Well, my weekend Sucked!

[Nathan K. Hammond]

So, we're (Me and A/P-IA Dad) doing the annual and things don't start well. Cracks in not one, BUT both inner wheel half’s. What's funny is they cracked where the bearing race is at. Next came the punch test, which wasn't a direct problem, it was making 55 pounds fine. But where ever we used the punch, it knocked A LOT of paint off, as in you could peel it like wrapping paper. And it's peeling everywhere! Then comes the final blow; we'd been watching an anomaly in one of the rear spars, a black line where a glue joint is, that came out of a bolt. It hadn't grown any, but was a little spongy and I could push my knife blade into it. And to top it off, there were signs of a possible de-lamination at the root.

So.... we made the decision to pull the airplane and start a rebuild. I ferried it back home and pickled the engine, talk about a lonesome, depressing flight!

Now begins the mad dash to put up a temperary shop at the house. Seems the wife doesn't like the idea of me doing wings in the living room!?!?! Go figure.

nkh

[MikeB]

Nathan,
At least when you finish you'll have the satisfaction of knowing the wings are airworthy. I'm guessing you're going to put wing tanks in too. Like you I've been watching the wings (loose nails, etc.) over the past few years as they were the only part of the Champ I didn't cover (had been previously covered in 1990). Keep us informed as you progress on the job.

Regarding covering at home: my shop is only about 75-100 feet from the house, but it's been cold (down to near zero) the last few days so I decided to bring the control surfaces I've been covering into our basement and save a little propane in the shop. It lasted about an hour and I had to move back out as the glue fumes were way too strong in the house, although the wife thought it smelled 'nice' .

Good luck on your project!

Mike Berg

[joea]

Nathan,

Remember the videos that you have been doing and the comment on your signature line?

Thank God that you found the cracks now and not the NTSB or your family. Do it right and get it done and you will be happy in the end. Engine was done recently so when you are finished you will have a plane that will last another 30 years!

Joe A

PS, do not understand the comment on the wife? You asked her? Just do it and tell her that each wing is a large ironing board and that she needs to get to work! (that would last until she hit you with the iron!)

[David Johnson]

Nate, darn it %^%$&&. This is how 2 of my 3 projects got started. Difference between me and you is you will get with it and get done. Me, I am still piddling around. If you need anything from our bunch up here let us know. You know I have an old set of spars with drill bushings in them don't you. I think you saw them stuck to the ceiling in my shop. Don't let Derek hear of this, you will be talked about bad. Hope this goes well, David Johnson

[MikeB]

At least you have a "in house" AP/AI (Dad). Just found out my AI is retiring/selling out . Hard to find a good one that will work with you and knows tube and fabric.

I agree with Joe, though. Once you bite the bullet and the start the rebuild process, you'll probably be happy you did and you'll know what you have when you finish .

Mike

[gusc]

Nathan,

I was feeling sorry for myself today after finding an exhaust/cyl leak and screwing out a spark plug bushing-until I read your post.

Now I know that my problems are minor.

I have a lot of antique vehicles of various descriptions and I find that when I spot something that might need a bit of attention that the more I look the worse it gets. The result is usually a half disassembled vehicle. However, since these are seldom safety issues they are a far cry from a spar problem.

It probably would have lasted for years-but maybe not.

I stopped doing punch tests years ago, those things are nothing but trouble and very often cause damage when the fabric is fine. They aren't really a legal test anyway-you can't ground a plane based on a punch test alone.

Mike,

Glue fumes might make your wife a lot more fun so maybe you should reconsider working in the basement!! If you are using Poly-fiber I don't think they are toxic anyway.

[jimboe]

Nathan,

In a matter of months you and your dad will roll a brightly painted, sound and restored Champ onto the runway and lift it gently and confidently into the air. You will realize the satisfaction that comes with a significant and focused effort, and you will welcome the joy of flying your new Champ.

At that time you will look back on this woe-full moment and marvel at what a great opportunity it was to pursue building the perfect Champ.

Or, you can compare your situation with mine. I had sinus surgery yesterday and have enough gauze stuffed up under my face to recover your left wing, assuming you like red. This is the first of 2 surgeries in hopes of curing my "mild case" of sleep apnea, which the FAA doen't consider mild enough to grant a 3rd class medical certificate. Oh, and you have a Champ, I don't. I just have your video links.

Get to work! And enjoy.

Jimbo

[Nathan K. Hammond]

Mike, hate to hear you're losing a talented old-timer. Is he giving it all up, or will he still do an annual every once and a while? Wing tanks are a must, most likely the little 5 gallon tanks. Question for ya Mike, since you've got another set of wings with the L16, are you planning on swapping out once they're built?

Joe, I knew this day was coming, but honestly was hoping I could get another year or two of flying out of it. But like my Dad said, 'when is a good time?' He has a good point, I'm fairly young with no kids; better now than later.

David, I actually have nightmares about the project turning out like Derek's. Thanks for the offer, I may give you a hollar later about your old spars.

Gus, true about the punch test not being an accepted test, but it is accepted as a supplemental tool for AP's to use when they have to judge fabric quality. It's one of those rare moments when the FAA allows common sence to play a role.

Jim, my imagination is running wild! I can see that day now. Thanks for pointing out it could be worse; hope you get to feeling better soon. And I think I'll pass on red fabic, looking at maybe doingn it in blue this time, but thanks for the offer.

nkh

[MikeB]

Nathan, My AI is one of those rare guys that will let me open things up so he can check this and that. If I do anything regarding restoration, he'll come up, check the work and sign the logs, etc. I haven't been able to get ahold of him, but heard through the grape vine he had heart trouble so may be in the hospital.

Regarding the wings: the ones I have for the L16 are not in the best of shape (one cracked spar and several ribs that are questionable). Right now I'm weighing my options. If I do rebuild one set or the other, I will definitly install 5 gallon wing tanks on both sides and keep the nose tank.

Mike

[Jody Wittmeyer]

Nate, you could come get my chief wings, so you could fly (stress relief) while you rebuild your, but I found the work goes faster if you work instead of fly. Used to fly 200 hrs a year. Think I only have 100 this year. Have been working hard on the chief. (sucks) Has to get done though. Tired of parts all over the hangar. Still, if you really wanted to fly, you could use them until spring, when they will get mounted on my other steed. It is only a chief though. Hey, if my wings got to fly on a champ, they would be really perky until they see their final destination.

[Nathan K. Hammond]

Thanks for the offer Jody! You say they'd be perky until they saw their final destination; does that mean your not gonna ring that Chief out? I've been thinking it over, and most likely will redo the entire airplane. There's several little squaks on the fuselage I'd like to take care of and once I get started, hopefully it will roll right along.

Lets see some pictures of that Chief Jody!

nkh

[joea]

Nathan,

Its been a couple of years now.

HOWS THE CHAMP GOING?????

Joe A

[Nathan K. Hammond]

I've actually started back on the project. Nothing spectacular happening at this point; just priming the last of the steel wing parts and a new set of wheels. David dropped off his Jointer so I can start the spar's any day now.... which means I'll have a trip to the doctor's office soon. I need a tetnis shot anyway.

nkh

[joea]

Let David do all that dangerous stuff, and you can sit back with the garbage disposal!

Keep chugging along at it and get that puppy up in the air for next summer!

Joe

[David Johnson]

Me trying to encourage. Me not doing too well. Not much to work with....However, he will probably beat me by several years! David J.