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Justin Fletcher's L45-019 Lear45 (Retired!!)

(Original thread started on 05-08-14 by Justin Fletcher)

Greetings Hangar 45!  I've been a long time lurker here at Hangar 45, I've been browsing the forums off and on for 4 years or so. I have finally got to the place where I can start my build and make some progress. A little background on myself: I live in Jacksonville, Florida; I'm a real world pilot (PPL/INS/HP) and work at Cecil Airport (KVQQ) in Airside Operations. I have been around GA aircraft for years. I have a passion for business jets and the flexibility they provide the operator. Like everyone, I thought the 737 was the avenue to pursue cockpit building, but the price of a well built sim was way too high. When I found Hangar 45, I knew the Lear 45 was the right aircraft for me.

 

I am blessed to live in Jacksonville, only 20 minutes or so from Ron. We spoke on the phone and he invited me over to fly his sim and we flew a local flight from KJAX Jacksonville International Airport. Ron's sim left me speechless. Every detail was perfect, pictures on this site do not do his work justice. I was sold...I want my own airframe sitting in a bedroom!

 

My approach will be similar to Ron's: Build the base, the shell, and then populate the furniture and MIP. I am dreaming big for this project. Total immersion via audio, visual, and tactile fidelity. I plan on fiber-glassing the shell kit so it replicates the actual aircraft. I will utilize Lockheed Martin's Prepar3D. To date, I have completed the base, cockpit furniture (TQ pedestal, Center pedestal, & MIP stand). Last night I finished the lower control column for the dual yoke system with the Project45 poly kit. I think the dual yoke system is a great example of the effectiveness of Hangar 45. All the information contained in the build thread helped me purchase the materials, assemble the components, and once installed it should fit perfect in the cockpit shell.

 

Framing up the base. 2x6's, 3 in lag screws dimensions - 48" x 80":  This is the rolling frame with the casters installed. Each caster has a weight bearing capacity of 330 lbs and rolls smooth across the garage floor:

Justin 1

 

Cockpit furniture mocked up...pre Bondo and sanding with the Lower Column Assembly completed with Project45 poly kit. This a great looking piece, it's a shame pieces like this are hidden under the floor:

Justin 2

 

Snapped this photo this afternoon...base is complete. Furniture is sanded, ready for paint. Lower column kit needs springs and eye bolts, and is almost ready to be installed.  Looking forward to L45-019 or 020 getting assembled in my garage very soon!

 

(Posted by Ron Rollo on 05-12-14)

Hey Justin, welcome to the Hangar!

It was great meeting you in person and from what I can see from the photos, your project is right on the money. Besides living in the Jacksonville area, another huge advantage that you have is the fact that you have spent five years looking and learning at all the info that is posted up in the hangar. This gives you confidence knowing that your on the right track with the build. Looking good and looking forward to seeing the build progress unfold!

 

(Posted by Eric Tomlin on 05-19-14)

Hi guys, I had the great pleasure to meet Justin on Saturday up here in Waycross Georgia and it was wonderful. He's an excited new LJ45 builder, but he's also a great guitar player too!

 

(Posted by Justin Fletcher on 06-06-14)

Hey Guys, it's been a few weeks since I have updated my progress. The project is rolling right along...

 

First, I took my lower column set I assembled over to Ron, I was having a lot of friction at the pivot point of the lower column, the pivot action was not smooth at all. Ron looked at it and immediately determined I had the wrong PVC adapter in the A-Frame. I followed Ron to Lowes, we browsed through the PVC, and picked out the right adapter. After I buttoned everything back up, the column pivots smooth as silk. Ron also ordered and cut the 2.5" PVC for the column pieces. Other than springs and paint, this piece is ready to go:

Justin 3

 

I met Eric Tomlin a few weeks ago in Waycross, GA and purchased his MIP/Glareshield. Purchasing his MIP will no doubt give me a jump start when it's time to start installing panels and switches.

 

I also picked up a set of backer panels for the MIP from Ron. These will be used in the future to mount Eric's backlit panels. Here they are curing on the back patio after a fresh coat of Testors Gunship Gray:

Justin 4

 

Finally, Today my wife and I met with Ron at his shop and picked up Shell Kit L45-019. We carefully packed #019 in the back my Toyota 4-Runner. Thankfully, every piece survived the 25 minute drive back to my house without a nick or ding! Following Ron's checklist, I took account for each piece in the kit. Ron's craftsmanship is truly stellar. Hopefully my project updates will be more consistent now that I have the shell. Pending the Florida summertime heat, I hope to get a lot accomplished!

Justin 5

 

(Posted by Shane Barnes on 06-07-14)

Great seeing another project start taking shape, we will be watching for the updates! I was looking at your base, you will appreciate using those larger wheels/casters when you need to work under the base!

