new Bushmaster build

[Barrie]

Hi All,
I was here in the fall inquiring about starting on a Bushmaster project (Amateur-built) and it looks like things are beginning to happen. I have acquired a set of early PA20 wings, new spars and a fuselage (already stretched from the baggage aft). Right now the wings are a priority for me and I'm hoping to glean a little info about ribs etc. I was planning to use what is good in the wings and supplement the remaining with new ribs, Carlson, Univair, or??. There is already one wing stripped and I expect to have the other one done by next week. I have done a set of D&E wings for a friend a few years ago and a set of C120 for myself but I think this project will be a little more testy on the pocketbook; so I guess what I really need is a bit of advice on what pitfalls may be waiting for me here. Any suggestions would really be appreciated.
Barrie Gittens

 

[Stephen]

I converted my Pacer to a stretched Pacer. Mine was done under the Super Pacer STC. It sounds like you will attempt an experimental version. Make sure you will meet the FAA requirements for experimental first! The challenge of going experimental besides working with the FAA is coming up with plans for your project.

As far as the wing, I acquired used Piper ribs for my stretch. I did not purchase new style ribs. Piper ribs are lighter and cost less and are extremely strong.

 

[Barrie]

Hi stephen
Just a little more info on my project. I will be working with what we call an MDRA (a transport Canada delegate). They have a pretty strict building process which I have been through a couple of times. I am building this airplane with the help of my son who is a machinist and my best asset.
Getting back to the wings; I will be using the Simpson design and will try to stay within the plans as drawn, as much as possible. The PA20 wings had the squared off wings with droop tips and I plan to retain those along with the extended flaps and ailerons. I understand that many people are using stamped ribs at the root and tip and I can see that would be good for plate nuts etc. - any thoughts on that? I also plan on using the original tanks and adding small auxiliary ones as in the Maule.
Thanks for the reply
Barrie

 

[Stephen]

It sounds like you are on track. Yes, stamped ribs are the way to go for inboard and outboard. That's what I did. Glad to know you have and are following the Simpson Super Pacer plans, especially for the wings. There are two designs for the sice reinforcement. One is simple, squared off like the Piper splice, only longer. The other is a tapered design. The tapered design is the latter design. Getting these plans for experimental projects are not easy anymore.

 

[Stephen]

What are you planning for the lift struts?

 

[Barrie]

At this point I haven't given the struts much thought but probably D&E? aluminum. There will be many many decisions to be made down the road. The spars are new full length so splicing is not necessary. However I was wondering what the MTOW for the Simpson wing is according to their plans. I was hoping for 2400.

 

[Stephen]

At this point I haven't given the struts much thought but probably D&E? aluminum. There will be many many decisions to be made down the road. The spars are new full length so splicing is not necessary. However I was wondering what the MTOW for the Simpson wing is according to their plans. I was hoping for 2400.

The spar needs reinforcement regardless of splicing. I don't think a full length spar cuts down much of the reinforcement. A friend and well know mechanic and SC expert in the NW, built his SP 40 years ago on a field approval without spar reinforcement, he never trusted it in turbulence and would not sell it since he felt it was unsafe.

I read somewhere that the aluminum struts are approved only to 1800 lbs. My Super Pacer has a 2100 gw. Being experimental you can ignore all of this but, you want to be safe. The aluminum struts would be simple.

I had Airframes make my struts and leave the upper end open, they also provided all the pieces to finish it. They also instructed me on how to make them sealed.

 

[Barrie]

Stephen,
Spar reinforcement is a definite given and I will be looking into that a little deeper when I can get the plans on paper(old school!) The struts issues are the kind of problems I am hoping to avoid, so I will be paying attention to that for sure.
Thanks

 

[Stephen]

Stephen,
Spar reinforcement is a definite given and I will be looking into that a little deeper when I can get the plans on paper(old school!) The struts issues are the kind of problems I am hoping to avoid, so I will be paying attention to that for sure.
Thanks

The owner of the Super Pacer STC only provides paper copies of the plans. They are 3 to 6 feet long and difficult to reproduce. He only sells the plans to certificate projects. There is so much information in the wing drawing, it took me many days to understand and I still had to call other builders. I have posted pictures of my project on this website to help.

