Monthly Archives: August 2017


Fastback 51

Not a ton to report tonight. In the photo below you can see the process of doing the final trim on the right side. This varied from a 1/4 inch near the rear to less than 1/8 at the front before the taper to the nose begins. The airport was dead when I got there, and I had no one to help me move the canopy. Considering the edges are still rough, I’m more-than-normally concerned about cracking the canopy in transit. It is too unwieldy for me to comfortably and safely move by myself. To address the problem, I trimmed it in place by propping up a bit higher with some spare wood. I used some clamps to keep the shape of the canopy. It tends to bow out under its own weight, and that also seems to be a good opportunity for a crack to develop somewhere.

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After I got the side trimmed, my hangar-mate Jim showed up to do some flying, and I was able to have him give me a hand moving the canopy. I began sanding all the edges and worked by way up to 220 grit before calling it a night. I will likely do a little more sanding and perhaps one higher grit before I go about drilling the holes for the attachment. This way, I can do the high grit sanding and polishing of both the edges and the holes at the same time.

The canopy fits perfectly. There isn’t one area where I have over-trimmed, and with the final sanding and shaping the reciprocal is also true.


Fastback 50

After my last session of priming the canopy skirt, it finally became time to look towards cutting and fitting the canopy. This post encompasses the work of several sessions in the shop over the course of the past week. The canopy skirt looks great – I am really proud of how its turned out.

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Canopy fillet

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Canopy skirt

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Left canopy fillet where the latch mechanism will reside.

The first step in cutting the canopy was to gather my tools, plan the cut, and make measurements. After some research I decided to use a 506CU cutting wheel on a dremel. Any cutting disc WITHOUT teeth should work fairly well.

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Dremel CU506 cutting disc.

Keys to a good cut: 1) Make sure its a warm day. Anything over 70 should be fine, but the warmer the better. 2) Use the proper tool – don’t use a saw or any blade with teeth. 3) Take your time. 4) Measure at least 4 times.

There are essentially two initial cuts that need to be made. The cut along the red line at the base of the canopy, and the rear cut for intersection with the fastback turtledeck. The first cut, in terms of difficulty is rather trivial. This is the cut along the base of the canopy. The second cut, at the rear of the canopy, requires careful measurement.

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Basic outline of cuts to be made.

Measurement. Showplanes instructs you to measure a line 77 inches from the front center of the canopy (on the pre-marked red line) and 72 inches along the side. The canopy itself isn’t necessarily perfectly true, and the extra material is certainly anything from square or equally spaced, so determining the exact center of the canopy can be a challenge. I measured in both directions around the side and used my eyeball to mark the center. This ultimately resulted in about 1/2 inch disparity between the left and right marks at the base. My friend Jack and I debated what to do about this. Certainly you could move the center mark 1/4 inch and level it out, but again, with things not perfectly true you’re still not guaranteed to be right on. In the end we decided to cut an inch less (moving the cut rearward). We could then put the canopy on the skirt and see the true fit.

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Trimmed to pre-marked red line

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Marking the rear cut location with tape

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Canopy after initial trim

Ultimately this was unnecessary. The 77 and 72 inch measurements were conservative. Had we made the cut at that point, we would still ultimately have had to trim at least another inch if not two. After we trimmed the both the base and the rear of the canopy we placed it on the canopy skirt and both on the plane. After reviewing the fit, I was delighted to find that I had not made the un-repairable error of trimming too much. Quite the opposite in fact – we had plexi to spare in every dimension. The question was then, which area to trim and fit first? I settled on the front of the canopy. The front will require shaping to match the curve and to be far enough aft to intersect the existing fairings.

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Initial rear cut – 2 to 3 inches aft of actual cut location

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Initial lower left cut. 1/2 inch to 1 inch extra.

My thought was that the front of the canopy, by virtue of its angle coming to a point was relatively set in stone. It must touch the skirt at the intersection points which thus dictates the forward/aft positioning of the canopy. Without shaping this gives you the distance, but further shaping could slightly affect the rear angle. So, in short – shape and fit the front first. This will provide the proper distance to trim the rear of the canopy. After you trim the rear, the canopy should be seated in the proper up and down position allowing trimming the sides. Trimming and shaping the front was a slow and iterative process. I took my time and got it right.

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Front intersection after trimming and shaping to match curve

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Second photo of front intersection post shaping

Trimming the sides is, perhaps, the most iterative portion of the trimming. The canopy is a circle that cannot lay flat while it isn’t fully trimmed. As you trim the canopy, the radius slightly reduces and thus your trimming dimensions reduce.

