Rebuilding a Hollmann Sporters

[All_In]

This is Chapter 31's Hollmann. She has been sitting for 10 years and we have to totally disassemble her. We have to inspect her and at least remove the corrosion acid etch and alidine (spelling) her and replace all the hardware with new and any un-airworthy parts. She has an O-320 ~150 hp Lycoming engine, normal aircraft gauges, 3 channel radio with intercom, and carburetor heat, although with this engine you usually don’t need it.

Finally, I can start a rebuilding thread and pay you rotorheads back for all you have shared with me and thank you for teaching me so much over the last 2 years.

I discovered it is difficult to stop at each component you are working on and take pictures of every procedure and greasy hands on my camera is not going to work but I will wreck my cell phone for ya.

Also thank you Builders for taking the time to take pictures guys and gals, it hard even to remember to take a picture when you’re in the battle.


The first pictures are of us pulling her our of the weeds and brining her new home at the shop at KSEE:

http://www.pra31.org/images/Chapters/31/Hollmann/1205000822.jpg

http://www.pra31.org/images/Chapters/31/Hollmann/1205000822a.jpg

http://www.pra31.org/images/Chapters/31/Hollmann/1205000822b.jpg

http://www.pra31.org/images/Chapters/31/Hollmann/1205001108.jpg

http://www.pra31.org/images/Chapters/31/Hollmann/1205001136.jpg

http://www.pra31.org/images/Chapters/31/Hollmann/1205001136a.jpg

http://www.pra31.org/images/Chapters/31/Hollmann/1205001137.jpg

http://www.pra31.org/images/Chapters/31/Hollmann/1205001137a.jpg

http://www.pra31.org/images/Chapters/31/Hollmann/1205001137b.jpg

http://www.pra31.org/images/Chapters/31/Hollmann/1205001138.jpg

http://www.pra31.org/images/Chapters/31/Hollmann/1205001139.jpg

[All_In]

The links did not work. I'll find out why later.
Here the last of bringing her home.

[StanFoster]

John- I love build or rebuild threads. This will be interesting. Thanks for something to watch.


Stan

[Gyro_Kai]

Hooray, so you found a way to build yourself into a flying machine! Good on you, John,

Kai.

[animal]

Cool deal giving a Gyro a new life on your Birthday.

this will be fun to watch this restore.
can't wait to hear how it flys.

[Vance]

She looks good John.

I look forward to seeing your progress.

I feel you will have a very nice aircraft when you finish.

It is a large undertaking.

I have always been fond of the Sporster.

Thank you, Vance

[All_In]

Thank you guys!
Life is good and it just keeps getting better.

...Mean while back at the shop. Our poor rescued, abandoned, and neglected girl set waiting all day Monday. No John or Dave and all the attention being given to other aircraft. She must have thought why did they bring me here, just to torture me watching only FW aircraft being repaired and flown. I'll bet it because I'm a rotorcraft?
But then on Tuesday there was hope again and then joy as she realized oh they do love me.

We changed the tire and tube.
Drained the 10 year old fuel out.

Greg happen to have a new picot for the fuel drain so he change it while he was down there.

Then we removed the cowling and cleaned and wax them to start the engine inspection.

We removed the spark plugs cleaned them and reinstalled them for the warm up and compression check.

It is so cool having all the tools and parts you need working at the airport shop oh and a brother that's and IA really helps!!! Am I lucky or what?

Next Greg started the inspection of the carburetor. The throttle and mixture were not connected so he checked then by hand. Throttle, no problem there, he checked the mixture no that’s not working. Dave and I saw it move same as the throttle so we ask why? It is moving like the throttle. He said it doesn’t feel right. It is frozen, we said but it moves? He said you’ll see when we take it apart.

He was right, as usual; we could not even split the case without breaking the attaching rod. Then we could still not get it to break free even using needle nose vice-locks. Therefore, we tried to drill a hole for an easy-out extraction and wrecked the seat and only broke it free after we tore the seat out too. We now need a new MA 4 SPA carburetor! But that didn’t stop us we can run her full rich at 400 feet above sea level so we put the carburetor back together without a mixture vale in it at all.
We then attached and tested the throttle cable and it was stuck tight so we decided to call it a day and let it soak.

[All_In]

Inside the carburetor and that is the seat on the end of the easy-out! Bummer!!!!

Looking for a MA 4 SPA carburetor, anyone have one for sale?

[All_In]

Today was my birthday and when my brother asked what do I wish to do today. I said do a compression check on the gyro and go flying. My wish was granted.

