DISCOVERY Mark Evans A Plane Is Born E06

in my workshop and I’m building my own light aeroplane this my plane building chums is a cockpit module you flip the page and it begins to look a little bit more complicated building plane is much easier than you might think it’s child’s play welcome to a plane is born there’s good news and there’s bad news the bad news is I had to sell the wife’s engagement ring the good news is though I’ve used the money to have this built it’s a special bespoke trolley for my fuselage and it’s really important because I’m going to be putting the cockpit module in here and I need to actually put weight inside this now and if it’s not properly supported I’ll go straight through the bottom so Pete mate give us a hand with this this is so incredibly light I mean remember the whole plane when built with engine in it everything weighs about the same as 3 and a bit big bloke about 700 pounds which is incredible so it really is amazingly light that’s on good man excellent wheel it over your way a little bit getting out of the way isn’t she gorgeous tail plane this half of the tail plane to starboard side to the right-hand side the airplanes had quite a lot of work done to it just to remind you started off as a foam core here and then all this lot and on tops being laid on has fibreglass the lay up that’s all finished job in here now is to cut out part of this tail plane which is a trim tab which makes the whole thing easier to control let me just show you where it goes on the plane there so you so you know that will go on there like that and then when you want to go up it’ll go like that when you want to go down it’ll go down like that ease in it then she comes look at that fantastic little trim tab and a beautiful cut on it next job is to bond in a plywood reinforcing plate which will go in there like that and also to do some reinforcing all along the edges of this and the edges of the tailplane here where the hinges will be to attach this trim tab it’s all fixed together what happen is when the whole tail plane moves up this will move up as well like that now while that laps been going up I have been busy doing a bit of work and you know my wife lost her engagement ring she’s now lost the kitchen as well because I’ve had to have one of these builds it’s a jig for this bit kit which is the tailplane talk to you which will have half the tailplane fixed to this side half the tailplane fix to this side but you need the jig to be able to make sure when you’re laying up the tailplanes in terms of actually setting them up on here they’re absolutely exact in terms of the way they lie so I’m going to use this inclinometer to be able to make sure everything is nice and true when I put it on so I’ve got this little jig block here which says on the tail plane level board so I know that’s the right one and if I put the in kilometer on here even though this isn’t absolutely level and true I can set this so that it’s a level datum so it’s a zero so everything else will then work to this level when I’m setting it out and calibrate it so that that level is zero there we go lovely so take this across ya know and what’s really a little bit tricky about this is that there are two metal bushes in there there’s one there and one in this rib here and that’s got to line up with the tube and according to the manual Arcas what I’m to see if you’re thinking that this needs to be a right angle to this tube it doesn’t like that now I’ve got to do next is the whole point of doing this is because I’ve got to line this up so that these little lugs here I’m going to need to go into bushes in this reinforcing place I’ve got that I’m gonna mark it up so that’s the whole purpose of doing this because all the effort from the controls to turn

