Bearhawk N813Z Build Reference
This wiki is mainly to keep personal build notes. My Bearhawk is a 2007-era quickbuild kit from Avipro. I began my project in January 2014. In order to have the airplane I want, I've decided to do many modifications to the original design.
Update November 2023: In October 2020 we pulled up anchor from Oregon and moved to northern Minnesota. This put the project into an indeterminate status where it was just stored in a hangar in Oregon. That, combined with a focus on getting my other aircraft (a tailwheel Pacer) flying, has caused more delay.
I will continue using this wiki for my main log and build notes. In the meantime I am focusing on the restoration of N6956B
Contents
Fuselage
Wings
Engine & Propeller
- [[Engine]
- Propeller
Electrical
Engine related
Lighting
Wire and components BOM
| Purpose | Wire spec | Size | Feet | Acquired |
|---|---|---|---|---|
| Starter wire | M22759/16-4-9 | 4 | 20 | Yes |
| Bus manager supply | M22759/16-10-9 | 10 | 20 | Yes |
| Main ground | M22759/16-8-9 | 8 | 10 | No |
Instrument Panel
I decided to make my instrument panel from carbon fiber, primarily to avoid riveting angle to the profile of the aluminum version. I like the Super Cub style panels that have a formed flange for which to attach the glare shield and boot cowl. The best way to do this was to do it with carbon fiber because it can be molded.
I build my mold from 3/4" MDF and used 2 layers. The top has the cutout shape of the panel. I used Bondo to form a fillet around the perimeter, and sanded it smooth, then primed and wet sanded. The next step is a glossy top coat to get the best carbon layup finish.
All Garmin panel...getting excited.
Panel layout
This is TBD.
Panel Construction
Because I want a smooth, filleted flange atop the panel like a die-pressed factory Cub panel for attaching the glareshield, I figured one way to make that happen is to use carbon fiber. I created a mold from MDF based on the kit panel shape and added a 1/4" fillet with Bondo. I then routed it with a rounded 1/4" bit to make a perfect fillet. Several coats of primer and wet sanding to get a smooth finish, and I have a nice mold.
The next step would be using a vacuum infusion method to press the carbon fiber layup.
Some years later though, with the advent of easy laser cutting, I've determined that it's hard to beat an aluminum panel and will likely just go that route, using 6061 and welding my flange on instead of giving up 1/2" to use riveted angle.
Interior
Exterior
Considerations here are fabric & paint system, and of course paint scheme. More...
Vendors
Coating
https://www.allresistantcoatings.com/
Wiring
Regulatory
N-number
Reserved N813Z — March 2023 Reserved N808ZX — February 2024
Builder's log
This wiki should become the builder's log.
To do:
- Add more photos of milestone actions
- Outline departures from standard BH build