Re-painting a 747. Pretty cool.

Samaritan's Purse - South Sudan - A Lifeline for Emergency Relief

South Sudan is calling!

Q400 assembly

I saw this video online and thought it was pretty cool...for all those maintenance specialists out there.

AMREF Flying Doctors

An interesting video showcasing the Flying Doctors, based at Wilson Airport in Nairobi.

Hiatus

I apologize for the lack of blog posting the past weeks.  We got our clearance for our son's paperwork and traveled very short notice to Ethiopia to pick him up.  Then we traveled back to the United States for our home leave time.

I will be posting some things as I come across aviation-related things...otherwise, be patient and don't expect too much over the next couple months.

Thanks!
nathan

5Y-CMA First Flight, 19 August 2011

Adventure in an Airplane...

Many of you are aware of the work that Samaritan's Purse has been involved in up in South Sudan.  They have been in the country for years, working with national people on a variety of different levels, but most importantly helping to take the Gospel to the people who need to hear about Jesus Christ.  They have been doing water projects, church reconstructions, medical projects, and most recently, food projects.

You see, the people of South Sudan are being severely harassed by the North Sudanese military.  They are being chased from their homes, bombed, killed, and otherwise greatly mistreated.  There is a large group of people that have been chased from their homes in the Nuba Mountains, which is right along the border of North and South Sudan.  They are fleeing towards the south and into a place called Unity State, which is a large land area like a US state or Canadian territory, though smaller.

These people,  numbering in the thousands, are seeking refuge in a swampy area with squalid living conditions.  They have no clean water, no food, no place to stay, nothing.  They have been eating things like grass and other plants for over a week now, simply because they have nothing else to eat.  Pregnant women have walked for miles to get there, only to find no source of nutrition for themselves and their unborn babies.

It was to this backdrop that we here at AIM Air in Nairobi readied ourselves the end of this past week.  We readied the Samaritan's Purse DC-3 on Friday and Saturday and went out for a day of practice on how to perform air drops into a remote location.  Then we went home, readied ourselves, and said goodbye to our families.  Early Sunday morning, we departed Nairobi and flew all the way up to the Unity State area and loaded up the airplane with bags of sorghum, beans, lentils, and a corn/soy protein mix.  Each load was 66 bags, each weighing 50kgs (a little over 100lbs).  We then proceeded to the drop zone and sent our load tumbling out the door of the DC-3 and into an area about 100 meters by 50 meters.

So began the week.  We continued over the next 5 days to drop food, tarps, and other non-food items to the people on the ground.  It was hard work, but rewarding, because we knew that people on the ground who hadn't eaten in who knows how long were getting a meal that night.  As we flew over each day, we could see more and more of the blue SP tarps being put up, and heard reports that over 95% of the food that we dropped was successfully recovered.  Going to and from the drop zone, we sat in the back of the plane and watched South Sudan stream past our door, in awe of the vastness of such a country.

We ended our days hot, sweaty, and sticky from thousands of pounds of sorghum, with bruised backs and legs, and aching fingertips.  But we fell into our beds each night knowing that what we were doing each day was allowing more and more people to survive another day.  Each day we rose, not knowing what the day held, but knowing that God works everything out for His good purpose, and we were happy to be right in the midst of some of that good work.

To see some pictures and video of some of what we did, you can go to these links:

"Aid for Refugees"

"South Sudan Airdrop"

Both are very well done, and give you a glimpse into what we were able to accomplish while there on the ground (well, in the air really).  Please continue to pray for the people of South Sudan as they seek to build up their new country and pray that organizations like Samaritan's Purse can continue to help reach people with food for their soul as well as food for their belly.

A somber reminder

As most of you will keenly remember, tomorrow is the two year anniversary of the accident that occurred involving an AIM Air aircraft and two of our close friends.  1 August 2009 was the day that these two fathers said goodbye to their families at home and went in to do what seemed to be a fairly "normal" flight that day.  However, we all know what happened and life changed forever.

For those of us who are still here working with AIM Air, I don't think we will ever forget that day, and the days and weeks following and the torture we endured watching these two young families walk through excruciating times that followed.  We often said, "Well, we don't know why it happened, but God is in control."  And I don't think a person on this earth still knows why God allowed it to happen, but He did, and we must keep giving Him the glory for why He does what He does.

