In an effort to continue the fine work that Don Hall has done on the Falcon, I decided to complete a thorough mechanical inspection of the plane.

Upon finding several faults due to age that I considered critical, I have undergone a two year restoration of the flight controls systems.

I am offer asked when the plane will fly. Due to this question the answer and the planes new name is now Tuesday…

“It will fly This Tuesday?” No just on a Tuesday, is the standing joke.

 

An examination found all that all nylon, rubber, and plastic parts were compromised due to age.

Many of the critical bolts were thought be fatigued and subsequently replaced to avoid any in flight failures.

To date approximately 95% of the hardware in the plane has been replaced. Only aircraft hardware was used at a considerable expense. To avoid errors due to disassembly of multiple components, only one subsection was disassembled at a time.  Thus the painfully LONG restoration process went on.  The following photos will document the restoration process.

 

This photo shows the small nylon cables and steering controls. All of the nylon stop cables, spring retainer cables and mounting hardware were replaced

This photos show the primary retaining bolt for the control sticks. Note that the securing nut is missing. This was missing on both controls sticks. The securing bolts could not fall out due to hitting the pulley. The loose bolts did prevent the free movement of the cable pulleys.  There are numerous nylon pulleys located through out the plane. ALL of them were found to be hard and brittle and most of the bearing sleeves were contaminated and would not roll. Thus the control cables were having a sawing effect on the pulleys.   ALL of the pulleys were replaced in the plane.  All new parts are marked with red paint and listed in the building parts list.

New pulleys and hardware for forward control stick. The new hardware is mark in red.