Today we re-installed the throttle cable and adjusted it. We tied her down, added fuel, installed the new battery. I got in and turned on the master, turned on the fuel pump, pumped the throttle 4 or 5 times and tried to turn her over. Nothing.

Greg said Master off, wait a minute and comes back with a volt meter and says hit it! Nothing.

Then he says master off, wait a minute and come back with the golf cart and jumper cables. Ah a low charged new battery.

He says OK I'm clear!

She barely can turn over and she says "HerRump, HerRump", and then roars to life. Oil pressure, check, oil temp check, even the EGT works!

Here is a link to the first time we started her! (You need quicktime)

http://www.pra31.org/images/Chapters/31/Hollmann/MOV05343.MPG

I love these very simple dependable engines and they are incredible.

10 years of sitting rusting away and she fires right up, I wonder what the compression will be?

With the mixture being more than full rich, as the entire seat and valve rod is missing and there is now a hole twice the diameter she ran rough but she ran.

Greg would lean her out with the fuel shutoff valve and she would rev up and start purring like a kitten.

We noticed blow by and oil leaks form the case so we know the rings are not seated and hope that will clear up as we re-break her in.

After she was warmed up we shut her down by turning off the fuel as we had no mixture control.

We remove the top plugs and did a differential compression test.
A perfect engine is 80 lbs pressure, we have never seen that but have seen 79 lbs.

Ours is:
#1 74
#2 72
#3 75
#4 74

Yippee, she just may be a new engine.

We then put new waster on and re-installed the top plugs.

We changed the oil, cleaned both screens, and Greg just happen to have a $80.00 oil quick drain so he gave it to us and installed it as well as the gaskets for the oil system.

We fired her up again and ran her some more. Less blow by this time.

We then celebrated by flying the 180. I did many touch and goes then flew to brown field and had lunch and did more touch and goes and back to Gillespie for a couple more.

It was a GREAT Birthday!!!

[bones]

John no.4 photo??? what you got a 6 blade prop on that baby?? must have some serious grunt that motor.
Hope you had a great day sounds like your in for more ahead.
Only joking about the prop, i know whats happening :)

[StanFoster]

John- You guys aren't messing around! Way to go, and it is exciting reading your progress so far. Life is so good when you are passionate. Thanks John for starting this thread. Stan

[animal]

Woo HOO! got a good engine it sounds like. wait till you price that carb. aacckk

man that is cool that it had good compression , I love these certified aircraft engines,mine had not been started since 1992 and once the mags where timed she fired right up.

I bet that baby sounded sweet to your ears when she lit off. Dave looks like a proud papa working on it.

I can tell you guys are going to have this baby in the air real soon.

I like the paint scheme on it, that is going to look pretty all shined up. who ever built that machine put a lot of thought into it,the side air scoops for cooling are a Great design and the top cowl will probably help the airflow to the prop.

Just wondering, how wide is that cockpit? it looks tiny. then again Dave is no small guy so the size reference might be throwing me off.

way to go.

[All_In]

@Bones
Thank Bones I did have a Great day and Great night!

@My brother Stan
Yaw Mon, I'm like you in so many ways every free minute I'll be there and as you know I've got a broken speed selector and only have high gear form birth.

@Tim
Ya we know. When Greg cracked the case he said, "Well that may have just cost us $800.00"
I'll measure it and let you know. It is made for big Guys as Hollmann is/was a big guy.
Dave and I sat in it and we have plenty of side room = no touching.

[Cowboy]

Inside the carburetor and that is the seat on the end of the easy-out! Bummer!!!!

Looking for a MA 4 SPA carburetor, anyone have one for sale?

www.preferedairparts.com

http://www.preferredairparts.com/asp/viewpart.asp?pid=27555

[All_In]

Thank Robin!!

My brother said to hold off on buying one as he is going to swap one out with a core exchange engine. A friend is a VP for a major aviation supply company and he said the next one that comes in just exchange the bottom cases. So looks like it may be for free.

It's good to have friends.

[All_In]

Today Dave Bacon and I DROVE his truck up to El Mirage and back for the blades.
Dave ask if we couldn't just remove the back of the plane and fly up, I wish we could have.
We met up with Teddy, he showed me around and had a great time.

I love his sense of humor he had me laughing almost the entire time. What a guy and a lot of fun!

I met Pete Prinis (spelling) an A&P and gyroplane pilot who was the last person to fly our aircraft. It's a small world as he also happen to work at Spiders a local aircraft engine rebuilding shop who's owner is a good friend of my brother and mine. He's going to look for a core carburetor for our engine too.

Greg had already worked out a deal with Mike the owner to swap out our Bendix Mags for Slicks from another engine.