 

(Posted by Justin Fletcher on 06-14-14)

Here she is guys...#019 sitting pretty after Phase I:

Justin 6

 

Hard to think just 6 weeks ago I was sitting in Ron's sim contemplating this entire build process. Glad I pulled the trigger! It's so exciting seeing this kit come to life. Phase I went really smooth. Only had a couple splits in the MDF. Lowering the torque setting on the drill solved that. All of the pre-drilled holes and markings on the kit make this fool-proof. Each step adds a little more strength and rigidity to the frame.

 

I completed Phase II this week. Installed all the bolts included in the kit. Kinda neat to see all the hardware being added to the kit. I only had a couple of splits in the MDF frame pieces, bolting closed them right up:

Justin 7

 

Justin 8

 

Here is the proverbial furniture shot...So Sweet!

Justin 9

 

Also started Phase III: Notching this week. I was very hesitant about taking the jig saw to the kit. After the first few notches you get the hang of the technique. It's a lot of cutting, filing, fitting, and filing some more until you get the right fit:

Justin 10

UPDATE:

It's been a busy couple of weeks since my last update. My daughter was born early last Tuesday morning (our first!). We spent all last week in the hospital. Mom and baby are both home and healthy...I can't ask for more!

 

I have made pretty good progress on the shell. I'm at the 50% point of Phase III. The Starboard side of the shell is notched in and all the lateral strips are installed. I even shaved the windscreen supports with the belt sander. Really happy with the progress thus far:

Justin 11

 

Love the curvature of the top two poly pieces once they are installed. These took some time to get right. A lot of sanding and shaping and test fitting:

Justin 12

 

Here is a close up of the shaved windscreen. Used the table sander to shape it. Cleaned it up with a palm sander and lighter grit paper. Nice contrast with the windscreen that hasn't been shaped yet:

Justin 13

 

I'm off work for the next two weeks, I hope to complete the Port side of the shell, get all the pieces notched, shaved, and painted apple green before I head back to the daily grind.

 

(Posted by Ron Rollo on 06-30-14)

Congrats on your little baby girl! Speaking of girls, my little girl's birthday is tomorrow, sweet 16!  Your shell is looking spot on. The second half will come along a little faster now that you seem to have the hang of it. Just take your time with this, it will pay off big time in the end!

 

(Posted by Shane Barnes on 06-30-14)

Congratulations on the birth of your baby girl! The shell is taking shape and the blending of the lower windscreen support looks great. As Ron said it will come easier now that you have the hang of it. Still a lot more fun in store when you start adding the metal then the foam. It gets really exciting then watching the shell take shape.

 

(Posted by Justin Fletcher on 10-17-14)

It’s been a while since I posted an update on #019 so I thought I’d stop in and show the progress on the shell. After my daughter was born, my build progress slowed as we adjusted to having a new baby around the house. Slowly we’ve gotten into a rhythm and I’ve been able to work on the shell more and more. Needless to say, Throughout the summer, my cockpit building didn’t go without a little drama.

 

While disassembling the shell for paint I had a major accident. I turned around to grab my drill and the port side of the shell crashed into my garage door (No damage to the garage door). The crash caused a clean break through the MDF of the center windscreen frame. Luckily that was the only component affected by the crash. I contacted Ron immediately and discussed my options to replace the windscreen frame:

Justin 14

 

I decided to use the starboard side windscreen frame as a template and cut another port side piece with the trim router and jig saw. After sanding, drilling new holes, and a small Bondo repair. This piece was ready for paint:

Justin 15

 

Prep work made the difference during painting. I sanded each piece progressively with 150, 220, and 320 grit sandpaper. The 220 and 320 grits between coats really brought out the smooth satin finish of the paint. All the hard work paid off during this step...here are a couple pieces curing in the sun after a coat of paint (Unfortunately, I didn’t take a lot of pictures during this step)

Justin 16

 

I had to make a Bondo repair on the port side upper windscreen frame. I let the belt sander remove too much material during sanding. After Bondo, sanding and paint you can’t even tell the piece was repaired!

Justin 17

 

Here are a few pictures of #019 as she sits tonight. Apple Green coat of paint applied, caulked, and reassembled for Phase VI!

Justin 18

 

Justin 19

 

Justin 20

Now that cooler fall weather is moving into Northeast Florida, I can start enclosing the shell!

UPDATE:

I read Eric's post about the "Summer lull," I thought I'd post an update on L45-019. Since my last update the build has progressed nicely and I'm finishing up the foam and getting ready for fiberglass. I have been involved in a huge project at work that has taken up a lot of my time; but I am finally able to refocus my energy on the build.

