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My winter projest is to mangle my perfectly good Pacer, by installing the Bushmaster STC.
This STC modifies the wings to a super heavy duty Super Cub wing. This wing will have four feet of spar reinforcing at the lift strut attachment, more reinforcing at the new jury strut, 13 ribls, double drag wires and compression struts in the new outter bay.
My first step was to make all the wing reinforcing pieces out of .050 aluminum.
Second was converting the Pacer aileron to 102 inch Super Cub ailerons by adding 30 inches.
Next step was removing the Pacer wing and removing fabric.
Next, buck hundreds of number 5 rivets installing the spar reinforcing at the new lift strut location. SC attachment brackets are used in the forward spar and the front Pacer attachment in moved to the rear spar.
Drag wires get moved and new compression struts are added.
Your can see how the drag wires are doubled for added strength in the outter bay.
This wing will be much stronger than a typical Super Cub wing.
Next step was removing the Pacer wing and removing fabric.
Next, buck hundreds of number 5 rivets installing the spar reinforcing at the new lift strut location. SC attachment brackets are used in the forward spar and the front Pacer attachment in moved to the rear spar.
Drag wires get moved and new compression struts are added.
Your can see how the drag wires are doubled for added strength in the outter bay.
This wing will be much stronger than a typical Super Cub wing.
What part number fitting did you use for the strut attach fitting to the front spar? I can't find any details in the drawings. Reading your thread, you say that you use a PA-18 fitting. When looking at the parts catalogs, I see the PA-18 fitting for the front spar (#14192) has five through holes in the spar area and in your picture of building it appears to me that there are 4 through holes in the spar area. In the drawing there is also 4 through holes in the spar web.
Where did you locate the angle extrusion called out for that is 1"x3/8"x4'?
Here are a few more pictures showing both forward and aft (middle picture) spar, all I could find on the brackets. I did use standard PA18 attachment fitting for the front spar and as I remember I had to cut them down because they were too long.. I spent a lot of time getting the attachment brackets located. But, there is some flexibility. The struts will be built to the actual distance.
Are you referring to the strengthing angle extrusion. The drawing called out the locations as I remember. I skipped the inboard pieces as I did not use the Bushmaster fuel tank set up. These reinforcing strips should be located so they don't interfere and allow the ribs to clear. I had to make my own strips, cutting down larger angle material on a table saw and cleaning it up on a belt sander.
I have lots more pictures that I may not have posted. Let me know if you want more detail on specific aspects of the project.
(QUOTE=Just Call Me Al;113979]What part number fitting did you use for the strut attach fitting to the front spar? I can't find any details in the drawings. Reading your thread, you say that you use a PA-18 fitting. When looking at the parts catalogs, I see the PA-18 fitting for the front spar (#14192) has five through holes in the spar area and in your picture of building it appears to me that there are 4 through holes in the spar area. In the drawing there is also 4 through holes in the spar web.
Where did you locate the angle extrusion called out for that is 1"x3/8"x4'?[/QUOTE]
Here are a few more pictures showing both forward and aft (middle picture) spar, all I could find on the brackets. I did use standard PA18 attachment fitting for the front spar and as I remember I had to cut them down because they were too long.. I spent a lot of time getting the attachment brackets located. But, there is some flexibility. The struts will be built to the actual distance.
Are you referring to the strengthing angle extrusion. The drawing called out the locations as I remember. I skipped the inboard pieces as I did not use the Bushmaster fuel tank set up. These reinforcing strips should be located so they don't interfere and allow the ribs to clear. I had to make my own strips, cutting down larger angle material on a table saw and cleaning it up on a belt sander.
I have lots more pictures that I may not have posted. Let me know if you want more detail on specific aspects of the project.
The pictures are excellent information in addition to your reply, thank you so much. The drawings are difficult at times to interpret. The more I study them, the more I glean from them.
On the angle extrusions, I came to the same conclusion and ripped down 1"x1" angle to the necessary dimensions.
What did you do to fill in where the spar strut attach fittings were on the original PA-22 location at roughly Station 79 11/16"?
The pictures are excellent information in addition to your reply, thank you so much. The drawings are difficult at times to interpret. The more I study them, the more I glean from them.
On the angle extrusions, I came to the same conclusion and ripped down 1"x1" angle to the necessary dimensions.
What did you do to fill in where the spar strut attach fittings were on the original PA-22 location at roughly Station 79 11/16"?
Are you referring to the 1/2" bolt holes? Those holes in the spar web are too small to have any load bearing issues. Make sure the holes are smooth and have no cracks.
I know what you mean about studying the plans. It sure would have helped if there were a set of written instructions. Although, it does leave a certain amount of flexibility.
Here are a few more pictures showing both forward and aft (middle picture) spar, all I could find on the brackets. I did use standard PA18 attachment fitting for the front spar and as I remember I had to cut them down because they were too long.. I spent a lot of time getting the attachment brackets located. But, there is some flexibility. The struts will be built to the actual distance.
For the front spar strut fitting, used Piper PN#14192. In the Sper Pacer drawings, it calls for a gap of 1.02-1.10". But with the 14192 fittings, they have an extra spacer (in the Piper drawing, PN#10541) welded inside the mating surface to strengthen the strut attach hole, which narrows up the gap by roughly 0.15". Did you space out the strut attach fittings further to account for this or make the end of the strut narrower?
I hope that the weight gain will be under 100 lbs. I have a few ideas where I can cut weight....Weight and cruise speed are the two factors that I am curious about.
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Super Pacer (Bushmaster) Mod
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Originally Posted by Stephen