Anyway, the blades are here Peter said he flew them but it almost hook him to death.

Greg is going to ask another helicopter mechanic if he will balance them for us with his Chadwick. I hope he will apparently they need it.

[All_In]

...

Just wondering, how wide is that cockpit? it looks tiny. then again Dave is no small guy so the size reference might be throwing me off.

way to go.

Tim we measured it today for you. It's 3 feet wide.

[ironcowboy]

I am most fascinated by the rotor head cheek plates and rotor head. I can tell that the cheek plates are not “standard” Hollmann blueprint, they are longer down the rotor mast with extra bolt holes… which I don’t see a problem in doing. The original print calls for a 4 bolt rotor cheek plate at the top. Although I’m a fan of keeping to the factory specs, only four ¼ by 28 bolts unnerves me in that area. I think I like your design better!

@ Animal… 3 feet wide! The Holloman is no wide body design from Boeing that is for sure… You can wedge two standard 16” wide Calumet 7 gallon seat tanks into that space, and still have room to spare with the 2x2 center cabin keel spar between the seats. I am 5’ 8” and 180 pounds, and I would rate my configuration as “snug.” It’s much more accommodating to the taller pilot, as opposed to the wider pilot.

[Vance]

Greg had already worked out a deal with Mike the owner to swap out our Bendix Mags for Slicks from another engine.

Hello John,

Why do you want to swap your Bendix magnetos for Slick magnetos?

Thank you, Vance

[animal]

Wow 3 feet sounds kind of snugg. wonder how wide and RAF-2000 is. The RAF-2000 seemed kind of snug to me. but to be honest I think the cab design of the Hollmann makes it look narrower then it is. I do like the design of it.

can't wait to see pics of it in flight.

John, did that guy Pete say much about how it handled?

[animal]

Hello John,

Why do you want to swap your Bendix magnetos for Slick magnetos?

Thank you, Vance

I was wondering they same thing.
My commuter H-1B has Bendix mags with impulse couplers on both mags.

It starts and runs great. I don't even have an engine primer and it turns over about 3 times and fires to life.

[dabkb2]

John, did that guy Pete say much about how it handled?

Pete said it flew ok with 22' Bensen blades, but that they were spinning very fast. He never went over 50 MPH.

[dabkb2]

The blades look big 30' with over a 9"cord, no visible damage but the teeter block is missing. Does anyone know how to determine the correct size of the block to get the right undersling?

[All_In]

Hi Vance.

It isn't because Bendix mags are inferior in any way they are not!!!

There is no engine log books so my brother has no idea how old they are.

He does know that it was stored out under tarps in the hot So Cal sun for 10 years+ and he fears the coils may go bad sooner rather than later.

They are both still running without issue but the more you vibrate the coils, ... well they may not stay that way and basically it just makes my brother feel better knowing the Mags history.

We know the Slicks history, they are new, and available now so that is why the change of brand no other reason.

Thank you Vance I should have explained that. I sure do not wish anyone to think Bendix Mags have any sort of problem these could still run for years.

[BEN S]

Sounds like a fun trip, I like Peter, he is pretty cool.
Did dave make you stop to purchase Gatorade and Resses Peanut Butter cups?;)
Ben

Looking forward to Thursday

[All_In]

The blades look big 30' with over a 9"cord, no visible damage but the teeter block is missing. Does anyone know how to determine the correct size of the block to get the right undersling?

Thank you Dave I forgot to ask.
Help rotorcraft wizards.

Does anyone know how to determine the correct size of the block to get the right under-sling?

[All_In]

Sounds like a fun trip, I like Peter, he is pretty cool.
Did dave make you stop to purchase Gatorade and Resses Peanut Butter cups?;)
Ben

Looking forward to Thursday

Yo Ben!!!
It was a fun trip on the way up Dave Flew like the wind, I like his style, and I was wide awake ...

on the way back with the trailer, not so wide awake.

I like Peter's laid back ways. Mr cool. It will be fun for all of us to fly together!!!

Yaw Mom we B pick'n you up in Yuma Thursday for the meeting.

Where can you board on the field? Looking at the flight guide Lux Air?

[All_In]

Here is a link to the first time we started her! (You need quicktime)

http://www.pra31.org/images/Chapters/31/Hollmann/MOV05343.MPG


PS:
I did not know he took this until today!

[Brent_Brown]

If you have a rotorhead you might want to just fit the hight to fit that or you will need to change the head too.

[StanFoster]

John- Way to go on your rebuild. Keep breathing life into this machine. It will be cool to see it flying.