these tailplanes it’s going to be transmitted through this arm here on the torque tube and that will then slot into bushes one there and one there and then when I talk to you turns the whole thing in turn so that’s like that now I need to do is get tail plane incidence block which goes on there like that I get my in kilometer back I’ll press another button because then it has a sound because it’ll tell me when it’s got to the datum point I set up just a minute ago put that on there like that and just get my shin yeah never throw these bits and weibo because you can always use them and what I’ve got to do just get this absolutely level to the datum when it hits the datum it should make a noise like that but it’s incredibly sensitive okay so I’m close look at that slips in a treat beautifully level fantastic now all that remains to be done is to take the whole thing to pieces again to get ready to bond in those little black bushes then put it all back together again with the bonding agent in place so it’s going to glue but before it goes off obviously you need to set it up so that everything is perfectly level to the same data miu’s before and then it can all be left right marked we’re gonna look at the circuit today so this will be very busy for you the circuit I mean that’s the thing that since learning to fly everybody i knows i’ve anything to do with flying they all talk about the circuit how many times you’ve been around the circuit until then a circuit to move something you drove a racing car around once you’re cleared for departure and we can accelerate the aircraft and remember looking for rotation between 60 and 65 knots and we’re not ready to add that right rudder for that slipstream effect and as the wheels come off the ground the tendency was for the aircraft to yaw to the left due to these lack of friction air from the tires so it needs an extra bit of right rudder as it becomes unstuck climbing at 75 knots so with their nose roughly on the horizon and we’re looking to climb on the runway heading to 600 feet at 600 feet we do a climbing turn and remember only 15 degree angle about maximum during filings to position ourselves crosswind if you start the attitude power trim top of the client procedure at 950 feet you’ll be level by the time you sorted it out hopefully at 1,000 feet circuit height now what we’re looking for is a 45 degree angle to turn to track the reciprocal along that way and that’s called downwind at this of being the upwind end we can start the pre-landing checks the [ __ ] you are we know the bond Fitch brakes undercarriage mixture pitch instruments carburetor heat patches and harnesses flaps etc etc your mnemonic for the pre Landing checks brakes of pressure a break but get out so when that’s the 45-degree angle you’re about the right point to make a 30-degree angle a bank turn because we’ve got no flap etc accenture we’re all nice and clean so we can do a medium level turn on to what’s called the base leg now we can start our let down to land now first thing we’re going to do is carburetor heat goes to hot power back to 1700 roughly just by what it sounds like don’t stare at the dial 900 stages of flap my target pointer now we use the philosophy which says during your approach power is responsible for your rate of descent and attitude controls your airspeed so if you slow lower the nose if you fast raise the nose so we’re flying the aircraft down and at the round adds

raising the nose to for the aircraft level and what’s your level which is not reducing the power reducing the power so we get a positive contact on the main wheels the power okay many questions are marked most obvious one you say you touch down but you don’t touch down really cuz you’re straight up and round doing it again how many times you get rid of keep an eye on your eyes and when they’re suitably glazed over then we’ll call it a day but sensibly we need to be doing this around about 6 or 7 times just to be able to get you into the mode and but not exhaust you too much just need to make sure we’ve got a stretcher ready for thee when you go flying for lesson the idea is this is cast clipboard and you should come back with it completely empty apart from another few little figures up here there should be nothing written down here now this is all due to the fact that I got it wrong isn’t it well actually it was going really well writing to the point we started the airplane what I write into the book we took off first time okay really really well it was generally good the height holding was quite poor though on the downwind leg and that’s quite scary here because of the helicopters a nun radio up to 750 feet we were sort of flirting around with the 800 feet mark how do you feel positive much more sermon it is definitely what you said about the first two or three lessons frankly I got to put it into the third one I thought this is too much I can’t you know I can’t get my brain around all this and there’s so much to think about and you actually worried yourself stupid you driving home thinking I’m gonna crash this thing because I do not know why I’m doing here but suddenly some of the bits of pieces start to actually become second nature so you can then add on a little bit extra each time and that last trip round was really good fun I mean it’s really actually looking out the windows and enjoying scenery a bit as well as flying which is nice so we’re getting there throwing an extra check that wasn’t recorded welcome back to a plane is born or should I say my plane is born this is one of the wings oh we have a look at this down here cuz I had a bit of a problem fixing all this lot together which is the aileron control but it’s all working beautifully now look down here we have a fully functioning aileron which is just the business one little change down here is I’ve had to put on these things one there one there called mass balance arms inside here you can see the dark color that’s actually led in there as a weight and the idea is that it balances the aileron so that when we’ve finished and the plane is actually flying this is perfectly balanced so that when you control it you can move it but it doesn’t actually flutter around in the breeze because if it flutters around in the breeze the wings fall off very important that doesn’t happen so those will be finished off later and we’ll balance that up and the whole thing’s painted the next job is flaps very easy really Pete we’re going to turn the wing round mate he’s so slow he’s old now I need that this end and 180 degrees okay that’s the fastest you’ve moved in ten years like that alright so here this is where the flap will fit these are the plates that will hold the hinges on for the flap to move so next thing is to assemble the flap and the reading today is taken from the build manual issue one page nine verse 10 and the factory did say to the idiot builder build yourself a flap hinge do it according to my instructions and all will be well joking apart actually the manual is really useful because the exploded diagrams are idiot proof because if you follow the line through of everything you need you know you’re going to end up with this bolt then a washer everything goes in the right order check strap goes on then another washer what this does the check strap is to make sure that when you actually take the wing off the airplane when you’re packing out putting on your trailer and then wheeling into your garage is that the flap doesn’t just drop down and kind of swing around it’s actually got this

