Problem-solving is an essential part of the aircraft engineering process. Every day presents a new challenge to overcome. – Unknown
A Biplane Scratch Build project comes with built-in obstacles. It is an assumed ingredient, a required staple in the recipe, which includes:
- Plans/drawings from which a Biplane Scratch Build is formed,
- Materials consisting of steel tubes, various sizes of pieces of wood, steel plates from which brackets are cut and formed, aluminum sheets, and an endless array of aviation-grade hardware,
- an equally endless supply of tools
- space to work in
- and unforeseen obstacles seeded throughout the process
As an aircraft engineer, problem-solving is part of your DNA. It’s what you do every day
Over the past few years of working with a team to finish this Experimental Aircraft Association (EAA) Biplane Scratch Build, my father started in the late 60s, I have come to realize that overcoming obstacles is part of the fun. So what are these obstacles? Here are a few I’ve discovered:
Expertise. This project sat for many years after my father passed for one reason: I lacked expertise. Yes, I am a pilot and have assisted with a lot of maintenance on my Aircoupe, but this was way outside my wheelhouse.
Time. A project like this demands allocated, focused time.
Energy. Both mental and physical energy are required. There is a learning curve that puts a demand on one’s mental energy, along with some physical stamina.
The Unknown Gaps. Then there is that “thing”, that gap in information between the paper plans/drawings and the application. The assumed knowledge that designers think you, the amateur builder, have, and the knowledge you actually possess. This “gap” roams around popping up in the process a lot!
Solutions To Biplane Scratch Build Obstacles
I am fortunate to have a local EAA chapter willing to take on my project. The group of fellow EAAers that meet each week to work on this project is in itself a means to overcome the various obstacles that arise.
Expertise. The EAA is the same age as I am. Founded in 1953, one of its core functions is providing a network of knowledge to draw upon. From webinars to seminars, meetings, fly-ins, and networks, there are other aviation enthusiasts ready and willing to help.
In my case, the core expertise represented includes former airplane builders, engineers, other pilots, aircraft manufacturing retirees, and folks who simply want to see what building an airplane entails.
Time. We allocate one afternoon each week to come together and work on the project. There is something about making a commitment to others that enables that time to be preserved. Even on those occasions when much of the time is given to “figuring something out”, e.g., dealing with an obstacle, having others along is somehow encouraging.
Energy. As above, knowing I have a group of folks giving their time, talents, and expertise at a given time on a given day keeps me energized. Knowing others will be there to guide and assist provides a certain synergy that keeps the project going. A cup of coffee can also be a great help!
The Unknown Gaps. As I said, the EAA has almost endless resources to tap into. It may take time to locate and plug in, but it is there. In our local group, there are the sherpas who guide us in our work. Those who have:
- Built airplanes on their own, and have a sense of what to do in what order
- Read and interpreted a set of plans before
- The ability to learn on the fly and contribute simple labor
- Welding and metal forming expertise
- Documentation and bookkeeping skills
- Computer Aided Design and engineering background to work out details, the drawings lack.
Biplane Scratch Build Surprises
The latter is one of the most surprising gaps: realizing the shortcomings of the drawings. Beautiful and detailed, however, how to apply those details remains for the builder to figure out.
During a recent visit by a brother-in-law who works as an aviation engineer, I mentioned this to him. Not surprised, he said, there are always gaps between the design drawings and the application. Something called work notes fills in those gaps. There are notes on these plans, but there is a lot of assumed knowledge behind those notes.
Thus is the world of experimental aircraft. Having owned, operated, and maintained a manufactured airplane for over twenty years, this is a new kind of aviation. A truly grass-roots, knowledge-building part of the aviation world. It is called amateur building, but in my view, you are more informed than the average aviator once you have built your airplane.
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