Bent lower longeron.
Bent engine mount.
Left front spar fitting pulled out of the fuselage.
The dis-assembly crew.
Parts ready to load.
Loaded and ready to haul.
Buckled rear spar.
Compressed tank bay rod.
Rusty aileron hinge.
Another rusty aileron hinge.
Corrosion on the false spar when the flap hinge was removed.
Bent inboard flap hinge.
Front strut attach fitting bent.
Front strut attach fitting bent and pulled bolt out of compression strut.
Bent front jury strut fitting.
Bent spinner bulkheads.
Bent front spinner bulkhead.
Bent rear spinner bulkhead.
Bend in lower cowl.
Bent airbox door.
Bent cooling scoop.
Bent nose bowl.
Bent lower cowl rail.
Bent and broken engine mount.
Broken engine mount.
Broken tail brace wire clevis.
Incorrectly installed clevis washers.
Clevis washers installed incorrectly.
Broken exhaust pipe.
Broken swing out mount.
Damage to boot cowl and firewall.
Tubing damage behind the firewall and bootcowl.
Egged out air filter dome.
Tubing damage behind firewall.
Bowed tube under floorboard.
Bent tube aft of rear spar carry-thru.
Bent bottom longeron.
Upper deck pushed to the right at the rear and to the left at the front.
Rusty tubing at the battery box.
Bent tubes at firewall from below.
Rusted out right "D" window. Left was the same but damaged in the accident.
Tubing under battery box after removal of rear shelf.
Rusty bent tube on the bottom of rudder.
Tip skin wrinkled on right wing.
Warped wing tip bowed.
Tailpost bent to one side from previous repair.
Fuselage on rotator.
The cutting begins.
RH flap bracket bent.
Worn flap bellcrank.
Fuselage in the jig.
Top deck being repaired.
Left wing going back together.
Pre-formed tip bows getting epoxy varnish.
Firewall/front section repaired.
Top deck getting repaired.
Top deck repairs.
Upper deck replaced with "X" brace installed.
Upper deck replaced.
Lower longeron repair.
Repair started on right side longeron.
Upper deck repaired.
Spalling on the crankshaft. Mains and rods turned .003" under.
Wings going back together.
New tip ribs being installed on left wing with new spars.
New "D" windows welded in.
Tabs welded under door frame for interior sheet mtal attachment.
Blasted, primed and painted all steel parts. Strut attach fittings.
New false spars.
No more rusty aileron hinges.
Lee is finally finished with the wings. :)
Beat up interior panels.
Interior panels are kinda beat up.
Rebuilt brake cylinders.
Some parking brake valve parts.
Rusty Seat Frame.
Blasting the fuselage.
Missing weld on the seat frame. Looks like it got past QC at Piper and didn't break over the past 30 years.
Weld here looks good.
Primed fuselage getting white polyurethane top coat.
Wing root fairings from left wing in poor condition. Right wing was damaged in accident.
Some corrosion found after stripping paint and primer.
Typical cracks found on brake pedal support. Will replace with heavy duty F. Atlee Dodge part.
Chafed RH cowl door. Wear and tear from years of no anti-chafe material.
Corrosion that has blistered the paint on the left cowl door.
Outside of right cowl door where chafing has creased the aluminum.
Stripped, etched and alodyned aluminum parts.
Fuel tank and belly covers, stripped, etched and alodyned.
Left cowl door being stripped.
Bottom cowl being stripped.
Stripper working on the bottom cowl door.
Seat tube weld finished.
Landing gear, cabane vee, window and seat frame sand blasted.
Vertical and horizontal and stabilizers, elevators, rudder, door and rear seat frame sand blasted.
Cracked front floor board.
Baggage compartment floorboard.
Battery box and ELT rear shelf.
Mag switches and cabin and carb. heat control panel.
Battery box lid.
Corroded battery box lid. Corner of insulator is missing.
Misc. steel parts being primed.
Seats, brake pedals, push pull rod and misc. rudder and brake pedal parts painted black.
Old firewall blanket.
Flap handle assembly.
Torque tube assembly with sticks.
Instrument Panel as is.
Vacuum instrument plumbing.
Panel and boot cowl installed.
Boot cowl installed.
Lower section of rudder replaced.
In the air conditioned shop to work in comfort.
Air vent laid out.
Fitting windshield strip.
Air vent clecoed in.
Windshield, "D" windows and skylight fit and drilled.
Floorboards cut and fit.
Baggage floor cut and fit.
Battery shelf cut and fit.
Windows cut to fit.
Floorboards stained and awaiting epoxy varnish after holes are drilled.
Primed small parts.
Fitting the throttle cover panel and metal headliner.
Fitting the metal headliner.
Panels behind boot cowl fit.
Pre-fabricated boot cowls are always too long as can be seen by the gap between the boot cowl and aft aluminum panel.
Gotta get rid of some metal.
Rivets in seam are drilled out.
Boot cowl is pulled in tight and drilled to attach to the forming channel.
Problem is the original rivet hole don't line up now.
Figure 8 holes as seen from the inside.
Making a "U" channel doubler for the boot cowl seam.
"U" channel formed.
"U" channel clecoed in place.
Final trimming on windshield.
New throttle cover installed.
Groove isn't wide enough for the throttle lever to fit.
Univair made them an 1/8" too narrow. Verified by talking to their engineer. Fix is in the works.
Filed the groove to where the bend needs to be and rounded the corner on a piece of steel to form the edge over.
Before forming a new edge with a wider gap.
Radius ed steel plate.
Plate in place.
Clamped to hold.
Part finished and fit.
