Kettle Moraine EAA Chapter 1158
West Bend, Wisconsin, USA

Newsletter
Sectional
Vol. 2 No. 6 - November/December 1997

Available in full color at http://www.hnet.net/~eaa1158

In this issue...

Upcoming Chapter Events - Packer Party!
Chapter Raffle - More improvements; get involved!
Spot Landing Contest - Hit the spot
From the Editor - Movin' on
President's Message - Autumn high
Classifieds - Oshkosh openings b'gosh
Builders' Corner - A cowling good time
Chapter Calendar - Packer Party!
Officers, Teams, Committees - Check for the openings
On the Fly - A roof over our heads
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Upcoming Chapter Events 

10/15 - Chapter Meeting
11/09 - Packer Party!
11/19 - Chapter Meeting
12/xx - No Chapter Meeting in Dec.
See the Chapter Calendar section for full details.
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Chapter Raffle
by Steve Roensch, Raffle Chairman

PRIZES... INCENTIVES... RAFFLE COMMITTEE... PACKER PARTY!


Our Harley raffle continues to improve:

PRIZES

Suburban Motors Harley-Davidson of Thiensville has pledged a Harley leather jacket of the winner's choice, up to $450! This great prize enhances our raffle at no cost to the chapter. Our prize list is now:

I have prepared a one-page color raffle sign with the 95th-Anniversary bike, HD leather jacket and Brett Favre. Microsoft Word 7.0a format, about 1/2 MByte - prints very well in color on an HP DeskJet. Let me know if you want a copy of the file. We will be getting a copy of a one-page color "brochure" to each member, as well.

INCENTIVES

We have added yet another incentive to get people out selling tickets. The member who sells the ticket that wins the Grand Prize will win a ride in one of the local T-28's, owned by Herb Baker and Bill Claybaugh. Again, we are keeping an eye on costs to our chapter. So our incentive plan is now:

RAFFLE COMMITTEE - RAFFLE BOOTH TEAM

The raffle committee held a very productive meeting on 9/24. A substantial number of members have volunteered for the "booth team". These people will identify the events, arrange for the booth, and schedule members to man the booth. If you'd like to join, we could use your help - call me at 375-2228.

PACKER PARTY!

We are arranging for a fun event which should be successful in moving a lot of raffle tickets. On Sunday, November 9th, a group of members and their significant others will board a bus (or multiple vans with designated drivers) for Lambeau Field. No, we don't have Packer tickets. But we will leave around 7 am, arrive by 9 am, and spend 2+ hours walking the tailgate parties to sell raffle tickets. Then, around 11:15, back on the road to a nearby establishment to enjoy the game. And then the ride home, celebrating Green Bay's victory over St. Louis. Many details are yet to come, but members will cover all costs of transportation and on-board food, beer and soda. Expect the cost to be on the order of $25 per person, plus whatever you spend during the game. Because we we will be watching the game at an establishment that sells liquor, this event is for adults only. Once we have reserved the bus/vans, the number of seats will be limited, so if you want to reserve a spot or two, call me at 375-2228 NOW.

KEEP IN MIND OUR TWO KEY RAFFLE POINTS:

  1. This raffle is our primary funding event.
  2. Success requires everyone's participation.
If you need more tickets, call me ASAP at 375-2228. If you don't have any tickets yet, call me to get some and get behind this very important chapter activity.
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Spot Landing Contest
by Steve Roensch, Editor

The weather cooperated nicely for our chapter spot landing on September 13th. Overcast skies and a steady wind down runway 13 made conditions near perfect for many of our pilots to strut (pun intended) their stuff with a non-pilot in the right seat.

Photo 1
On the approach
The idea was to plant your mains on or beyond a line of lime that had been laid across the runway. The distance beyond the line is your score for that landing. On the line is 0 feet, and before the line gave you a penalty score of 300 feet. After three landings, throw out the worst and average the two remaining distances. Each pilot could enter more than once by getting a different passenger to ride along.

Photo 1
Winner!
The results were surprisingly good. Mark Hanrahan took it all with the average score of 4 feet, beating by a half-a-spinner-length Ed Emanuel's average of 4 feet 6 inches. Others had averages in double digits, and a few seemed drawn toward the river at the end of 13. Many of us had u-g-l-y landings, trying to plop things down in time, or stretch a glide a bit too far. All in all an educational and enjoyable experience.

After the contest we enjoyed the grilled turkey legs which were leftover from our fly-in. Everyone brought a dish to pass, and it was great conversation trying to figure out how the contest leaders had tricked all those judges standing at runway's side.
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From the Editor
by Steve Roensch, Editor, Webmaster


As we begin to approach the end of 1997, it is inevitable that members will move in and out of the volunteer roles that make our young chapter so successful. For example, Mark Hanrahan has taken the fly-out reins from Jim Retzlaff. Thanks for your efforts, Jim. Allen Bruggink has resigned from the board to attend a class, and Paul Lupton is now on the board as our Educational Coordinator. Thanks for your time and contributions, Allen.