 

The aluminum went in fairly smooth, I ran into a couple panels that wanted to bind. I ended up mocking up a new panel and cutting the aluminum again. Really happy with how it turned out:

Justin 21

 

This panel gave me the hardest time...not sure if it was the aggressive curvature of the shell but I finally got the aluminum installed and happy with the fit:

Justin 22

 

Fourth times a charm! Finally happy with the aluminum on the top...now I need a ton of caulk!

Justin 23

 

Ron graciously helped me cutout the window templates for #019. I installed the window templates earlier in the build, than recommended in the SAM. I wanted to confirm the upper and lower window pieces were sanded correctly. Here they are installed and foam applied on the top:

Justin 24

 

This may be my favorite picture I've taken of the build so far. I sanded the foam and you really see the curves of the shell emerging. She's slowly moving into the final stages of construction!

Justin 25

 

Split the shell in half, waiting on the next round of foam:

Justin 26

 

Finally, this Saturday I spent a few hours cutting, sanding, and shaping the foam. I'm going to let the foam cure for a couple more days and go back over it again with the orbital sander:

Justin 27

 

I'm trying to take my time and do this build right. I hope to keep this shell around for a long time! I've got fiberglass mat on hand, I'm ready to move to the next stage! Looking forward to working with Eric and Ron purchasing their components and getting the interior populated.

 

I took off work this week and am focusing on fiberglassing the shell (my summer break in September). Since I have never fiberglassed before, this was the phase of the project is was really apprehensive about. I Studied Ron's shell manual, input from the forum, and watched videos online, I'm glad I moved forward and went this route. I purchased 6 rolls of matting from Jamestown distributors, I'm going to order 3 more just to be sure I get enough to cover the shell 3 times over. Most of the articles I read online recommended shying away from Bondo brand resin, I haven't had any difficulties so far. It cures up really well.

 

I'm working on one half of the shell at a time so I can keep up with my progress. The starboard half doesn't have fiberglass yet:

Justin 28

 

Justin 29

 

(Posted by Ron Rollo on 09-16-15)

That's what I'm talking about! Jump in with both feet. Fiberglass is one of those things that the best way to learn about it is to just do it. Just in this short period of time you have probably learned countless things about it that you will be able to apply to the rest of the fiberglass project. How much hardener to use, how much time do I have, it gets hot because of the chemical reaction of the hardener, working out the bubbles, gravity pulls on it, it's messy and lumpy. With all that said, it's hard to mess it up to the point that you have to start over.

 

Your shell is as good as finished now Justin. You are past the hard part which was just getting started. Now all you need is time. Take your time and work on it like it is a piece of art! You will have a Lear45 shell by Christmas!

 

(Posted by Shane Barnes on 09-16-15)

Nice! You won't have any trouble with the Bondo brand resin, it is cheaper too and easy to find locally at Wal-Mart. I used Bondo brand on mine. Three to four layers of fiberglass will give you a strong shell and give you some extra layers to hopefully prevent you from sanding all the way thru when smoothing your shell out. If you do, it is not a problem, just cut the area out. You might have to remove a little foam and build up layers of fiberglass back to a thicker area and smooth down again. I had a couple areas that I had to do this.

 

(Posted by Justin Fletcher on 02-08-16)

Hey Guys, It's been a while since I updated my build thread. The build is progressing, albeit slowly; however... I can see light at the end of the tunnel! The Bondo stage really sucked the life out of the project for me and I had to really motivate myself to push through. Luckily, that stage is complete and the shell is nearing completion. I can't wait to start working on the column system and start wiring up panels!

 

Picking up from my last update, the fiberglass is complete and I learned a lot during this stage! Really glad I decided to fiberglass the shell, I'm super happy with the final product. I have 3 layers of fiberglass mat and it is REALLY strong!

Justin 30

 

Once I sanded the fiberglass I started Bondo and filling and smoothing the imperfections. I really wish I would have tracked all the hours sanding the shell:

Justin 31

 

The windscreens came out with little trouble. I ran into the problem of fiberglass resin drying in a couple of the screw heads. Vice-grips made quick work of pulling the screws out:

Justin 32

 

This weekend I started filling in the little craters and pin holes with spot putty:

Justin 33

 

Shooting the first coat of primer and more spot putty:

Justin 34

 

Here she sits this evening sanded with 400 - 800 grit sandpaper. Everything is super smooth and ready for the final coat of primer:

Justin 35

 

I'm keeping my fingers crossed that I'll be able to paint this coming weekend!

 

(Posted by Ron Rollo on 02-08-16)

Wow Justin, you have officially made it into the "Hangar45 Shell Hall of Fame"! I told you it would be a heck of a lot of work but well worth the effort when completed. Michelle and I might be out and about this next weekend. If we are out that way, I'll call you and see if it's cool to swing by and take a look at your shell in person.