Badland Part 103 Pilots and Builders Forum

ksatter26

Chasing worked. Although it seems the probe description as 8x1.00mm isn't right ( unless it references the adapter). I found the bolt, boss, and probe to be M6.

Probe mounted. Awaiting female plugs for the sensor wires.

ksatter26

The brass fitting is some sort of adapter. The short probe can screw into the center but the fitting is too large for the tapped boss on the exhaust. The probe itself seems to be tge right Suze for the boss, but mine seems to bind within a trunk or so. I hesitate to just torque my may thru, but the ...

ksatter26

Progress on this 70 degree, mid-January day in North Texas. I fabricated the panel center brace and did a trial fit. The panel is hinged to allow easy access to the firewall *wiring") side. The center brace was made from a length of 0.5" aluminum tube, flattened on one end to fit the angle...

ksatter26

Chris is awaiting some materials shipment in order to complete my replacement control arms. In the meantime, I'm going to "drill out" the closed (arm) end with my 0.875" bif. The flaperon spar OD is 0.875 so I'll probably have to spend a bit of time filing to get it to fit over the sp...

ksatter26

The tubing on my control arm fits OVER the flaperon spar. So if I am able to drill out and ream the closed end I could slide the arms onto the spars and have a nice fit for aligning the arms with the push-pull forks. However, I just heard from Chris and the design had changed. He said he'd send out ...

ksatter26

Trying to respond to your comments ...Still very much confused ... HELP!

ksatter26

The Throttle assembly is really nice (~$15 from Aircraft Spruce). As delivered, it has a rather heavy ratchet feel but a few turns of the center screw and the ratcheting can be adjusted to your preference for holding in flight. Throttle.JPG The two controlling factors on my panel layout ... max widt...

ksatter26

Checking with Polini, relocating the radiator below the engine requires several new/replacement parts (to the tune of about $110) (1) The engine is delivered with a straight water inlet connection. I asked about just installing a 90 degree, 16mm radiator hose elbow and connector (seems this is a sta...

ksatter26

I'm still quite confused on a couple of items not describe very well in the build manual. (1) I've asked this question about the spar jig/tool before, but I think what I really need is some pictures as: when I position the jig/tool over either the fwd or aft spar fixtures on the fuselage ... I see n...

ksatter26

I have a source of 100 LL Avgas somewhat at the Caddo Mills Airport (about 16 miles away). Lots of open flat space grass runways and a nice 3000'+ asphault. I'll be testing the bird there while getting my 700' grass strip into shape. I also have a case of Blue Diamond 2-stroke oil. It was recommende...

ksatter26

Sneaking in some building time between Bowl Games. Just finished clecoing in the lower flaperon mounts into the port wing. I have match drilled the upper and lower mounts and have the flaperons mounted (via clecos... both wings]. Current thinking is to rivet the flaperons to the wings after covering...

ksatter26

I've been without internet (or TV) for over 2 weeks (neighbor got a new backhoe and cut my relatively new fiber optic connection). IVO Prop makes a really nice 3-blade, ground adjustable prop at a reasonable price. The guys there are most helpful in advise. Minus 15, 30 mph winds gave us -5 wind-chi...

ksatter26

I have the 55mm E-Prop mounting bolts. The WhirlWind prop on my Viking 110HP used Nord-Lock washers. Thinking of using them on the Polini with locktite and torqueing to 8N-meters (70 in-lbs).

Any thoughts out there?

ksatter26

E-bay Honda motorcycle throttle cable less than $8 (free shipping). I had to file down the tiny ball on the end of the cable to fit the Polini carb. Works well and is just about the right length. Got in some more work on the starboard wing before the weather got colder. Unable to epoxy the outboard ...

ksatter26

I really thought I had posted an intro when I noted ordering my F3 kit about a year ago. Evidently I did not do so. Formerly a Software and Manufacturing Engineer turned to Industrial Engineering Prof. Started building a Bower's FlyBaby a number of years ago. At about 90% complete (with 65 Franklin ...

ksatter26

Mounted the Polini to get an idea of where to locate firewall pass-thrus. (Yes, Chris has informed me that the firewall is mounted upside-down ... will fix). IMG_0681.JPG I have a 12VDC 5 Amp-hr motorcycle battery that I will locate on the cockpit floor centered against the firewall and secured via ...

ksatter26

Most definitely helps ... thanks. Not there yet, but making progress. Good friends head me complaining about our last cold snap and all chipped-in for a really nice Slaght128 Heater/Air-Conditioner. Along with my *)K BTU propane heater, it ought to heat the hangar/shop nicely. Looking forward to see...

ksatter26

Only drilled one end of each for the AN3 bolt.

