Sullivan Wing Extension

Stephen

FRIEND
Lopez Island, WA
Here are some pictures installing the Ron Sullivan wing tip Mod on a PA-20
 

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31 foot wing span.....still not a Cub....but. this guy likes to carry his moose out of the tundra...can't do that and take a buddy in a Cub.
 
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Here are some pictures installing the Ron Sullivan wing tip Mod on a PA-20

Nice Stephen. Please keep us abreast on the progress with this project. Most definitely very interested in Mr. Sullivan's tips.
 
....but. this guy like to carry his mouse out of the tundra...can't do that and take a buddy in a Cub.

His mouse, or his moose?
If he is hunting mice, he might just want to drain a gallon or two of 100LL!!!
 
So Stephen,
You got me out looking at my right (ground looped) wing tip and have me wondering, when you remove that perfectly good stock tip whatcha doing with it?
Those pictures are great by the way, helps a guy like me see what's underneath before I get there!
Joe
 
Fitting the wing tip and traiing edge.

Joe, They belong to a customer, but he does not need them anymore. I've got the bows and fitting pieces.
 

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Joe, They belong to a customer, but he does not need them anymore. I've got the bows and fitting pieces.

Sorry I kinda hi-jacked this thread with my own interest but I have great news Stephen. Your post has encouraged me to spend some time in the garage with a #30 drill and a Corona this evening. About 40 minutes later it looks like my wing is in much better shape on the inside than it looked on the outside!
 

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Found this in my Clipper Paper Work

I talked to Ron Sullivan last year about wing tip and he mailed me this. I don't think he would mind if I shared.
 

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Stephen, tell me about the third picture in your first post. Is that a bending jig using the clamps and a 4x4?
 
Stephen,
Looks good! Guess I joined the wrong "shortw........" forum before. I was wondering why every thread I opened had "no new posts in 30 days"

Anyway, keep the updates coming.

Brent P.
 
Stephen, tell me about the third picture in your first post. Is that a bending jig using the clamps and a 4x4?

I used a 1 x 2 clamped to the cap strips to do the bending. It is about 3 feet long and straight. It worked fine, I also put some heat on the cap strips from a heat gun and very, very slowly made the bend. The front spars are the most critical since they bend the most. I did get a small crack in the web straightening on one of the sides. Ron said that was not uncommon and to stop drill the cracks. The plate bolts inboard of the bend. The prupose of the stick is to reduce the deforming of the cap strip when straightening. More pictures coming of the mice-moose hauler. I'm in the "recovering" (actually, in more than one since last night) process now...Love that Stewart System!
 
These pictures show the final wing work prior to the recover.

Recover is Stewart System.

Ready for rib stitching, then fill coat.
 

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Tips

Are these extensions still available from Sullivan? I just picked up a Clipper and would be interested in adding them. Put Stewart tips on a previous Tripacer, but these look simpler to complete. Thanks.
Mike Koch
 
Think so. The Stewart STC kit is complete. You'll have to put the Sullivan out of parts from one place and another.
 
Are these extensions still available from Sullivan? I just picked up a Clipper and would be interested in adding them. Put Stewart tips on a previous Tripacer, but these look simpler to complete. Thanks.
Mike Koch

Ron Sullivan sells the tips (which are excellent quality), end ribs and prefabed attachment pieces for the end rib. All that is needed is the hardware, use his list....but add screws, bolts and nuts. And, a new or used full length replacment rib. He lists a Univair number, or you can get it from Dakota Cub ( I think they are lighter), or shop for a used pair ($70-$80 new each). The only other materials that are needed is for recover (Stewart System is the easiest way to go).

I also think it is easier than the Stewart wing tip to install and it adds more square feet of wing area, which should transulate into better glides, lower stall and faster cruise (due to decreased AOA). All measurements are dependent on a number of factors, many particular to you own plane. Which, is why the Stewart's do not advertise specific numbers that you can expect to gain from their tips.

I did a wing extension last year on my plane...keeping the old druped tips (not the faster and lighter Sullivan tip)...my increased wing area made a much more dramatic change to the A/C performance than VG's...longer glide and lower stall.