It has been an emotional (as much as can be for man, haha) these past few weeks as we have slowly finished up our CMA project.  Many of you might not know, but this airplane was the one that was supposed to be flown that fateful day two years ago.  When Frank was doing his pre-flight, he discovered that there was an electrical problem, and that's how Ryan got involved.  They decided that there wasn't time to fix it, and another plane was used in it's place.  Since then, CMA has not flown.  Two years of inactivity; a constant reminder sitting quietly in the back of the hangar.

Tomorrow is the two year anniversary.  And tomorrow, CMA stands ready.  The project has been completed.  The engine has been run for the first time (and did well!).  And so, the airplane stands quietly again.  This time, however, it stands with fuel in the tanks, oil in the sump, and a whole new look about itself.  This week, it will again roar to life (as much as a Cessna 206 can!), taxi down the taxiway, and once again take to the blue skies of Kenyan airspace.  And we will all be reminded of our friends and the sacrifice they made to serve the Lord out here in Africa.

AIM Air - "Serving those who serve"

All cleaned up and ready to go!

Interior - Check!

 We've been drawing close to the end of the CMA project rebuild.  Pretty much the final installations are the headliner and the remaining plastic interior pieces, both of which are brand new.  We had the headliner installed on Monday of this week and we finished up the plastics yesterday.  Then we went to have the airplane weighed.  Sorry!  I totally forgot to take my camera with me when we went for weighing.  Oh, well.  Enjoy the pictures of some final assembly. 

 This is the fundi (worker/technician/specialist/etc) from Sai Cushion, where we purchased the headliner.  It is custom made for a Cessna 206, with a few things that we request.  This guy had the thing installed in just a couple hours. 

 And it looked great! 

 We have some special zipper sections so we can access certain things, like the flap and aileron cables (the long lateral zipper), the fuel quantity transmitters (the smiley shaped zipper), and one of the radio antennae (the short lateral zipper). 

 Crew seats installed for weighing.  Also notice that the upper plastics have been installed, including the speaker/light pieces above the crew heads. 

Crew seats.  We use the JAARS seatbelt attach points, which also give a cargo button for cargo tie down options.  

 Caleb finishing the rear access panel.  Notice the anti-skid on the floor. 

 Pilot side, rear cabin. 

 

Rear cabin area.  The tie downs on either side of the middle window are for the rear seatbelts.  They also have the cargo button for cargo tie down configuration.  You can also see the orange ELT in the back and part of the HF just below the ELT.  

There's a light at the end of this tunnel...

 ...because CMA is almost done!  We have been putting some of the finishing touches on CMA this past week or so.  It's been really nice to get some of the final double inspections done with and get things closed up.  Right now, we're waiting for some inspector's from the KCAA as well as some other things.  Within the next week, we hope to finish closing up the aircraft and get it weighed.  Then we're ready to run!  Then a test flight!  Oh, it's getting closer!  Meanwhile, enjoy some pictures...

 Pete and Marko discussing some things about the aileron rigging. 

 Pete really did have his hands all the way in CMA!  

 Another one of Pete, this time installing the battery and battery box.  

 John getting the floor panels together and installing them in the plane.  We put anti-skid down on the floor to help things not slide around so much.  That's what the black stuff is. 

 Pete and myself.  I was getting some of the interior installed while Pete was working on the battery. 

 Here's Caleb getting the wing strut fairings installed.  They required a bit of..."persuasion."  :)  That just means that they weren't exactly fitted well before painting.  Turns out a few new nutplates in the right place = fits just right!

  One of the last things we do is check the toe and camber adjustment.  This ensures that the airplane tires will wear correctly when the airplane is fully loaded.  Also, to be sure there isn't any undue strain on the wheels and axles.  Here Caleb is checking the measurements to see if there needs to be any shimming. 

 Guess there needed some shimming!  You change shims located between the axle and the gear leg to achieve the proper toe and camber.  

 We also unwrapped the new windshield for the first time yesterday.  Here's Tim starting on the right side. 

And Caleb finishing on the left side.  Wow, it's clear!  It's exciting, that means that we're close to having to see out the windshield!

Taking the next steps with 5Y-CMA

 This past week provided us some more solid time spent with 5Y-CMA.  We really got some good work done, and some good double inspections have been occurring as well.  Double (and triple) inspections are always a good thing, as it gives another person a chance to look things over, things that you have been staring at or working with for who knows how long.  It's easier for them to spot any problems since they're just now coming to the airplane, or to the specific item.  Anyways, we finished our fuel system inspection, so we took the plane out to fill 'er up!  While out there doing fueling, we got some other things done as well.  Enjoy the pictures!