Trial mount if the engine to locate the positioning of components on the firewall: starter relay, fuel pump, fuel line/ filter, pass-through for throttle,, CHT, AND EGT cables.

ksatter26

I mean part # 60136 ... Wing Lug Pattern ... it is no more than a short length of tubing. Pictures and description in the build manual don't make much sense to me ... of course I'm not to that point in the wing construction/rigging yet ... just trying to understand. The jury strut fixture is nothing...

ksatter26

Some concerns. I believe I can make the battery removable since the pull starter is integral to the Polini. Will check the weight once I have the wings on. I'm going to have to check with Chris. I have been over the manual and few pictures several times and am pretty much in the dark about the use i...

ksatter26

Here's the method/tool I came up with to flatten the ends of the jury-strut arms. IMG_0653.JPG (1) bent an L-angle shape of scrap aluminum sheet and cut a 0.5" notch to fit the strut rods. I mounted this on a piece of scrap wood as a positioning support for the rod. (2) I cut a slot into anothe...

ksatter26

Fuel Mgmt System ... The tank fitting is connected to a Tee which provides a quick connect drain fitting at the bottom of the fuselage and a connection to the engine. TankTee.JPG The fuel line from the Tee to the engine runs along the starboard side of the cockpit to a panel-like fitting secured to ...

ksatter26

As requested ... Elevator Push Rod coated and installed ... ElevatorPushRod01.JPG Lift strut and flaperon mount parts (done, but not pictured are the jury struts)... StrutsPowder03.JPG StrutsPowder01.JPG New 80K BTU shop heater ... now I just need some gap seals on the hangar door-frame. 80K-BTUheat...

ksatter26

The battery charger for my Cannon SureShot finally showed up so I'll catch up on several of the pictures missing from a few previous posts ... Fuel Mgmt ... I fabricated a mount for the fuel system primer pump bulb and cutoff valve. I mounted this to the stb side of the cockpit using nylon cable cla...

ksatter26

Finally the proper Polini Thor 303 Mount Ring showed up. I spent this morning inserting the rubber shock absorbers into the ring and finally mounted the ring on the very fine firewall weldment provided by Chris. I also set the rudder travel stops. I've worked out the fuel line routing and have come ...

ksatter26

I'll get better pix of the drain/disconnect ( nylon from US Plastics). I'm re-thinking the fuel line routing to the starboard side. The fuel level transducer wires are on that side.

ksatter26

I won an E-bay auction for a 1.75" punch-flairing tool. It arrived just in time for the cold weather which curtailed my wing trailing edge epoxying plans. The tool works just fine and I managed to punch and dimple 19 1.75" holes in the seat back and bottom in less than 2 hours. If anyone n...

ksatter26

The bar positions the rudder Pedal in the neutral position as is the rudder also clamped in the neutral position for setting the control cable length. The L-angle is pop-riveted to the firewall and allows 5 locations for attaching the rudder and brake return springs. ControPedalSpringMount01.jpg The...

ksatter26

The bar positions the rudder Pedal in the neutral position as is the rudder also clamped in the neutral position for setting the control cable length. The L-angle is pop-riveted to the firewall and allows 5 locations for attaching the rudder and brake return springs. ControPedalSpringMount01.jpg The...

ksatter26

I only have a small contractors heater for the 30'x40' shop ... lightly insulated but lots of gaps in the hydraulic hangar door frame. I'm investigating a larger propane heater. I have completed a few things on the project so I am making progress .. (1) Started routing the fuel line. I added a T-fit...

ksatter26

The replacement mounting plate fixed the positioning of plate-to- engine mount holes BUT the shock mount holes were bored oversize. Chris has made the CAD fike fix and I expect a good one in a week or so. I got all the lift and jury strut parts off to the local powder coater. I expect those back nex...

ksatter26

Still waiting on my replacement Polini mount ring so no progress on mounting the 303. The engine comes in a nice welded tubular steel box frame so it is really ruggedized for shipping. Chris says the tailwheel angle should be near 58.8 degrees mine is 56.9. He says that should be fine. I can slightl...

ksatter26

Hirth makes a good engine. I had the F33 in my MiniMAX 1103R. Ran really well with a 3-bkade Ivo prop.

ksatter26

Over the weekend we determined that Polini sent the wrong mount ring for my Thor 303. Chris was all over it he said that Polini sent 2 of the same part numbers with mismatching rings. He's getting my replacement out today. This morning I tore-down the trial fittings of the controls parts so that I c...

