In 1995, inspired by the excellent article written by Alan James on G-BUCO (Popular Flying Dec 1994), my father and I took the first step toward a long-held ambition to build an inexpensive, two-seat vintage aeroplane, and purchased the plans for a Pietenpol Air Camper. The plans were all obtained via UK source Jim Wills, and were comprised of the original drawings, plus Jim's supplementary drawings (including those for a three-piece de-riggable wing utilizing a new spar design and aileron auto-connect system). Every project of this nature needs a modicum of good fortune, ours was in having John Cook, PFA Inspector, agree to oversee our build whilst we were in North Lincs. Under his guidance our 32feet X 12feet garage was turned into a workshop, and a workbench some 16 feet X 3feet was installed. Fitted with an MDF work top painted matt white, it was to provide the ideal surface for constructing the assembly jigs necessary for building the "stick and gusset" type structure. John Cook became our font of knowledge, showing us how to select the "right" Spruce for each application, and how to prepare the glued samples needed for destructive testing. Samples had to be submitted for every "mix" of Aerodux, and cross referenced to the application. As the number of "approved samples" increased, so did our confidence in the structure we were creating. Having decided that the flying surfaces where not only the most critical items but also the most complex to construct, we agreed to tackle these first. A visit to a PFA Rally at Cranfield enabled us to discuss the project with other builders, and we were fortunate to meet Joe Cronk and his wife. They had brought along some of his Air Camper components and sub-assemblies. Seeing the very high standard of his work almost made us consider giving up before we had really started! Joe has subsequently received many well deserved accolades for his craftsmanship, he certainly impressed us!
The tail feather drawings were "lofted" onto the MDF work surface and a set of wooden blocks and locking cams positioned to complete the assembly jig. Rather than using pins to hold the structure in place during bonding with Aerodux, we opted to use a number of "home made "clamps screwed into the MDF worktop. Next on the agenda were the wing ribs. With the help of an old drain pipe and commercial wallpaper stripper, the cap strips were steamed and shaped . The rib jig was constructed along the same lines as the one for the empenage but in duplicate, enabling us to work on two at time. Once the other 1000 plus bits of wood had been cut, shaped and glued, it wasn't too long before we were the proud owners of a complete set of wing ribs! Although the metal parts are available commercially, most are easily fabricated from sheet steel. We took the easy option and bought the control hinges, but we've made a majority of the brackets etc…ourselves.
Unfortunately, after the centre-section started taking shape, the project was put to one side. All the usual excuses playing their part- moving house, new job, starting a family etc… With the move out of the way, the new workshop (albeit not yet capable of withstanding a British winter!) and workbench were completed. We then contacted local PFA inspector Des Holcroft, who checked over our spruce and new workshop, and cleared us to start work on the wing spars. Due to the perceived problems of safely storing a completed wing, we set aside our wing 'kit-of-parts' (including the almost finished spars, leading/trailing edges and wing tips) and started work on the fuselage. Along with giving us a sizeable volume of aeroplane for a relatively small number of glue joints, it will also gives us something to sit in, and somewhere to dream…
Although progress has been slow, with the help of our power-plane, Perma-Grit sanding blocks and the encouragement of other builders, we are determined to raise the momentum of the project. Frequent over-flights by locally based Arthur Mason in G-ADRA provide a welcome reminder of why we keep getting ourselves covered in glue and sawdust! The eleventh UK Air Camper is about to take to the skies, and many more projects come close to completion, it would be nice to think that we could at least make the first twenty-five! For up-to-date progress on this 'Camper project and others visit: www.flyerworld.com/shenty/ukaircampers