Its been over a year since my last post.  And what a year it’s been.  ”Busy” just doesn’t seem to convey the brutality of it. 

I will pick up the story just days after Shane’s ride in the Stearman.

September 2008 will go down in my book as one of the worst, best times of my life.

I will try to hit the high parts of the story, but first a little background.

I was the Outside Maintenance Service Manager at a large FBO and Flight School in Hillsboro OR.  The shop consisted of myself, three A&P mechanics, an Avionics supervisor and three avionics technicians.  It was the loss leader for the company, but an important part of the overall operation.  For example, because my shop was a Cessna Service Center, it allowed the company to buy parts at a discount when purchasing from Cessna, and that is important when the other part of the company, Inside (or Fleet) Maintenance, was maintaining 50 or so Cessnas for the flight school.

In the middle of September I learned that the Director of  Maintenance of over 20 years, had been terminated, the chief inspector was forced to quit, and the owner of the company had decided to ground his entire fleet of over  70 aircraft to get them re-inspected to ensure their airworthniness.  

I volunteered my shop to do the bulk of the fixed wing fleet.  Some of the Cessnas were at satallite fields when the grounding came, and other maintenanace shops at those airports would handle those.  The inside shop would concentrate on the 15 0r so piston helicopters and the Helicopter Charter division would handle the 7 or so turbine helicopters.

As you can imagine, the place was crawling with FAA Safety Inspectors.  I generally had three at any one time in my shop watching the guys work…even on Saturdays and Sundays. After my shop had completed 5 or 6 six aircraft, they moved on to other, more target rich, environments.  I was told they were happy with the way the shop was run and the quality of the work from my guys.  The pressure of constant survelliance was over but we still had dozens of aircraft to complete.

I think we finished in 5 weeks.  The owner of the company paid me a visit late in the process that I lovingly call The Great Catostrophy of ‘08, and sat down to talk with me.

He said that in good times, everybody works about the same, and all perform well enough. But when the feces makes contact the rotating air distributer, things look a little different. The “Superstars” show what they are made of under pressure, and others that he had thought were up to the job, were unfortunately not.  He told me that I was one of those Superstars and that my shop lead the way when others would only follow.  We out performed every other shop in the company, not to mention the other businesses we had contracted to do the work at other airports where our aircraft were grounded.

What I didn’t know at the time was that others had noticed too.

On the Homefront,  my pregnant daughter, Stormi, and my USAF son-in-law, Mason, were transfered to the USAF Presidental Security Detail at Andrews AFB.  

My son, Shane, decided that he was serious about becoming an Army Pilot, and knew his grades were not up to snuff.  He applied for, and was accepted to the Oregon National Guard Youth Challenge.  Its a six month, military style (basic training) alternative high school in Bend, OR.  Over 400 kids applied for class number 2009-1.  180 kids were accepted and 123 Graduated in June 2009.  Shane found that he had brains he never knew he had, and did very well at a tough school, where the minimum passing grade was 80%.  He was sorry that  students are allowed to attend only one school year and that he had to leave.  

He is seriously thinking about joining the Oregon National Guard after his 17th birthday this coming December, with his ultimate goal of becoming a Warrant Officer flying CH-47 Chinooks.

After the Kids moved away and Shane was away at school, my wife , Kim and I remodeled the house.  Its amazing how much you can do on a tight budget.  It took most of the six months that Shane was away, but the house looks great and I joke that it looks rich people live here.  Next on the “to do” list is new furniture for the living room.

I really made no progress on the Long EZ with all this happening.

Here is where the story bends around a  curve.

For over 10 years, I had had an application in with the FAA.  I had a short  and informal talk with the  FSDO in 1998 after leaving the Army , and another short talk with Heavy Helicopter Unit Manager at the Portland FSDO several years ago, but nothing came from either .

In mid June, I received a call from an  HR person from the FAA Northwest Mountain Region HQ in Renton, WA.  I thought to myself  OH YES!, I’m going to get to schedule an official interview now.  Instead, she offered me a job at the Portland FSDO starting in 10 days!  I excitedly told her yes.

When we finished up our conversation and I hung up, it  occurred to me that I now had to tell  my current bosses that I would be leaving.  I really hadn’t been looking for a new job, and liked my job as Service Manager.  I felt bad about leaving them short handed, but I had to weigh that against the big raise and security I would be moving to just one and a half  miles further down the road from my current job. 