I did a modification to the Sullivan STC that I'm currently installing for a customer, by making the tips removable, attaching it with screws.....This does require that the end rib be strengthened so that it does not flex when the fabic is tightened....I learned the hard way.....should have known.

Opps...forgot you need some leading edge and trailing edge material....make you own if you have access to a brake..I found buying the parts from Univair expensive and by the time I modified it to fit, I would have been well ahead starting with my own sheet aluminum.
 
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Stephen, Why is your trailing edge sticking out past the tip rib after covering?
 
Looks odd???...Because, when I install the Sullivan tip..it will mount to the tailling edge that I left sticking out....just the way I decided to do it. The Sullivan Tips are open on the trailing edge and a little long to be trimmed and fitted.
 
Stephen,
Show us a picture of the rest of the airplane when you get a chance. I think I saw a big bushwheel in one of the pics? Any other specs on the airplane? (a little off topic I know......)
 
I did install 29" Bushwheels on this Pacer.

Here are some pictures of how I reinforced the ribs and riveted gussets on the trailing edge.
 

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It's hard to get a pictures of the whole plane, as the hanger is dark and full of stuff. I've reworked the brakes system, installed the Bushwheels, wing tips, repaired exhaust system, lots of patches in the fabric, OH the tailwheel and I'm waiting for field approval to install 61 gallon Dodge tanks.
 

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Here are some current pictures of the Sullivan Tips.


The third picture shows how I attached the fiber glass tips.
 

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Sucessfully test flew the Pacer today, after some rigging adjustments, it is performing better than expected....increased glide, better cruise (even with new 29" Bushwheels) 110 knots at 24500 rpm (assuming...the instruments are correct??) and it seems... a lower stall speed (the AS was not reading anything...during a stall). I did not have a GPS to check the information. I found no noticeable change in the roll rate. This Pacer has a 160hp engine with as Borer prop....I hate to say it....But, it clearly got off quicker than my Pacer....Damn.
 
Stephen,
Thanks for the update! Our Pacer goes under the knife the last week of this month. Ron has the tips ready to ship and I am looking forward to the results. I think the tips really look nice and clean.......great job.

Any Idea what pitch the borer is? Ours is pitched at 42 and I am seeing about 100 knots at 2450 (160hp) with the 8.50's. I am really interested to see if I pick up any cruise with the Sullivan tips.

I have also noticed that with the borer, it feels like with longer gear/bigger tires, the airplane would get off quicker with an increase in AOI. As soon as I can get it in the air it is ready to climb. Wonder how much different the AOI would be with 31's over the 8.50's? With the 74x56 I could get it in the air, but it would need to be in ground effect for a little while before it would climb.

Anyway, thanks for posting the pictures and flight reports from the test flight.

Brent
 
110 Knots indicated? Wow, that's impressive pushing the big tires and a climb prop.
What was the altitude and OAT?? My stock 150 tripacer would never do over 103 knots TRUE at full throttle!
24500 rpm?? That a new two stroke STC for the 160 lycoming?? ;-)
 
Is there an STC for the Borer? Mine is sitting on 29" Bushwheels but am trying to finish Cathy's Tri-Pacer before I can get to play with mine. :rolleyes:
 
Svenn's aviation has an STC to install a McCauley 1A175GM824X on PA-20 and PA-22 series aircraft that have an O-320 installed. They also have the STC for installong the PA-18 tail. They can be contacted at svennandsons@yahoo.com. If I remember correctly I think the STC was a couple of hundred bucks. The STC # is SA02670CH
 
I recently got a field approval for putting a Borer on my Pacer and that is how it was done on the Pacer I'm working on....But, I think I remember someone getting an STC????? If not you are welcome to my paper work. Now I've got to save up to purchase the prop. Maybe, I'll have it for Johnson Creek.

The AS check was done at 700' and about 55 degrees...in the sunny San Juan Islands, WA. I do need to varify the AS with a GPS.

I liked how this plane performed...the Sullivan's are well worth the cost.
 
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