Single Seat Super Cub

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Pops

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Bolted the engine on today. Now I can just set on a stool and finish putting it together. I want to put the dual ignition single port heads on it and still haven't installed the new valve guides and valves. Need to get busy.
Good picture of how I move the oil dip stick to the rear for ease of use. I recalibrated the dip stick for when the tail is down by drilling a 1/16" dia hole in the dipstick at the quart marks and full. Normally when the airplane is in the hanger I have a stand to set under the tail wheel to keep the fuselage lever so I will not hit my head on the wing. So, I can check the oil with the fuselage level or with the tail on the ground.
The alternator is at the limit of belt adjustment and will just hit the inside of the top cowl. I need to get a 1" shorter belt so the alt will be lower.
 

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Pops

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My goal was to have the wings covered by May 1 of this year. I will be starting on one of the wings tomorrow. Have the small damage repaired. Broken wing tip bow in one wing and a damaged to the plywood leading edge on the other wing fixed.
Both wings inspected and ready to cover.
 

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Pops

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Have the first wing with one coat of Poly-Fiber Poly Brush on and the reinforcement tapes over the ribs ready to start the rib stitching. I layed out the position of the stitches and put weights on each end of the control cable to keep them taunt and marked their position with masking tape so no stitching cord will be close to the cables. One time I didn't do this and had to cut the rib stitching and redo 1/2 of the wing.
 

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Pops

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Been busy mowing 2 acres of grass between rains and not getting much rib stitching done, but I have one wing 1/2 done. Ran into a little problem, the 3/4" square compression strut out in the wing has a 1/8" plywood gusset exactly where I need a stitch. A wing with the geodetic strips are a bear to get your rib stitching somewhat close. I'm using the J-3 Cub spacing of 2.5" in the prop wash and 3.5" everywhere else. The stitch came out in the middle of the plywood gusset. Thought about drilling a hole in the plywood for the stitch, but no, not going the have the raw wood exposed and no way to seal it. So, I made two stitches on each side about 1.25" apart and have a space over the plywood of 3". Sort of like some of my welding, " doesn't look great, but strong as a gorilla".
 
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Pops

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Sometimes life gets in the way of getting things done. 7 days ago we had a very hard storm all night long, no one got any sleep. Started about dark and stopped about dawn. When it first started I saw a funnel cloud about 2 miles south and that is where it took out a major power line that put 75K people out of electric. So we were out of electric for 3 days of high temps. Rare to get any really hard storms on east side of the Ohio river.
Finished the rib stitching a couple days ago and now on with the painting.
 

Pops

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One wing painted . Now to install the fuel tank and bolt on the fuselage. The other wing is ready for the silver ( Poly-Spray). Each aileron is 7' long by 12" wide. Lots of aileron.
The top of the fuel tanks is the structure skin of the wing. (.050" ) Structure screws holding the fuel tanks , same as C-150-172 fuel tank structure screws.
Have the engine controls hooked up and all wiring finished.
 

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Pops

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About ready to bolt the wings on the fuselage. I sold SSSC in 2017 because I thought I didn't have room in the hanger for 2 airplanes along with everything else. Need to do some moving and storing some things over the office storage space and I think I can make space for 2 airplanes, a pickup truck, Dodge Caravan and a mud buggy and the workshop. Sold the camper and gave the MF-135 to my daughter for her farm, so that opened up some space. Yes, believe I can do this. :)
 

Pops

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Wings and struts bolted and installed the jury struts Saturday.
Installed and rigged the ailerons today. Need to drop the fuel tanks in the wings. They mount from the top and connect the fuel lines up in the top of the cabin. Also install the new windshield. Have the old windshield as a pattern. The new prop from Culver Props should be here in 3 weeks , same as before, 60"x 26". Hope to have most of the things finished at that time.
Been working on it 18 months .
 

Pops

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On that sample weighing, I just put the fuselage up level and weighed the weigh on the tail wheel. I know the weight of the prop and put a piece of steel the same weight attached to the prop hub. Put the old fiberglass nose bowl in position and the same for the cowl top and bottom. The old tailwheel weight was 18 lbs with the fuselage level. This time a little under 19 lbs. The only difference from before is the use of douglas fir instead of spruce for the fuselage longerons.
New prop is on they way, been making new aluminum faring for the tail and wing to fuselage. Still need to install the windshield and fuel tanks. The old windshield looks good, so might just re-install.
 

Pops

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Finished the alum tail farings today. I'll prime and paint all the farings when they are removed for the next conditional inspection. I just want to get it back in the air before winter gets to bad. Next is installing the wing fuel tanks in the wings. You can see the place where they go in the top of the wings. The top of the tanks are also the structure skin of the wing.
When installing the tanks for the first time I made a tool to install the fuel line lines for the outlets and site gauges to the inside of the cabin . I cut a deep well socket off and welded to a long 4130 tube from the scrap box. Drill a hole to turn with a screw driver on the other end. Works good.
 

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Pops

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The fuel lines had to be taken off before the fuel tank could be taken out of the wing. The rear outlet fitting in the fuel tank galled and pulled some threads out. I tapped the pipe threads deeper to cleaned the threads up. Now the shoulder on the fitting bottoms out before getting tight. So going to have to mill about 1/8" off the face of the boss. Lots of material to do that so no problem.
Just life in moving west.
 

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Pops

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Right fuel tank installed and finally finished building and installing the new Stainless Steel single port intake manifold.
Have a rear side glass install and 90% of the windshield.
Wish the new prop would show up.
 

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Pops

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Did a W&B today. Went from 485 lbs to 493 lbs. Not as bad as I thought. Used Douglas fir instead of Spruce for the fuselage longerons and cross pieces, added an oil filter and lines and a manifold pressure gauge. CG is within 1/10 th of an inch from where it was before.
I'll take that.
 

Pops

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Rebuilt the cylinder air scoops for the single post heads instead of the dual port heads. Past owner installed dual port heads because he said he wanted more power. Told him that he would get less power with a straight drive swinging a prop on the VW. He call and said that it was not climbing like before.

Received the prop a few days ago. ( Culver 60"x26") So now I need to install the prop and adjust the valves and the engine is ready to run again.
 

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Pops

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Finished all the paper work on the logs last night. Down to valve adjustment and routing the spark plug wires and one rear window to install. Made new tube sight fuel gauges. The old ones were getting smokey since installing in 2006.
 
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