I let my bosses know of my decision that day.  Later in the afternoon, The owner found me on the flight line and walked right up  and hugged me.  He said that I would be missed and that he loved me.  I choked up.  He was such a good boss, I really hated leaving.  The next day he took me to lunch and told me that no matter what happend, I would always have a job waiting for me.

It turns out that when the FAA had been in my shop, I had impressed them, and was hired  based on the reports from the Inspectors I had worked with during the Great Catastrophy.

So, I’m working on my 4th month as an FAA employee, trying to sip water from the fire hose.

And again,  the story takes a corner.  David is a retired  Oregon National Gaurd  CH-47 Chinook pilot and instrument examiner hired by the FAA the same time I was.  When he came to my cube to introduce himself to me, he saw my Long EZ pictures and Burt and Dick Rutan autographs.  I told him about my project and he said that he’d always wanted a Long EZ.

David came up with a plan for us to share a shop to build two Long EZ’s.  I will teach him composites and he would teach me instrument flying.  Its a win-win-win for me.  I get to have a real shop to work in and work on my instrument ticket.  Shane gets a mentor that has actually done the things he dreams about doing. And Kim gets to put put her car back in the garage.  

David and I are currently attending the FAA Acadamy in Oklahoma City for our indoctrination training and while here,  he  bought a 50% complete (with 90% to go) Long EZ project with Drybread retracts. I’m jealous of his landing gear, but I joke with him that if I forget to extend my gear, I will be embarrassed when I have to  get out, crank the gear down,  and taxi in.  If he pulls the same stunt,  he’ll need a crane.

We will be moving our projects to the new shop as soon as we get back home in November.  Pictures to follow.

My 15 year old son, Shane, went flying in a 1941 Stearman this Labor Day weekend!  As you can imagine, he had a great time.  He said it was the best thing he’d done all summer…then corrected himself and said “no, not this summer…Best thing  ever!

After the flight he was all smiles, despite shivering from the cold.

Shane and Tracy after the flight

Shane and Tracy after the flight

When you are 15, 18 seems like a long way off, but as of now, Shane wants to join the  Army and become a helicopter pilot.  Good Luck Kid! (your luck’s been good so far!)

With the Champ at the airport, there is finally room in my garage for the Long EZ. Now,  whenever the urge hits me, I can go and get some “garage flight time”. 

Longest “flight” so far?   40 minutes! 

I am making plans to start on the canard.  ( I have a Grumman Goose rudder and aileron to cover and paint for a customer first)

Just for fun, I duct taped the upper strake skins on for the photo.


My friend, Jon, and I moved the Champ fuselage to the airport today. We will try to move the wings tomorrow, weather permitting. 2 and 1/2 years of work now out of my garage and making more room for the Long EZ.

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The Champ is geting to that 99% completed with 75% to go stage, but I have kept the Long EZ Project moving as best I can. The last couple of weekends, I have prepared all the templates required for the entire project.
For template material I used a sort of particle board that was used as a shipping protector for sheet aluminum shipped on a pallet. It is 1/4 inch thick and cuts like butter and is a wonderful material for templates. I attached the paper templates to the board with WEST System 205 epoxy. I put a skim coat straight on to the board, laid the patterns on the board, and then coated it a with a pretty heavy coat sqweeged over the paterns.
A couple of hours later, after the epoxy had cured, I cut the templates on a bandsaw. In the picture above you can see that I have yet to complete the final contouring on about half of the templates. A Long EZ “Guru” might notice that the lower template for the lower winglet is missing. That is because I don’t plan on installing the lower winglets, as many builders have noted that the aircraft does not notice them being gone. Besides the Beech Starship doesn’t have lower winglets!
Al Wick, a Cozy builder from Portland,is going to let me borrow his hotwire saw to cut my cores. Cheers, more later.
(see Al’s link to the left)

(UPADTE 4-13) I visited Al Wick and his very cool Cozy this morning.  His ability to “see” system failures before they happen then and ” build-the-safety-in” to the Cozy to assist in preventing them is truly amazing.  Thanks Al, for the loan of your Hot Wire Saw!  I hope to be cutting foam within two weeks.

