Thank you greatly for your candor Larry and I appreciate it.
++++++++++++++++++++++++++++++++++++++++++++++
Michael,
Don't allow anything I said discourage you from completing the build.
We all have different road blocks to overcome in the build process. The
primary consideration and question to ask when diverting from proven
plans is "what happens if this component fails?" If there is a way to
test the change by all means do so and if not use your best judgement
based on the experience of others. There are many items on the airplane
that are not "flight critical".
The flat plates on my passenger side rudder pedals is material from a
discarded lawn chair.
https://www.dropbox.com/s/igceovjb6hdk8fh/image000000-6.jpg?dl=0
The nylon blocks for my canopy latch are from a nylon cutting board.
https://www.dropbox.com/s/nxpos54022pebri/image000000%20copy.jpg?dl=0
The handle on my throttle is a portion of a broken mop handle
https://www.dropbox.com/s/jclba8zdu3sefbp/image000000-2.jpg?dl=0
The rod end bearings on my gull wing door are from a copy machine and
the gas spring from the tailgate of my pickup truck.
https://www.dropbox.com/s/1sno1rx7vo7qmyr/image000000-5%20copy.jpg?dl=0
The stainless steel screws in my wheel pants are from the local hardware
store. My wing gap seal is roof flashing cut to size and mounted with a
few small screws top and bottom
Just consider the purpose of a component and judge it ability to meet
the task.
As far as your fuselage structure, what is the difference in weight and
strength between aircraft ply and marine ply. Would marine ply with a
single layer of glass be sufficient or is the glass even necessary?
Several builders have eliminated the ply all-together and gone with a
glass sandwich.
I would rank my importance of items on the airplane in the following
order. Structure and control system as number one. I see no way of
placing one over the other in importance. Second would be fuel system
and engine. Again, those two go hand in hand. Beyond that a failure in
other areas leaves you with a "reasonable" chance of survival. You
might say a bird strike at night through the windshield over water might
be just as bad but then what are the odds?
So, identify your obstacles, find a solution, and keep building. A great
deal of fun awaits you at the finish line.
You said you did some skydiving. I spent 150 hours hauling guys like
you to altitude and I was never once tempted to follow anyone out the door.
Larry Flesner
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