Leaping Back Up from the Rocking Chair

Dear Friends Hello once again, Troopers. I was asked to write an occasional column in this newsletter, so standby while I knock the rust off of this keyboard.

Before we get too far into this project, I need to thank all of you for the wonderful support and encouragement shown to me when I received the Master Mechanic award. Working and flying airplanes all these years has been a dream, but without you, they are just aluminum, steel, plastic, and fabric.

Recently I have been thinking a lot about my career with it’s highs and lows. The lowest of lows are the friends I have lost. I would like to list them here because I miss them, and to introduce the subject of this column.

5 killed. Helicopter VMC into IMC Controlled flight into Terrain.

1 killed. Instructor in IMC (Blizzard)

1 killed. Lawyer. Controlled flight into terrain. IMC Lake Tahoe.

2 EAA members stall/spin on base to final turn.

Makes grim reading. It would be tragic to add to this list.

When military pilots are in combat training, they establish a “Hard Deck”, an altitude they will not go below while maneuvering. We as pilots should make our own Hard Deck limits, for instance: What minimum fuel do we feel safe with for the proposed flight? Am I comfortable with the route MEA for the weather conditions? Max crosswind components I will accept. What are my personal VMC visibility and ceiling limits? Think about all the limits you are comfortable with, and make a list for each airplane you fly. In the scheme of things, if you miss an appointment by a day, it won’t matter if you are safe on the ground.

One of the greatest freedoms we enjoy with Experimental aircraft is the ability to construct our machines of any materials or processes we want. Most kit suppliers provide the proper components for building safe aircraft. But what about designer/builders or plans builders? It has taken more than 100 yrs to develop materials and parts for Certificated aircraft, and even though expensive, it is my opinion that Aircraft Quality components should not be substituted for in Experimental airplanes. What am I referring to? Let’s talk.

Steel- Use only 4130 chrome/moly. Light and strong. Welds well with any process, even stick welding if person welding is experienced. Available in many shapes and sizes.

Aluminum Alloys-

2024t3- High strength, not good for welding, poor corrosion resistance when not clad with pure aluminum. Use for fuselage skins, bulkheads, ribs, etc.

6061t6- Medium strength, good corrosion resistance , good weld ability. Use where parts require a certain strength and corrosion resistance.

7075t6- Good high temp strength (below 150 deg. C), good low temp strength, poor welding, and stress corrosion cracking. Used for upper/lower wing panels, stringers, etc. Hardware- For many reasons, please only use AN/NAS or foreign equivalent hardware. Finally, let’s talk a little about wood and fabric aircraft. Sitka Spruce, Douglas Fir, Baltic Birch or Mahogany plywood should be used. As for fabric covering, there are many systems available. Be sure to use all the recommended procedures and materials for your chosen application.

In April, 1995, famous racing pilot and aircraft designer Steve Wittman and his wife were killed when their O&O Special broke up in flight. Investigation showed that fabric on the wings had not been installed in accordance with the Poly-Fiber covering and paint manual. Wing plywood was not treated with Poly-Brush compound. Accident cause- Aileron-wing flutter induced by separation at the trailing edge of an unbonded portion of wing fabric at an aileron wing station. Debonding of wing fabric was a result of improper installation. Aircraft total time=208 hrs. When I walked into the shop at my A&P school for the first time, I saw a sign with this quote by early British pilot, Capt. A.G. Lamplugh, “Aviation in itself us not inherently dangerous, but to an even greater degree than the sea, it is terribly unforgiving of any carelessness, incapacity, or neglect.” This quote has served as my guide for more than 50 yrs.

Thank Y’all for joining me around the campfire, Troopers (and Troopers ladies).