N994PT (IVPT) in extensive rebuild now.

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Tom Sullivan
Posts: 95
Joined: Mon Nov 28, 2022 2:33 pm

Wow, cool story Rock!!
Tom Sullivan
Posts: 95
Joined: Mon Nov 28, 2022 2:33 pm

I headed back to Florida yesterday (driving, argh) to bring my ‘63 Chevy Impala SS and Harley back for the summer. This last session back home we were able to complete a LOT OF WORK on the project. The last challenge was completing all repairs to the belly tank from the “no gear” rough terrain landing. I had 3 penetrations into the tank and one spot with enough evidence of damage I had to open it up and inspect it (ended up being fine). Two of those repairs were fairly extensive, with one requiring repairs to the fuselage below the wing fairing attachments.

I ended up making a Styrofoam MOLD to reproduce the destroyed lower front area of the wing fairing, which ends up being part of the sealed area of the belly tank. It turned out great. This past Monday we closed out the last two large repairs, after extensive cleaning of the belly tank using various toolls, mirrors, flashlights, and a borescope.

I also repaired the bulk of the wing fairing, performed micro bodywork on my intake transitions for smooth air flow into the intake plenum. We fitted one gear door and are ready to fit the other one. When I get back to Michigan my next project will be leak testing the tank.
Attachments
Mold complete for reconstruction of wing fairing / belly tank sealing surface
Mold complete for reconstruction of wing fairing / belly tank sealing surface
IMG_3619.jpeg (4.07 MiB) Viewed 10071 times
Shot bags applying pressure on wet layup of wing fairing reconstruction
Shot bags applying pressure on wet layup of wing fairing reconstruction
IMG_3621.jpeg (3.76 MiB) Viewed 10071 times
Aft area belly tank repair all tank sealed
Aft area belly tank repair all tank sealed
IMG_3632.jpeg (3.33 MiB) Viewed 10071 times
Front belly tank repair with flox dam to support close out panel
Front belly tank repair with flox dam to support close out panel
IMG_3633.jpeg (3.3 MiB) Viewed 10071 times
Front belly tank repair fuel tank sealed
Front belly tank repair fuel tank sealed
IMG_3634.jpeg (4.13 MiB) Viewed 10071 times
Aft belly tank repair close out installation with Hysol
Aft belly tank repair close out installation with Hysol
IMG_3636.jpeg (4.09 MiB) Viewed 10071 times
Aft belly tank repair sanded out
Aft belly tank repair sanded out
IMG_3639.jpeg (3.54 MiB) Viewed 10071 times
Front belly tank repair closed out
Front belly tank repair closed out
IMG_3637.jpeg (4.45 MiB) Viewed 10071 times
View of wing fairing reconstruction
View of wing fairing reconstruction
IMG_3638.jpeg (4.07 MiB) Viewed 10071 times
George Wehrung
Posts: 213
Joined: Tue Nov 22, 2022 3:56 pm
Location: KMRH

That’s quite the extensive work!!!

Did you drive the lizard back down to Florida?


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Tom Sullivan
Posts: 95
Joined: Mon Nov 28, 2022 2:33 pm

I drove my truck down this trip to pick up my ‘63 Impala, my Harley, and Joe Trepicone’s engine in Deland.

As far as “the lizard”, I think you’re referring to Rock’s encounter with one in his IVPT. That wasn’t me.

Tom
George Wehrung
Posts: 213
Joined: Tue Nov 22, 2022 3:56 pm
Location: KMRH

Sorry. I guess I got the posts missed up


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Ryan Riley
Posts: 155
Joined: Tue Nov 22, 2022 4:59 am
Location: Phoenix

Lots of work, but looking like great progress.
-Ryan
Lancair LNC2/Legacy/ES/ES-P Instructor
LOBO Webmaster
2007 Lancair ES
Tom Sullivan
Posts: 95
Joined: Mon Nov 28, 2022 2:33 pm

My New Engine for the airplane rebuild saw it's first run by Quentin Cook on Friday, June 7th. Quentin commented it was a VERY STRONG engine, seeing really high torque without hitting max ITT !!! Hopefully it makes for a FAST IVPT !!



Tom
Tom Sullivan
Posts: 95
Joined: Mon Nov 28, 2022 2:33 pm

I have had little work completed since my last post. I spent the summer and fall finishing a huge EAA Chapter Hangar project (I’m the president) that has been ongoing for 5-6 years.

I filled my belly tank with Avgas (yes, it’s a turbine but avgas leaves no residue if you need to fix any leaks). That was in July and I had numerous leaks to deal with.

I finally got on it seriously just after New Year’s and have completed 3 more leak repair sessions, with one left requiring rotation of the fuselage to upright. These were found with minimum vacuum cleaner “out pressure”, not even one PSI, and a soapy water solution squirted over the tank. Hopefully I’m nearing the end and can try avgas again.

We’ve made significant strides on the slow build wings by being able to use nearly all the original wing structure between the two spars. The right wing sheared of about 65% outboard from the root, so some structure has been built new. This week we pulled the lower skins down and installed all 4 wing drain points, laid up (and vacuum bagged) a new pitot mounting flange, and bonded all into the skins. We also installed the 4” fuel cap rings.

My last work session we cut out a new Ventral “lower” fin from 3/8” prepreg and bonded it to the lower fuselage as long as the plane is upside down on the rotisserie. That will get 4 bids of carbon fiber added and a tie down extended through the fin into the inside of the fuselage, at the original location at the aft bulkhead member.
Attachments
Fuel cap retainer ring Hysol bonded in place
Fuel cap retainer ring Hysol bonded in place
IMG_4684.jpeg (3.18 MiB) Viewed 705 times
Fuel cap retainer ring
Fuel cap retainer ring
IMG_4685.jpeg (3.25 MiB) Viewed 705 times
Fuel drains bonded in and ready for carbon fiber overlay
Fuel drains bonded in and ready for carbon fiber overlay
IMG_4686.jpeg (2.78 MiB) Viewed 705 times
Cored out mounting area in left lower wing skin for pitot mounting flange
Cored out mounting area in left lower wing skin for pitot mounting flange
IMG_4687.jpeg (3.64 MiB) Viewed 705 times
Vacuum bagging a 6 bid pitot flange
Vacuum bagging a 6 bid pitot flange
IMG_4688.jpeg (1.95 MiB) Viewed 705 times
Pitot flange fresh out of the vacuum bagging
Pitot flange fresh out of the vacuum bagging
IMG_4689.jpeg (1.81 MiB) Viewed 705 times
Newly laid up Pitot flange fitted to pitot
Newly laid up Pitot flange fitted to pitot
IMG_4690.jpeg (1.84 MiB) Viewed 705 times
Pitot mounting flange with pitot being aligned to straight forward for bonding.  Note square on wing joggle and paint stick protruding out the TE of the wing for alignment reference.
Pitot mounting flange with pitot being aligned to straight forward for bonding. Note square on wing joggle and paint stick protruding out the TE of the wing for alignment reference.
IMG_4691.jpeg (3.44 MiB) Viewed 705 times
Ventral fin, aligned with string to front and rear center of fuselage
Ventral fin, aligned with string to front and rear center of fuselage
IMG_4694.jpeg (3.21 MiB) Viewed 705 times
IMG_4573.jpeg
IMG_4573.jpeg (4.21 MiB) Viewed 705 times
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