Going with a new spar is a lot more work, good luck.

 

[Barrie]

My first project was an RV6 and the plans were what spoiled me. They were excellent and easy to understand but that job was pretty well "paint by numbers". Compared to that, this is going to be very demanding but who doesn't enjoy a challenge. Anyway; it will all be basically new with everything laid out correctly and according to the plans. I do have a STC'd Bushmaster close by for reference if needed and I plan a visit there quite soon. I am trying to learn all of the options that are open to me(such as the struts, etc.)
I have been lurking on the site over the winter and looked at your Superpacer - very very nice work

 

[Stephen]

I just saw the Airframes is working on an STC approved aluminum strut for PA 22/20. This might work for certified Super Pacers. If Airframes sells the aluminum strut and STC to a PA 22/20 owner the mechanic could combine the SP STC and Airframes STC and use aluminum struts for their certified Super Pacer. Airframes would have to leave the aluminum strut long so it cut be cut to size for the SP.

 

[Barrie]

I will certainly keep that one in mind. Thanks

 

[Southern Aero]

Barrie

If you build to the plans specs I have all aluminum struts available (experimental). I have made them for the for Bushmaster types with gross up to 2900 pounds. They are in either the Bushmaster style of attachment (sorta Decathlon), the SC style that have the 5/8" fork at each lower attach point or if angles are unknown a "universal" type of fitting can be used. I will also have the wing reinforcement parts pre made for the experimentals soon if interested.

Several examples

 

[Barrie]

That gives me a lot to consider. It's good to know you have such a large MTOW. Sending a PM soon.
Thanks

 

[Swimaway]

The spar needs reinforcement regardless of splicing. I don't think a full length spar cuts down much of the reinforcement. A friend and well know mechanic and SC expert in the NW, built his SP 40 years ago on a field approval without spar reinforcement, he never trusted it in turbulence and would not sell it since he felt it was unsafe.

I read somewhere that the aluminum struts are approved only to 1800 lbs. My Super Pacer has a 2100 gw. Being experimental you can ignore all of this but, you want to be safe. The aluminum struts would be simple.

I had Airframes make my struts and leave the upper end open, they also provided all the pieces to finish it. They also instructed me on how to make them sealed.

Stephen,

I too am building wings right now for my experimental super pacer. This is kind of an eye-opener. Do you have any documentation on the reinforcement needed?

 

[Stephen]

Stephen,

I too am building wings right now for my experimental super pacer. This is kind of an eye-opener. Do you have any documentation on the reinforcement needed?

The plans are too big to copy and that would infringe on the owner of the plans. But, I have posted pictures of my build, including photos of the reinforcement. It is an expansion of the approved Piper splice. The plates are on both sides of the spar and are about 3 feet long. Since the splice is just outboard of the lift strut attachment it serves both to reinforce the splice and the lift strut area. I believe it is .060 or a bit thicker. There are three layers, each layer slightly shorter. You can find info about the Piper approved spice on this site. I think common sense works for this. You can PM me with your ideas, and I will comment.

 

[Swimaway]

The plans are too big to copy and that would infringe on the owner of the plans. But, I have posted pictures of my build, including photos of the reinforcement. It is an expansion of the approved Piper splice. The plates are on both sides of the spar and are about 3 feet long. Since the splice is just outboard of the lift strut attachment it serves both to reinforce the splice and the lift strut area. I believe it is .060 or a bit thicker. There are three layers, each layer slightly shorter. You can find info about the Piper approved spice on this site. I think common sense works for this. You can PM me with your ideas, and I will comment.

Who has the plans? I will just buy a set

 

[Stephen]

James Smith james@skicarstunt.com He may not be willing to sell them for experimental projects.



Here are some pictures of my project. The first is all the reinforcement material that I cut out as per the plans. The last picture shows the doubling of the compression struts and drag wires. I believe these are the key elements to the wing reinforcement.

 

[tim bandy]

could you use bearhawk 4 place spars and just mod the rib distance ?