stuff that needs to be ready for paint...gas caps, window trim, inspection covers and of course, all those damn screws that hold everything together!
I'm still on the fence concerning the Maltese crosses...
I could mask and paint them or take the easy way out and or have my friend at the sign shop make them out of vinyl and put 'em on...the cost would be about the same.
All parts skinned

20 miles of masking tape

My friends bought me a big Snoopy (the Baron's back seater?)


Chris

 

[Bob Turner]

Up to batteries above - we have 85 hp Cubs with B&C starters. Using the smaller Odyssey PC 545 we get up to 75 starts between charges (no electrical system).

I am considering the EarthX ETX-680C. We are using two, for radios, and folks who use them with alternator systems are giving positive feedback. We pull them out to charge. I will soon try them on the B&C starters.

When it says lithium, I worry - but they now have a PMA version. Talk about lightweight - just a plastic shell with a lot of imaginary power inside! Be careful when you pick one up - your arm will hit the ceiling.

 

[Big Ed]

Going from a lead-acid behind the baggage compartment to a lithium on the firewall would be a substantial improvement in a Decathlon. More useful load, moves the CG forward, and simplifies the electrical system. Not to mention crawling over the rear seat to access the battery is a huge PITA.

 

[Bartman]

Going from a lead-acid behind the baggage compartment to a lithium on the firewall would be a substantial improvement in a Decathlon. More useful load, moves the CG forward, and simplifies the electrical system. Not to mention crawling over the rear seat to access the battery is a huge PITA.

no can do, i already asked. inverted oil stuff is in the way.

 

[Hiperbiper]

Polybrush sprayed


Polyspray sprayed

A wee bit of sanding and I'll shoot the last coat of silver...
With luck I'll get the white Polytone basecoat done this week and be ready to shoot the Red and White Aerothane next week...

Chris

 

[Hiperbiper]

Today I added to my list of things not to do again...like don't run with scissors, don't piss off a redhead, etc.

Don't eat at Juan & Pancho's before entering the paint booth...

scratch one Tevek suit...

Chris

 

[Hiperbiper]

Got the last coat of Polyspray silver on and checked for any problem areas.

Waited a few days to let the solvents wick off and sprayed the White Polytone basecoat.


Monday I'll hopefully get it taped up and get the White Aerothane shot. Then re-tape and shoot the whole thing Aerothane Christian Eagle Red....
This IS the fun part!
Chris

 

[Bob Turner]

I assume it is better to use Aerothane white as a base coat? I would have done the white with Poly Tone.

 

[Big Ed]

Wow, you are moving along nicely!

So, is Aerothane a catalyzed urethane over a Stitts base?

 

[Hiperbiper]

I assume it is better to use Aerothane white as a base coat? I would have done the white with Poly Tone.

That's what I did Bob; white Polytone over the silver Polyspray to make the red aerothane pop...I'm also putting white areothane over the white Polytone so my red and white topcoats have the same sheen.

Wow, you are moving along nicely!

So, is Aerothane a catalyzed urethane over a Stitts base?

Yes. The Aerothane (same as Ranthane of yesteryear) is the two part catalyzed urethane used in the Stits/Polyfiber process...it's harder to shoot than the polytone paint but it's damn near bulletproof once it drys...
Chris

 

[Hiperbiper]

Today I got the landing gear axles and oleo tubes bead blasted and primed with white epoxy. I have the white Aerothane shot on the fuselage and I'm shooting the Red Monday and decided to get the gear ready for red paint too...
After the paint is dry I can bolt up the main gear permanently (Oleos are already rebuilt) and put the tailwheel on and roll her around without the dolly. WooHoo
Chris

 

[Bartman]

Looks great Chris!

 

[Hiperbiper]

Thanks Bart, the stupid axles took some time to get right. While cleaning them up I found the new top end bushings (that attach to the center yoke) fit too loosely. I had to weld the holes up and re-bore them.
I can't understand how that could happen in only 70+ years of use...
All good now!
Chris

 

[Hiperbiper]

Welp;
The paint on the fuselage and landing gear is done and the plane is back on the landing gear permanently! I've decided to use black vinyl for the Maltese Crosses so I'll probably wait until the wings are done and do 'em all at one time (unless I just can't wait).
It'll be flying Dawn Patrol in no time...


Chris

 

[Hiperbiper]

Next up:
Polybrush and Polyspray for the flippers and such.
While waiting for everything to dry I'm also lining up all the small stuff to prime and paint...

I don't remember there being so many small pieces when I took this stupid thing apart...




Chris