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Left lower cut line marked in tape

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Close up of left cut line

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Post cut fit

My technique here was to position the front and rear of the canopy in their final locations and centered, and then tape them in place. I then taped the canopy as tightly in place as possible and used tape to mark the trim of both the left and right. I only trimmed the left side. After trimming the left side, I again put the canopy back on the skirt and this time I was able to tape the canopy in position on the front, left, and right. As predicted, this reduced the radius and resulted in the trim line on the right moving about 1/2 to 1 inch! Had I trimmed both, I would have still had to trim the right again.

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So, now I trimmed the right. And, again, placed it back on the skirt. You’d think it’d be a perfect fit, but again, a small change meant I still needed to trim a little more.

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Right side ready for trimming

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Right side after trimming

Unfortunately, I’m still off by about 1/8 to 1/4 inch when the canopy is squeezed into its final position. I will evaluate options in my next trip to the shop.


CFI-I Add-On Practical Exam Notes   Recently updated !

In February, I completed my CFI practical exam with Designated Pilot Examiner (DPE) Mike DeRuggiero. It was a thorough and complete check ride. The oral was nearly 6 hours and then a 2 hour flight. At the end, Mike said that my performance was above average and he thought I’d make an excellent instructor. It was nice to hear, particularly considering I’m not nearly as proficient as I once was. Getting back to a decent level of proficiency after a gap of many years is a challenge. In fact, I will likely never reach the proficiency I had in 2007, but I digress.

Immediately following the CFI, I put my sights on the CFI-I. Unfortunately, I was very tied up with work, and running out of GI Bill funds to allocate to the process. Between the February CFI Practical, and the July 30th CFI-I Practical – I only logged 4 flights in an actual plane. Three of these were in the Piper Archer. Originally, I was scheduled to take the CFI-I Practical in early June, but then the Archer went down for maintenance. I rescheduled for later in June only to find out the Archer would still be out of service. My back up plane, the Piper Arrow, was also down for maintenance. I rescheduled for July 30th. Surely, one of these two planes would be back up after two months? Regrettably, neither were. I was left with a choice, either cancel the check ride for the third time, or take the check ride in a plane I hadn’t flown recently. I opted for the latter. They had a 2002 C172S available for the day of the check ride, and I was able to log one preparatory flight the day before the practical exam. I was quite worried about this. Sure, I’ve flown a Cessna, and yes they fly at the speed of smell, but going into a check ride of any type with unfamiliar equipment is not a recipe for success. Further compounding this was the GPS, a KLN 94. I had never flown behind a KLN 94. The Garmin 430 is frustrating enough from time to time, and I wasn’t eager to learn a new system.

Luckily, the KLN 94 is fairly straight forward. In fact, I would say that its user interface is more logical and straight forward than the 430, even if the unit as a whole is slightly less capable. In the end, I wound up doing the practical in with an airplane that I had flown twice in the past 12 months, and after a nearly 7 week break from flying. Because of this, I was more nervous about the check ride than I would normally be. In the end, the nerves were unfounded. The check ride went smoothly.

The oral portion of the exam lasted between two and three hours. I lost track of exactly when we ended as I needed to get lunch, preflight, and have the plane fueled. As expected the oral exam with Mike was by the book. Many CFI’s avoid Mike DeRuggiero as a DPE. He has a reputation as giving very long and tough oral exams and being a generally tough and intimidating examiner. Mike is certainly by the book, and he should be. But he is by no means unfair or unpleasant, and he certainly doesn’t play games. Quite the opposite in fact. I find Mike to be polite and knowledgable. I have walked away from both check rides having learned, and that is an important point. Even during the exam, Mike is eager and willing to share his knowledge.

The oral exam followed the PTS rather dutifully. He quizzed me on endorsements and regulations including requirements for the instrument rating. He had me prepare for a student undergoing an Instrument Proficiency Check. As I knew this was a scenario ahead of the check ride, I created a course on my Moodle instance at cfi.papalimabravo.com that provided direction and materials for a pilot under going an IPC. Part of this material included a survey on the pilot’s aeronautical history. The week before the practical I sent Mike a note telling him I had created an account for his pretend IPC student, and that I would ask any pilot flying with me to complete the survey on their aeronautical history so that I could tailor the IPC accordingly. Mike followed suit. He logged in and completed the survey. With this information I designed a course of instruction that included preparatory work, ground work, and the route of flight. I made sure that the tasks outlined in this contained the minimum IPC requirements from the new ACS.