For myself, I plan to remain on the board through the elections at the end of 1998. I will remain the raffle committee chairman. And I will remain webmaster for now. However, I plan to relinquish the newsletter editor position as of 1/1/98. Hence, the next issue will be my last. That will make 9 issues, or exactly a year-and-a-half. I notified our president of this decision in early August, and our board has been working on finding a pair of co-editors to take over the job.

If you're not yet on a committee or team, now may be the time to look over the list in this issue and find a place to contribute. It's a great way to meet your fellow members and become an active part of your chapter.
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President's Message

by Howard Kaney, President


Another month has gone by, and some of the most beautiful and challenging flying days are upon us. Autumn is my favorite flying time of year. Nature is alive and changing, laying out beneath your wings a matrix of color and texture unequaled at any other time of year. Those crisp autumn breezes mix with warm southerly flows, playing games with direction, intensity and stability of the air masses. The other day I flew over Random Lake, departing West Bend in my Cherokee 140, arriving RDL in about 3 minutes. Wow, I'm thinking, the performance is so great today I'll skip those speed mods I was considering. Bad news is it took almost 20 minutes to get back. Practicing commercial manuevers in those conditions is challenging. Turns about a point at the correct pivotal altitude? - nah, forget it. I'll settle for turns that start and end in the correct county.

But if you know and abide by your own limitations, you'll enjoy some great autumn flying days. Wind is a subjective element. You can say "15 gusting to 25" means I'll be giving my pilot reports from the coffee shop. Or you can look at extra wind velocity as a means to extend a runway simply for your flying pleasure on a beautiful autumn day. It's all a matter of attitude, perspective, knowledge, experience and limitations. Just the way flying should be. Fly safe, and enjoy!
 ---------- Classifieds

Wanted

EAA Headquarters is looking to fill the following full time positions in Oshkosh. Contact Howard Kaney or EAA for full position descriptions.

  1. Program Administrator, Government Programs - Flight Advisor, Ultralight and other government programs
  2. "FLYING START" Program Administrator
  3. Technical Information Specialist - To interface with EAA members on information requests
Chapter #1158 members may place their ad free of charge. Submit your ad to
Steve Roensch, 414-375-2228, fax 414-375-2212, sroensch@execpc.com
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Builders' Corner

by Jim Rodrian

Defiant Front Engine Cowl

While making the cowl for the front engine of my Defiant, I was reminded of the fact that I am building an "experimental" aircraft. Since this was my first attempt at making a cowl, I learned by experimenting to gain the knowledge I needed to complete the task. My goal was to perform only one experiment, but as is usually the case with a new endeavor, one experiment was not sufficient to achieve the goal.

Photo 1
My son Jeff shaping urethane foam around a Lycoming 0-360
My first attempt at making a cowl mold was to use polyurethane foam, as suggested in the plans, to encase the front Lycoming O-360 engine. (Photo #1) This didn’t work for several reasons. The polyurethane foam was too soft and the bulkhead patterns provided with the Defiant plans were too small for my aircraft. As a result, my son and I spent many hours adding bondo to the polyurethane foam mold in an attempt to get the cowl shape correct. However, this was a slow process, added weight to the mold, and the polyurethane foam sagged under the weight of the bondo. On to another technique.

Photo 2
Second attempt using polystyrene foam
My second attempt was to use styrafoam insulation instead of the polyurethane foam and cut the bulkhead patterns ½" oversize. This worked quite well. (Photo #2) Gaps or low spots in the foam were filled with Polycel Expanding Foam. While the styrafoam didn’t sand as easily as polyurethane foam, it was easier to control the shape of the styrafoam mold. Also, the styrafoam and Polycel are available locally and at a much lower cost than the polyurethane foam.

Next, I made the cowl with graphite and fiberglass cloth rather than only fiberglass cloth. Recent articles in several builder newsletters indicated that the cowl would be 5 – 10 lbs lighter and stiffer if it was made with graphite rather than fiberglass. I laid-up 1 ply of BID graphite @ 45 deg, 1 ply of BID fiberglass @ 0 deg, and 1 ply of BID graphite @ 45 deg on the styrafoam mold and used epoxy to wet-out the cloth. After this lay-up cured, I cut the cowl in half and removed the top and bottom halves from the foam mold. Photo 3 shows the top half removed from the mold.

Photo 3
Top half of cowling removed from the engine
I am pleased with the result. Since this is the first cowl I made, I don’t know if I actually saved weight by using the graphite cloth. I will need to check with other Defiant builders to find out the weight of their front cowls.

However, I am not finished. I need to add inside ribs to stiffen the cowl, add fasteners to hold the cowl halves together and to the fuselage, add a door to allow access to the oil dip stick, finish the air inlet, and finish the air outlets. Then I can start on the cowl for the rear engine!