strap to hold it from going too far I tend to over tighten everything I’ve sheared off loads and nuts and bolts in my time but just take it nice and easily there we go it’s a stiff nut so it’ll be absolutely solid and check straps should be able to move freely like that well they’re actually building the whole hinge is actually quite complicated it’s broken down into individual bits it’s not too bad because this is very simple now she’s putting these two plates together like that of these two bolts and it’s just got a block in between and then a washer and a stiff not either side the most important thing is make sure everything in the right orientation it’s very easy to get things upside down so you keep checking that with the picture if you’re not used to working from these kind of drawings as I’m not they can look incredibly confusing and the trick is really to focus down on the bit you want so ignore the bits you don’t want we don’t want that bit already done that bit up there in that bit down there so we’re focusing on the bit in the middle and then just follow through I know I’ve got to start with that bolt there and then follow the line that goes through your washer down here and up to all the parts in the right order are all in the line that goes through the middle of them down to that stiffness at the end you can get them all in the right order and that there makes it really really simple so there’s everything in a line we need that’s all set up this bracket is going to fix on there and all those bits are going to hold it together so first job is to get this tube through there and then you can sit on all the washers and spacers and it’s symmetrical both sides that case on the first and one of those each side little light washes and spacer tube both sides mm-hmm some of this is very fiddly and you do need three hands ideal because I haven’t got three hands but I’ve got an idea how to get this washer in here you need a magnetic screwdriver or put in your mouth ah tastes disgusting yeah I got one more to do tighten that up right that sorted next job is to build another hinge to go on here and hinge to go on here but they’re actually simpler because they’re made up of one plate rather than two so while I’m getting on with that take a look at the aluminium vans our v6 built by fellow KITT plane anorak Ollie burr kissed lots of pilots come from Sweden my craft is from a an American kid it’s advanced or v6 it’s made of aluminum riveted together it took me about three and a half years to build the aircraft and over that period I spent about 3500 hours that’s a matter fact is all the off-duty time I had and all the vacations and everything so I have a very understanding wife I come over from Stockholm in Sweden we have one of Europe’s largest home builders Club at an old military I have been outside Stockholm cold Valkyrie we have about 40 or 45 home builder and totally about 80 aircraft in the club I have also built an actress before which was a really real challenge because that was a composite aircraft built from scratch I just bought a bunch of papers with a lot of texture there was a real challenge I mean this was more equipped and very well done drawing something so I didn’t find any really difficult things about this is a tremendous aircraft I mean it has saved me a couple of times from because I’m not a very skilled pilot but the aircraft is very forgiving so it helped me getting out of troublesome situation feeling this aircraft today would cost me in the amount of almost 400,000 Swedish crowns we see which is about forty thousand dollars and you can raise that money once you can tell your wife I need this money because I want to

be in the north end okay once doing it again I think it’s a bit difficult really when you have decided to build an aircraft stay on the project don’t do anything else during the project because otherwise it will never be finished it’s a tremendous challenge and when it’s finished you have something that not many people have you know you will be very happy with what you what you have accomplished here is with hinges attached now what I got to do next is drill out the plates that are in the wing here to bolt these hinges to the wing itself right now anyway oh good timing can I put this on there right a couple of inspections first before it does glue on right flat on the leading edge probably a check that you’ve put there right reinforcing plies in the right position and the quality of the lap so we’re checking that you’ve put the bid brackets between the spa and the skins and the ribs the plates for the flaps there’s no voids so how you know you’re checking it purely visual if it’s too dry they’re white flecks if you’ve got voids they sharp as a silver fisheye if it’s resident rich it’s too shiny and slick but this is yeah you do know you’ve you pick it up we’re also checking the push rod that we have to clearance in the ribs otherwise it would Jam if you were pulling algae and you can the wings Bend you don’t want to jamming up ruin your whole day so you happy with that yes forever yeah it’s perfect yep it’s a good one that’s why I like to hear another great day’s work and I’m one step nearer my dream see ya