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Screenshot of the IPC page including the Guidance from the ACS

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Survey for the pilot’s Instrument Experience

 

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Simulated IPC Agenda

This is a good point to emphasis the obvious but seemingly often overlooked. The CFI and CFI-I practical exams are less about how well you can fly and much more about how well you can teach. Confidence, good instructional technique, well prepared materials, and a positive professional attitude will go a long way towards success. If you are a pilot preparing for your CFI practical – do not neglect the teaching part of training. It is by far the most important skill the examiner is assessing. Ultimately the examiner is determining if you can safely teach others.

Topics covered during the oral exam included, the vacuum system, pitot static systems, ATP instruction considerations for a CFI-I, and a detailed discussion of VOR tracking. The VOR tracking included discussions on holding entries and techniques as well as how to instruct brand new students on VOR tracking. It also touched on localizer tracking and localizer reverse sensing and how this compared to VOR tracking. The operation of VOR ground stations and aircraft VOR equipment were also examined. We covered GPS components, IFR approaches, and charts. Mike simulated that he was the pilot doing the IPC and demonstrated to me how he would plan for the flight I had assigned. Mike used Foreflight for this demonstration, and for the most part the pretend-IPC-pilot hit all the major planning considerations. However, his planning order was a bit convoluted. He started by charting his course, and then looking at weather and adjusting from there. My critique of this was that weather should be the first consideration, as it will affect your decision as to whether or not the flight and route is even viable. After weather, I would generally look at NOTAMs. NOTAMs could also greatly affect the route selection. Approach facilities could be out of service, or minimums could be temporarily raised (the second was true for the intended route of flight and naturally I had done my homework and knew this beforehand.) I left my critique there. Sure, I could go into every detail – but the simulated pilot clearly knew most of it, he just needed to re-cage his process. Mike seemed very happy with this response. You do not need to show the examiner you know everything – again he is testing your ability to teach as much, if not more, than your knowledge. A new student will be hindered by overly long or complex explanations.

When the oral exam was complete, I told Mike I would need to get lunch before we flew. I hadn’t had breakfast and with the early morning, I knew I’d need some calories. I ran out to grab a quick bite and then did the pre-flight. We discussed the flight portion in detail before going out to the plane. As the route we would fly was not what I had planned for the pretend IPC, I asked Mike for some time to study the charts and do my pre-flight planning. He gave me all the time for lunch and planning that I needed. The pretend IPC I had planned was based off a recommendation from Jason Cobb. It started with the ILS 26 at KMRB and proceeded to the VOR A at KOKV and ended with the RNAV RWY 5 at KFDK. However, Mike wanted to take off from KFDK, perform the unusual attitudes, and proceed to the RNAV RWY 16 at KDMW as a coupled approach. We’d then do a circle to land and proceed direct to EMI for the VOR RWY 34. This would likely be partial panel and end with a missed approach back to EMI and hold. Following the hold at EMI we’d return to KFDK for the ILS 23.

The actual flight was spot on to our flight plan. There were only a few changes. He flew the initial take off as an instrument take off under the goggles and had me critique him. No critique was necessary. He flew the instrument takeoff as well as most people perform a VFR takeoff. We then setup for unusual attitudes and he had me take the foggles and he put me in an unusual attitude. No sweat here. Then the coupled approach. I was a bit worried about this. After all, I had exactly one flight behind this GPS, and this autopilot. If it didn’t work the way I wanted, my ability to troubleshoot would be limited. The procedure turn entry to the RNAV 16 at KDMW is a holding entry. I set the GPS up for the approach as well as the autopilot, but neither the GPS nor the autopilot grabbed the holding entry leg. Shit! Just what I was afraid of. Well, there was nothing for it, so I pointed out that it hadn’t picked it up properly and switched to heading mode. I used the heading bug to enter the hold. When established on the proper final approach course I reselected the leg in the GPS and it finally armed with the autopilot and flew the approach. I was a bit sloppy with my power settings through the approach. Circle to land was easy and we broke off before even turning base. Then it was straight ahead to EMI for another holding entry for the VOR approach to KDMW. This was, as foretold, a partial panel approach. Again, easy day. In a slow stable platform like the Cessna, partial panel isn’t tough. I was, however, sloppy on my power settings again. Missed approach back to KFDK for the ILS. KFDK was busy. There was a lot of traffic and Mike was great at this point making sure we each knew what the other was doing and de-conflicting VFR traffic with tower. This is an area where things can get very messy, particularly in training, without clearly defined roles and good communication. The ILS approach I did was without a doubt my strongest procedure of the day. I had that localizer and the glide slope absolutely pinned dead center all the way down to minimums with a substantial crab for a 90 degree crosswind. It was a great note to end on. After landing, all that really remained was the paperwork. Mike did show me around his Grumman Cougar he flew out to the checkride. It was in great condition, and I’m excited that I’ll be doing my multi-engine add on in the same model starting next month.