questions about the LegalEagle

[sierra_bravo]

Hello everyone,
For some time now i've been interested in building my own ultra-light for 2 (main) reasons. 1st to learn more about the construction of fabric and tube aircraft(my favorite type) and 2nd to be able to fly affordably compared to renting something similar to a Citabria.

Before I start to plan the cost and build, I had a few question about the Legal Eagle.

One major concern I had was welding,  is it a safe idea for a person with very little welding experience to attempt to weld a aircraft fuselage? And if it is a good idea(although i suppose it depends on the welder) what type of welding would work best for someone with very little experience, oxy-acetylene, mig/tig, hire someone?

besides that, my only other major question at the moment is, besides a 1/2 VW what other engine options are there, and would direct drive 2 stroke with a vibration reducing mount be a sensible option? 

Thanks in advance 
-Sam

[scottiniowa]

Hello everyone,
For some time now i've been interested in building my own ultra-light for 2 (main) reasons. 1st to learn more about the construction of fabric and tube aircraft(my favorite type) and 2nd to be able to fly affordably compared to renting something similar to a Citabria.


Before I start to plan the cost and build, I had a few question about the Legal Eagle.

One major concern I had was welding,  is it a safe idea for a person with very little welding experience to attempt to weld a aircraft fuselage? And if it is a good idea(although i suppose it depends on the welder) what type of welding would work best for someone with very little experience, oxy-acetylene, mig/tig, hire someone?

besides that, my only other major question at the moment is, besides a 1/2 VW what other engine options are there, and would direct drive 2 stroke with a vibration reducing mount be a sensible option?

Thanks in advance
-Sam

Sam,  I don't think you could really compare flying a Legal Eagle or XL version, with a Citbria rental  Nor any other rent-able aircraft.  Just not even close.

I feel I could teach anyone willing to learn, how to weld.  And could teach any of the methods. But in your case it should be gas/or tig... and this of course has been debated on every aircraft building forum out there, so a little research will turn up ALL OF THE DETAILS   And there are very good video's or you tube lessons out there.  I would say out of every 10 students (young or old) I find one willing to practice to really become competent, or good, or good enough. Sometimes it is the teacher, but most times it is the willingness to practice. So it is a pretty simple matter, practice-practice-practice. 

And your engine question, really congers up the stories of 1 change makes 10 more.---  I would suggest, if you have a thoughts of a different engine, than what is recommended, then build/fly the aircraft that commonly surrounds the "other" engine you may want to fly behind or in front of.   

Best of luck down your road of research!

[CHARLES DEBOER]

I had no welding experience so I took an EAA welding seminar, three days hands-on,  in Georgia.  When I finished there was a definite need for more PRACTICE.  I found a community college that had a welding course and spent three semesters learning and mostly PRACTICING.  It is easy to learn but the confidence comes with PRACTICE.
I purchased a TIG welder and wished that I had a GAS welder for the very tight angles in the fuselage. You will need a gas welder for bending the landing gear brackets and bending the seat back.  So just go with gas.  They have been building airplanes with gas welding since the very beginning.
I have flown an ultralight for many, many years and have few hours in Citabria and Scott is sooo right there is no comparison to an ultralight.

[914pete]

Hi Sam,

This is my first time with O/A torch welding.  I have some experience with mig and arc welding as I like to "tinker" and repair things and I have to say, the torch was a little intimidating at first.  But I did plenty of research on the net, watched videos as well and asked questions here and it turned out not being all that scary.  I still prefer the mig for all my other non-aircraft projects but with A LOT of practice, I picked up the torch welding pretty quick.  I recently finished welding up my XL fuselage.  I must emphasize PRACTICE though.  Sometimes several weeks would go by before getting back on the build and I always would start off welding some scrap before working on the fuselage again.  I also rented a DVD series which helped a lot.  https://www.tinmantech.com/products/dvds/aircraft-aviation/  well worth the $16.50.

As far as equipment goes, I bought an O/A set from Harbor freight.  http://www.harborfreight.com/oxygen-and-acetylene-welding-kit-98958.html  and actually with a coupon, I paid less the $100 and it came with a cutting torch and some other tools.  Now, TM Technologies above offers midget type torches and light weight hoses which I think would make things a lot easier as the HF torch and hose is a little clunky and tough to get in tight spaces but its working fine.  I've had no issues at all with it.  One thing I wish I did though from the get go is buy the gas tanks rather then rent them.  I thought I would be done much sooner with the fuselage and really am ending up paying more to rent the tanks.

As far as an engine goes, this is my first aircraft project, I'm sticking to the plans and will eventually purchase a 1/2vw.  One thing I learned over the years, and having no experience with any of this, if it ain't broke, don't fix it.

[XL-C-100]

Sam, 
I would have to agree with Scott 100% that learning to weld as with learning most things it's more about the desire to put in the work. Since I learned to gas weld several people have come to me saying they wanted to learn, so I showed them the basics and told them to practice. After a few hours they set down the torch and didn't come back to it. What I am trying to say is you can most certainly learn the skills to weld up your own fuselage, It's more a matter of will you enjoy yourself enough to stay with it.

As for the engine choice I went down the road less traveled and installed a 4A084 Continental on my XL. What others will tell you is true.  There is much more time spent figuring out things like motor mounts, CG concerns, prop choices, control hookups, and so on. When I was all finished I ended up with something that was very affordable (less than $1000 firewall forward) and I was happy with but I will say if I had $4,000 to lay out for a motor I would go with the 1/2 VW and save yourself a lot of headaches.