Al Wick\'s Subie/Cozy

December 15, 2007
Updated January 5, 2008
Updated February 19, 2008
Updated March 16, 2008

Greetings, Friends of Canardia, All hail Rutania!

My name is Curt Cowley. I’m a 45 year old father of two from Hillsboro, Oregon, with a hankering for a Long EZ. My wife is being a very good sport.

This blog will act as my Builder’s Log for my new (old) Long EZ project. First, a little about me and my Long EZ. While I was a Huey Medevac crew chief stationed at FT Lewis, WA. in the early 1980’s I watched civilian technicians build two Long EZ’s for the 9th Inf. Div. as experimental recon. aircraft.
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Click on the picture for full-size. Thanks to Tom Staggs for the photo.

In 1995, when I was the Non-Comssioned Officer-in-Charge (NCOIC)of the OPTEC Threat Support Activity (Aviation),FT Bliss, TX, I was tasked to aquire a UAV simulator. I was able to sign for the surviving Army Long EZ for our project, then being stored at Redstone Army Arsenal in Huntsville, AL. We had good ol’ Dick Rutan come out to give check rides to the project pilots and I had the honor (horror?) to have LTC Rutan, Richard, USAF (Ret.) inspect the aircraft prior to our test flights. He is what you might call…ah…ah..picky! (I Survived!).
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Luke AFB: 4517 CCTS Class 68-A 6 Feb 10 Aug 1967.
Dick (Misty 40) Rutan is standing in front of the Cactus .
Click on the Picture for full-size

Here I am in the business end of my old “office” as the Weapon Systems Operator in one of OPTEC’s Russian-built Mil Mi-24’s, tail number 270 in 1996 or 97.
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You might recognize the “I can’t believe I get paid for this!” smile on my face.
Click on the picture for full-size.

These days I am a Service Manager for a large Hillsboro , OR  aviation maintenance shop.

I purchased my Long EZ from a salvage dealer in Bremerton WA. In 2002, he bid on and won the contents of a storage unit that nobody had been in since 1990 and the rent had not been paid in a very long time. He was not happy to find an unknown (to him), unfinished homebuilt airplane. After he found out what type of aircraft it was, he attempted to sell the it on one of the Canard Websites. The folks that contacted him about the ship asked such “inside baseball” questions that he decided it was not worth the trouble and put it back into storage. Can you imagine having no idea what you have and people keep asking, “do you have the GU or Roncz?”.
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By the way, it has an unfinished Roncz canard, but the fellow moved it and stored it on the unfinished foam side to protect the fiberglass skins(!) on the bottom. I’ll be building a new canard. (see the link to Eureka CNC)

(Update 5Jan) Thanks for the help with my canard questions Dave! Based on the information Dave provided me, I may be able to save the canard.

(UPDATE 19Feb) The canard is NOT usable, I spent some time looking at it this last weekend and I don’t like fiber orientation on the lower skin…too sloppy. I counted my foam blocks and have found that I have ONE extra to use to cut a new core.

I started emailing the salvage dealer once a month in the May 2005 and he finally answered me in October 2007. After inspecting the plane, a deal was struck and I purchased the project for a very good price. The project included pre-molded Task Research fuel strakes with baffels, upper and lower cowling, all the raw foam for the flying surfaces, one roll each of BID and UNI, and the Brock metal kit.

The project is through Chapter 18 (canopy) and someday I hope it will look like Steve Volovsek’s beautiful Long EZ.

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Click on the picture for full-size.

My friends and family always ask “isn’t that the type of plane that John Denver died in?” Yes, it is. To make a long story short, John would be still with us if he had just flown the plane. See a more detailed explaination in my blogroll to the left.

I’ve waited 22 years to get a Long EZ, but for now she’s making her first “flight” hanging from the rafters in a friend’s shop for a couple of months, while I finish the 7EC Champ restoration that is in my garage.
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Here is a picture of the Champ getting ready for her trip to the paint booth. I got a bunch of strange looks from other drivers going down the road. What’s the matter with everybody? Haven’t they seen a ‘61 Corvair Rampside pick-up towing a ‘56 Champ by the tailwheel before? I mean Come on!

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Click on picture for full-size
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Click on picture for full-size
I’ll be moving on to the Long EZ project soon.
UPDATE
The Champ is still in the way of the Long EZ getting serious attention. This is the state of the ship as of Easter Weekend.b021.jpg