|

FALCON, COLORADO
RECENT PROJECTS |
 |
| |
| 2007 |
| 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 |
 |
| Trailing Edge Fences help keep the
ailerons alive at slow speeds |
| |
 |
| Airflow Performance fuel injection
on my O-360 |
| |
 |
| The fixtures above are on my own
Cozy and are not as refined as those below that are on on a Long-Eze but
are doing well with over 150 hrs on them |
| |
 |
| The fixtures above utilize a
separate plate on the inside of the strut to make it easier to install.
|
| |
| 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 |
 |
 |
 |
 |
| |
|
|
|
|
|
| |
|
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 |
|
 |
 |
|
 |
 |
|