Firewall holes cut and routing laid out.
Horizontal stabilizers covered.
Tube for shoulder harness welded in.
Fresh air vent riveted in.
Fresh air vent door installed.
Fresh air vent box.
Floorboards, rudder pedals and brakes in.
Trim system installed.
Jackscrew and trim and stringers installed.
Stringers and trim installed. Fabricating fuel lines.
Left wing through silver.
Right wing taped.
Left wing painted.
Right wing covered.
Installing fuel system.
Fabricating new fuel lines.
Dakota Cub fuel valve and Cub Crafters headerless fuel system.
New fuel lines installed.
Final fit of interior panels.
White Polytone base.
Newly plated and painted parts prior to assembly.
Assembled with new tail spring.
New tail spring with the old bent spring.
Trim goes full nose down and the bungee cable is the correct lenth now after fabricating a 1" shorter cable for the Dakota Cub jackscrew and yoke assembly.
Dakota Cub jackscrew/yoke assembly with bungee cable mount. Cable has to be custom made 1" shorter because of the new location of the mount to the jackscrew. Also if you use the hardware as listed in Dakota Cubs instructions it hits the tubes and doesn't allow full nose down trim. Used one size shorter bolt and a low profile "Jesus" nut for clearance.
Vertical stabilizers covered, stitched and taped.
Door covered and taped.
Elevator with one side covered.
Stabilzers and rudder covered stiched and taped.
New brake lines installed and ready for cover.
Tail feathers in silver.
Door, gear and rudder ready for silver.
Rudder, gear and door through silver.
Tail feathers, gear legs and door painted white polytone.
Tail feathers in final paint.
Wet sanding lift struts.
Lift struts primed, painted and put away for safe keeping.
Paint removed from fuel tank and surface corrosion found after noticing bubbles in the paint.
Close up of the corrosion pitting on aluminum fuel tank.
Another spot of corrosion starting.
Area cleaned of paint and etched to kill the corrosion.
Deep pits probed for soft spots.
Hole in the fuel tank from corrosion under the primer.
Old antenna hole on back of left fuel tank cover that needs patching.
Another old antenna hole on right fuel tank cover that needs patching.
Cracked screw hole at trailing edge of fuel tank cover.
Laying out the stripes.
Ailerons prepped, primed and painted.
Ailerons, lower shock strutc and misc. cowl supports painted.
Stabilizers and elevators installed and rigged.
New fuel tank covers damaged in shipping.
Box doesn't show much evidence of damage.
Patch welded over the corrosion on the fuel tank.
Prime and paint.
Flat black boot cowl and wing root covers.
Laying out stripes.
Tail assembled and rigged.
Instruments and plumbing removed.
Doublers riveted in bungee cover ends.
Bungees going on.
Boot cowl striped and other misc. painted parts.
Electrical panel lettering going on.
Electrical panel lettering.
Oil pressure flex hose like new now.
Dry rotted fuel cap gasket.
New gasket installed.
Amp meter prior to paint.
Circuit breakers prior to clean up.
Radio rack built and secured.
Vortex generators going on.
Vortex generators installed.
Panel powered up.
Caliper pin engagment of the brake caliper.
Not much engagement.
Someone added spacers behind the brake disc which limited the caliper pin engagment.
Proper caliper pin engagement once spacers were removed.
Paco inspected it.
Felt glued to the tubing to eliminate rattleing interior panels.
Interior panels installed.
Nothing keeping the seat springs from spreading apart.
Fixture for making the right size hog rings.
One half of a hog ring.
Hog ring formed.
Wing root fairings fabricated.
Wing root attach fairings.
Wing root attach fairings crack.
Wing root attach fairings bent.
10/32 Clipnut on belly fairings.
Southco fasteners on belly fairing.
Inside the belly.
Belly panels installed.
Belly panels installed, less four screws in the middle.
Aft belly panel.
Southco fastener with nylon wear washer to eliminate hole elongation.
New tab sewn on and rips repaired in rear seat cushion.
Windshield and sktlight installed.
1981 fuel line is a bit stiff and a bit worn.
1Q81 Got good service out of this fuel line.
New nose bowl installed.
New cowl doors fit.
Need to do some triming for the Hot Rod Muffler.
Need to patch this crack in the airbox scoop.
Same thing on the other side.
Skylight, wing root panel and fuel gauge installed.
Plugs for the push to talk switches on the sticks so they can be easily removed.
Doublers riveted over cracked corners of air scoop.
Old and new headset jack housings.
Catch for the cowl door prop rods on old cowl doors.
The stiffeners on the new cowl doors are wider.
Material to make the brackets wider.
Tabs weldes on.
Corners rounded to fit the cowl former channels.
Rivet in place.
Crack in the airbox housing.
Patch rivet in.
Crack in the air scoop corner.
Doubler riveted in.
Filling the brakes.
Window cut out for fresh air vent.
More primed parts.
Bottom wing root fairings fit.
SCAT hose installed.
New fuel line with fire sleeve installed.
Inspection plates painted white.
Cowling painted white.
A little brass corrosion. Cleaned with vinegar.
Parking brake placards cleaned up with a little vinegar.
Leading edge wing root fairings fitted.
Parking brake push/pull rods installed.
Wing root fairings with nut plates riveted in to eliminate sheet metal screws.
Shoulder harness installed.
Wing root fairings.
Worn out hole in the air filter cone with a patch cut out.
Putting a little crown in the doubler/patch.
Shrinking the edges a bit.
Pretty good fit.
Doubler/patch clecoed in place.
Riveted to gether and ready for primer and paint.
Windows, door and wing root fairings installed.