If you are going to be making your own cowl, I suggest that you talk to someone who has done it before. Also, read Sportplane Construction Techniques by Tony Bingelis. Pages 108 - 124 contain information on making a cowl mold and making a fiberglass cowl. ----------




Chapter Calendar

Chapter Meeting: 3rd Wednesday of each month, 7:00 pm
(Bring a chair)  West Bend Airport, Hwy 33 East, West Bend, Wisconsin

10/15 - Chapter Meeting, 7 pm, West Bend Airport
        - Aircraft Insurance
        - Pilot Insurance Issues

11/09 - Packer Party!, 7 am - 7 pm
        - Sell raffle tickets at Lambeau Field
        - Call Steve Roensch at 375-2228 to sign up

11/19 - Chapter Meeting, 7 pm, West Bend Airport
        - Fire Safety
        - Fire Department/Paramedic Night

12/xx - No Chapter Meeting in December
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Officers, Teams, Committees 
(Officers July 1996 - December 1998)
                                        Area Code 414
President                 Howard Kaney    334-9451 hkaney@execpc.com
Vice President            Richard Feldschneider II 677-3416
Secretary                 Allan Price     334-1278
Treasurer                 Glen Brandt     268-1648
Board Members             Don Brinkley    335-6519
                          Ron Champeny    334-4309
                          Paul Lupton     338-1826 plupton@hnet.net
                          Steve Roensch   375-2228 sroensch@execpc.com
Fly-out Chairman          Mark Hanrahan   243-3666
Historian                 Ernestine Lynfoot 377-9163
Internet Webmaster        Steve Roensch   375-2228 sroensch@execpc.com
   Home Page              http://www.hnet.net/~eaa1158
Membership Committee:
   Chairman               Dan Staehler    338-1351 staehler@execpc.com
   Welcoming Chairman     Allan Price     334-1278
Newsletter:
   Editor                 Steve Roensch   375-2228 sroensch@execpc.com
   Reporters              Ed Emanuel      334-4520
                          Paul Lupton     338-1826 plupton@hnet.net
                          Ernestine Lynfoot 377-9163
                          Jim Rodrian     377-4320 jrodrian@elsyn.com
                          Mike Schram     242-5992
   Proofreaders           Kris Hinterberg 334-1809 kris@hinterberg.com
                          Jim Pieper      334-5856 pieps@execpc.com
   Publishing Team:       Bill Groeneveld 334-9436
                          Gary Lackie     375-0859 glackie@execpc.com
                          Paul Lupton     338-1826 cfiphd@aol.com
                          Marv Powell     791-4737
                          Rick Woyak      338-3801
                          Sandra Zorn     626-8764
Program Committee:
   Chairman               Ron Champeny    334-4309
                          Allen Bruggink  335-6459
                          Terry Ganzel    338-1574
                          Bill Groeneveld 334-9436
                          Howard Kaney    334-9451 hkaney@execpc.com
Raffle Committee:
   Chairman               Steve Roensch   375-2228 sroensch@execpc.com
   Regulations            Richard Feldschneider II 677-3416
   Printing               Howard Kaney    334-9451 hkaney@execpc.com
   Treasurer              Glen Brandt     268-1648
   Manage Booths
     Co-Captain           Richard Feldschneider II 677-3416
     Co-Captain           Terry Ganzel    338-1574
                          Glen Brandt     268-1648
                          Don Brinkley    335-6519
                          Dale Carlson    334-3533
                          Ron Champeny    334-4309
                          Sue Good        644-0511
                          Al Loecher      335-3284
                          Allan Price     334-1278
                          Pat Schmidt     533-5499
   Publicity/Advertising  (2 volunteers needed)
   Drawing Event (6/27/98 after Fly-In)
     Captain              Steve Roensch   375-2228 sroensch@execpc.com
                          Jack Hinterberg 334-1809 jack@hinterberg.com
                          Kris Hinterberg 334-1809 kris@hinterberg.com
   Prize Donations        Steve Roensch   375-2228 sroensch@execpc.com
                          (5 volunteers needed)
Recognition Committee:
   Chairman               Allen Bruggink  335-6459
                          Don Brinkley    335-6519
Young Eagles Coordinator  Don Brinkley    335-6519

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On the Fly


EAA Chapter 1158 receives a generous donation

One of our Chapter members, Duane Orzechowski, has donated a lightweight portable tent for our Chapter's use. Look for an 11x13 portable structure with a beautiful green and white striped canvas at our outdoor chapter functions. This tent is also available for booth sales for our major raffle. Contact Terry Ganzel at 338-1574 if you'd like it for some chapter function. And thanks again, Duane and Michelle, for the wonderful contribution to our cause!
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EAA Chapter 1158 website and Internet account sponsored by Hnet, Washington County's Hi Tech Hi Touch Internet Service Provider. Call Kyle at 334-2624 or Hnet at 338-6808 for more information.

This and all Kettle Moraine EAA Chapter 1158 newsletters are provided for your enjoyment only. No claim is made and no liability is assumed, expressed or implied as to the accuracy or safety implications of any material presented. Viewpoints of the writers are not necessarily those of this or any EAA Chapter or of the Experimental Aircraft Association (EAA). Use of any of the material presented, whether by applying, copying or quoting, is done solely at the risk of the user.

© 1997 Kettle Moraine EAA Chapter #1158. All rights reserved worldwide.
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How to contact us...

email Kettle Moraine EAA Chapter #1158 Webmaster
414-375-2228