Stan

[ironcowboy]

This is awesome!

[okikuma]

Hi John & Dave,

Here's an idea.

If by chance you can not find a good replacement for your carb, you might want to consider an Ellison Throttle Body, or an Aero Carb Throttle Body set up. You'll save a good amount of weight, and have a new carb for at least half the price of the orginal carb you took off.

Wayne

http://www.ellison-fluid-systems.com/

http://www.aeroconversions.com/products/aerocarb/index.html

[All_In]

If you have a rotorhead you might want to just fit the height to fit that or you will need to change the head too.

Thank you Brent
I'll ask Dave, I'm not sure I would know where the under-sling is suppose to be set. But may be it will become obvious when we fit it. It's worth a try.

If no one can advise how tall to cut the blocks I will call Hollmann next week when I have more time.

Thanks again Brent for the help!

[All_In]

@Stan
Thank you buddy, it is fun to have a gyro to restore.

@Cort
Yaw Mon it was exciting seeing her start after ten years of sitting.

[All_In]

Hi John & Dave,

Here's an idea.

If by chance you can not find a good replacement for your carb, you might want to consider an Ellison Throttle Body, or an Aero Carb Throttle Body set up. You'll save a good amount of weight, and have a new carb for at least half the price of the orginal carb you took off.

Wayne

http://www.ellison-fluid-systems.com/

http://www.aeroconversions.com/products/aerocarb/index.html

Those look like excellent replacements. Is anyone using them?

Thank you Wayne!!!

[animal]

Yaw Mon it was exciting seeing her start after ten years of sitting.

Yeah I know that feeling ,the first Time my Commuter fired to life after being in storage since 1992,was a real thriil.

I am really looking forward to seeing this Bird take flight again.

[okikuma]

Hi John

I've seen a number of installations of both examples on VW engines, Jabiru engines, & Continentals to Lycomings. A number of Pitts Special owners use the Ellison and are quite happy with it along with many Vans RV aircraft builders.

Wayne

[ironcowboy]

I too was wondering if any gyro pilots are using the Ellisons on their machines. I was thinking about going that route when I get to that point.

[All_In]

@Tim
I remember being excited hearing your ride fire up for the first time too.

@Wayne
Thank you buddy, that's makes me feel very good! If we cannot get a bowl for ours we will try it, it does look good and about 1/2 the cost!

@Cort
Should we start looking for an engine for you?

[ironcowboy]

I’m not quite ready to obtain an engine yet. What I need to do is develop contacts to know what it out there and where it’s located… I’ve been thinking about what you said in regard to finding an older grounded aircraft that is "frustrated." The more I think about that, the more I like that idea.

Cort

[animal]

I’m not quite ready to obtain an engine yet. What I need to do is develop contacts to know what it out there and where it’s located… I’ve been thinking about what you said in regard to finding an older grounded aircraft that is "frustrated." The more I think about that, the more I like that idea.

Cort Hi Cort,this place gets a lot of Engines and parts and really good prices.

check them out.

http://www.DawsonAircraft.com


http://www.aircraftpartsandsalvage.com/power-plantprops-engines-c-303_84_77.html

[All_In]

@Cort
I'll let you know what we find we are looking.

@Tim
Thanks for the links!!!!

[okikuma]

Hey John,

What's the latest on the Sportster restoration?

I'll be in San Diego January 25 for the AFCEA West 2012 at the convention center. Let's meet up for dinner and look over the Sportster too.

Wayne

[dabkb2]

hey Wayne, it will probably end up as yard art, or in a museum. It just needs to much.

[WHY]

Been to Dawson aircraft salvege, it's a candy store !!!!

Tony

[ironcowboy]

Are there any good usable parts, like engine mounts? V and H stabs... ect...? I may be very interested in making an offer on this aircraft for salvage value. Keep me in mind with this baby... I could probably use some parts as like an organ donor... :angel:

[All_In]

Hey John,

What's the latest on the Sportster restoration?

I'll be in San Diego January 25 for the AFCEA West 2012 at the convention center. Let's meet up for dinner and look over the Sportster too.

Wayne
Great idea Wayne your on!!!
I'll PM you!

[All_In]

Are there any good usable parts, like engine mounts? V and H stabs... ect...? I may be very interested in making an offer on this aircraft for salvage value. Keep me in mind with this baby... I could probably use some parts as like an organ donor... :angel:

It would be a shame to tear her up for parts... Bruce is working on getting her donated to a museum.

However if that fails you can have first crack on our parts.

[ironcowboy]

I know what you mean by that. I would imagine that you could find a museum who would take her. Good luck and let me know.