ksatter26

Sure enough, Chris has heard from Polini and we have the wrong mounting plate. He has the replacement and is sending it out today. I'll return the one I have to him.

ksatter26

Todd left me a msg saying that you dud not route your flaperon cables per the manual and that yours operate more smoothly. Can you post a description? I'm finishing up the mechanicals of my fuselage/controls build and will probably start working the wings soon as the new Polini supplied mount ring d...

ksatter26

Chris took one look at the pix of the Polini mount ring positioned on his beautifully welded, 2-piece mount and said that it appears Polini has changed tge configuration of the mount ring. He's going to check and either get me an older version or fabricate one for me. With the mount stumbling block,...

ksatter26

After a seemingly forever wait (almost 2 weeks) for for my 10-32 Left Hand Threading Die (at a horrendous shipping cost), yesterday I was able to complete threading the ends of the eight 3/16" 6061T6 round rods, fitting the clevis fork ends, and installing on the aircraft.

ksatter26

The solid rod tail-spring is a new feature from Chris. Goes together much more easily than the flat spring. Probably is the norm for all new kits. Finished up the 3/16" 6061T6 rod flying wires today. The long delay was waiting for the left hand thread die. I bought 2 on-line, @ $4.50 each. I co...

ksatter26

Finally got the starboard wheel problems fixed. Solution was to replace the Azuza provided tube with an 8" wheelbarrow tire. Works fine. I created a jig to set the gear at 61" (outside track width and set camber at 1.5 degrees. The airframe was supported off the gear via my engine hoist th...

ksatter26

Mounted and leveled the horizontal stabilizer. I was able to get good measurements for the lengths of the 4 upper and 4 lower flying wires and the angle to which the wire tangs need to be bent (40 degrees seems to be proper for all 8 locations). I have access to 3/16" 6061Tg aluminum rod so I d...

ksatter26

For the 3rd time I picked up my port wheel assembly from the tire shop that finally consented to doing the mount of tube & tire to the 6" split nylon Azuza rims. When I tried t0 do the mount as I did on the starboard wheel, I managed to pinch the tube between the rims so after 2 shops refus...

ksatter26

The Rudder and Brake Pedals are installed in the fuselage with the 5/8" bushing stock provided. However both sets require the pedal 5/8" mounting tubes to be reamed out to remove slight scale on the interior from the welds. The Tail Wheel is the new solid rod spring design. It went togethe...

ksatter26

Tank installation process requires several trial placements to determine the placement of the tank and the location/length of the uprights and pre-bent brackets and to also locate the mounting bolt hole locations for the Adel Clamps. The BarnDoor 5 gallon tank fits snugly in its proper position behi...

ksatter26

After a lot of grinding/sanding of the interior tire rims to fit the 6" nylon split rims. I finally took the assemblies to a local tire shop to get the tubes into the tires and split rims. It was worth the $20 to have them done as I spent 4 hours trying myself and only managed to hole one of th...

ksatter26

Should have edited the post ... the fuselage is THIRTEEN feet SIX inches not 16.5' ...

ksatter26

Chris adds an aluminum plate with the A/C Serial # to the lower cross-member behind the cockpit area. Mine seems to indicate that it is his 15th F3 A/C. Somewhat going from the Build Manual provided. I started with the Main Gear Assemblies. I have the 15x6.00x6 nylon split rims, tires and tubes (for...

ksatter26

Wednesday 9/7/2022: flew SWA one-way ($132) Love Field, Dallas to MSP (Minneapolis). Picked up a Budget 16' Package Truck, one-way, 5-day, unlimited miles and drove to New Ulm, MN (85 miles) over-nighting there. Thursday morning drove to Chris/Badland in Truman (35 miles) where we had a great visit ...

ksatter26

Check out the U-tube later posts from John Croke on building the Affordaplane. He covers the tail surfaces and wings using the Stewart System and exterior latex house paint. My original order indicated a preference for the Oratex but I have since been sold on the Stewart System. A limited selection ...

ksatter26

F3 Kit Order # 1261 - 27 September 2021 F1 kit complete PLUS: (1) 160mm Hydraulic Heel Brakes (2) Cabane Coil Spring Main Gear (3) Composite Tail Wheel (4) Pre-cut Aluminum Instrument Pnel (5) Pre-cut Aluminum Seat Set (6) Pre-cut Aluminum Floor (7) Flaperon Tips (8) White Powder Coated Airframe (9)...

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