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FALCON, COLORADO

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2007, A YEAR OF EAGLES, FLAGS, MOVIES AND BUREAUCRACY

BY BURRALL SANDERS

2007 was a very busy and interesting year at Freeflight. Below are some of the highlights of the projects we saw this year.
At the beginning of the year we were heavily involved in the production of

"The Cozy Mark IV" DVD that my friend Paul Drexler of 4D Solutions http://www.4dsolutionsinc.com/index.htm created for Aircraft Spruce.

                      

Above are some shots of the Cozy at work on the project.  I felt very lucky to have been able to participate as a subject ship pilot, Aerial Director and Technical Advisor. This was an amazing learning experience.  The camera ship is owned and piloted by my long time friend and neighbor, Richard Martin, flying his BD-4 modified for camera work                        

The DVD has an astounding sound track in 5.1 Dolby and was written and produced for this DVD. If you do not yet own it you can get the DVD from Aircraft Spruce at http://www.aircraftspruce.com/menus/kits/cozy.html if this does not motivate you, better get  your pulse checked!!

In March Kitplanes came to town to do the August cover story on Cozy N14CZ.

The writer was in town for two days then the photographer came.  The photographer said that the last thing the editor told him that it was for the August issue so there could be no snow!!  March on the front range of the Rockies is the snowiest month of the year. I was to fly the BD-4 as the camera ship for the mission and suggested that we go to Pueblo Reservoir where at least the water was not frozen and was blue.  So it was there and over the Royal Gorge that we got the great shots that turned up on the August cover and article.  My good friends Aaron Hollingsworth and Chris Woodard were pilot and co-pilot as well as the owners of 4CZ.  They did some excellent flying. Both guys from Kitplanes were professional and personable.

 

The  aircraft pictured below has been flying for several years in primer on the outside and no interior paint.  There are several innovative features that were incorporated by the builder. These include armpit scoops for downdraft cooling, unique exhaust ports and roll-over protection with rear tilting dual canopies.

Freeflight has had this aircraft for six months while we performed maintenance, repairs and re-worked the body fit and finish, cleaned and prepped the interior and sprayed Zolatone after we installed a fresh air ventilation system and a few personal touches for the owners., We also installed arm rest pads and control stick boots to match the existing seat arrangement (not pictured). The artwork on the belly was a very interesting and labor intensive job.  We needed to turn the entire aircraft over and then after the artist was done, turn it all back over without chipping or scratching the beautiful and expensive paint job. We expect to have it ready right after the first of the year 2008 for the anxious customers to come pick it up.

.

 
                                  
                        armpit scoops with downdraft cooling                                     forward tilting canopies          exhaust outside the prop arc
 
                                        
                                                                          Prepping the bottom side for the artist
 
                                  
                                                                     The artist does his magic
 
                                  
                                                                      After the clear coat is on....amazing (these photos do not do it justice!)
 
                                               
                                                                       This airplane also got an interior upgrade
Somehow, I managed to get a lot of work done on my own Cozy.  This year I  completed the contour and most of the finish sanding, engine installation and finished up the electrical system and have started taxi testing while I wait on the FAA to register the airplane. (20 weeks and counting) The plane is in primer so it does not pass the 15 foot test but is good enough to fly  off the phase 1 testing before I take it out of service this spring for paint. I am happy with the panel, it is engraved and powder coated aluminum, with Dynon ,Garmin, Trio and Lowrance.   Below are a few pics of the plane in the shop.

On January 22,2008 N139BJ was issued a special airworthiness certificate (Amateur Built).

On January 24 it made its first flight, two days later it made the second flight.  Initial test results are encouraging.  With only two hour of testing  the plane there are many things that are favorable.  Highest CHT is 385 and the coolest is 340.   Oil temps stabilized at 205...a little warm but acceptable.

 

                          
                          
  
                          
close up shots of panel attach backing plates

 

The Long-Eze below came to us for a new panel.  We got that done and it seemed to motivate the owner so he asked us to paint it too. Here are some shots of it. Stars and Stripes Forever!!

       

         

The panel is below, a good functional cockpit.  
Long-Eze with new panel  using Dynon, Trio, and Composite Design
            
2002, 2003, 2004 and 2005 and 2006 projects from here down  
STEEL ROLLOVER STRUCTURE ON  DENNIS PURDUSKI'S VARI-EZE         
              
Canopy Key lock installation  Vari-Eze
            
outside view         Locked                                 Unlocked
   
           Lancair Super ES               First Flight
                
                
   
                                
                                
and rudder pedals  
                                
and auto pilot servos,  
                      
and elevator push/pull tube cover in the baggage area  
                      
and door frame and door  
                      
                      
                      
                      
                      
                      
                      
                      
                      

This COZY III
is nearing completion of all structural fabrication,
soon to begin the finishing process

 

 

 

 

 
                                  
                Fuel line routing from front seat to  rear  
 

Another Cozy III is getting the wings aligned and bored

rear window cut outs      rear windows jigged in place
building the fuel           strakes   getting the curve
jigged strakes                  jig removed        
applying foam to leading          edges sanding to contour    
                                                    

A 300 h.p. VELOCITY XL gets canard and control systems, converted to fixed gear and is almost ready to fly!!

          

             

 Building the gear leg

fairings for retract

 to fixed conversion

 

 
UPDATE:  This beautifull Velocity XL was flown for the first time December 9, 2004 in Mojave California.  Burrall Sanders was the pilot.
The proud new owner has since flown it and has begun flying the test phase.
 

         

                                  

                             Crankshaft main seal retainer      

 
 

                             

 

A VARI-EZ gets new main gear extrusions after runway debris seriously damaged the originals

 

An EXPRESS gets near the tail close-out chapter

 

A VELOCITY RG gets a new, larger oil cooler
which required  a plenum and duct to be fabricated