 At the front of the hangar to do fueling.  This is part of our safety program: no fueling or de-fueling inside the hangar.  It was also nice to get out and get some fresh air and sunshine! 

 The main project that day was calibrating the JPI EDM-930 fuel quantity system.  Caleb made out a nice chart for the test...

 ...and then we went to it.  Here I am looking like a true supervisor watching my friend do all the work.  HA!  We put in 10 gallons of fuel in each tank at a time so we could calibrate the 930 with the OEM fuel quantity transmitters.  It took a while, but we got it done.  However, we did find a few small fuel leaks along the way.  Ah, well, nothing we can't fix relatively quickly!  Better to find them now then find them later. 

 In the mean time, Pete was in the back of the plane installing interior...well, that was when we let him in the plane.  Have to be still to measure it out right! 

 He has this look of disgust almost...'you mean I have to get out again?'

 'Are you kidding me?  AGAIN?'  Despite having to get in and out, in and out, in and out, Pete has done a nice job getting the interior installed so far. 

So now the airplane is sitting here in the hangar...out of the paint booth!  We had to move over to the C210 for a few days, so she's by herself again.  But she's looking better and better.  You know you're getting closer, when pilots start coming down and you can see the drool in the corner of their mouths. :) 

Propeller Installation on CMA

 Last week we got the prop installed on CMA, along with some other things.  It has been a very productive couple weeks on the airplane, as there wasn't much else going on in the shop. Things have been moving along with the progress, which is good.  The airplane needs to fly soon! 

 Caleb prepping for the prop installation. 

 All cleaned and ready to go!

 Caleb and myself installing the prop. 

 Torque it up, and she's ready to go!  Well...not ready to go, but getting closer!

 John and Adamson cleaning up some of the mess on the firewall. 

 With a new engine comes new baffle seals...which, in this case, rub the cowlings a bit different than the old baffle seals.  So in this picture, I am making sure the baffle seals are fitting snugly all the way around the engine and cowling.  It's a good think I have long arms...I can just reach to the rear baffle seal.  

Our illustrious AIM Air general manager Dale showing John how to polish the spinner with your fleece. 

The work moves onward...

 While things have been relatively "slow" in the rest of the shop, we have been plugging away at CMA.  We've been working on all sorts of things.  Flap rigging, rudder rigging, interior, instruments/instrument panels, placards.  We're getting so close to doing to system checks, it's good to see it all coming together well.  Keep checking back in as we keep working through it to finalize this project 206...

 Here I am working with some of the new plastic interior pieces getting them fitted just right.  Shout out to City Compressor for the cool t-shirt. 

 Joseph fitted the new plastic panels for the three doors. 

 Goof-off.

 Gregg has been helping with the flap follow-up rigging.  It's been a bit of a challenge for the guys, but he finally figured it out.  Nice job, guys! 

 Shot from the back of the hangar where CMA currently is.  It will be good to get her out of there and onto the flight line. 

 Instruments!  It sorta looks like a weird little city of black buildings...

 We had the instruments installed, but had to remove them and install the panel by itself.  Gregg is taking the instruments out of the panel in this photo. 

Alright...here's the last photo for this set...can you find me?!

Nose cowls...

 ...are finally finished!  We have been working on the nose cowlings for CMA.  The old ones were just really bad off...fiberglass coming apart, screw holes all wallered out, that sort of thing.  We had a set in our inventory, but they required some "modifications."  My co-worker Jose did most of the work getting them fitted properly so that they would match the main engine cowls.  It took a lot of time and some trial and error, but they came out looking pretty good!  We painted them, along with the rest of the blue stripes on the nose section, and they are ready to go. 

 Pre-paint.  Pretty much everywhere you see white, that's where Jose had to "modify."

 Lookin' good with that tuned induction IO-550-N.  Check out those exhaust pipes, too, courtesy of Leading Edge Exhaust Systems. 

 AIM Air short termer Gregg, checking out the preparation job for painting. 

 The airplane looks like it's taking a nap with all those blankets.  All that for a few little blue stripes. 

 Cowlings taped off for the first set of stripes. 

 Marko busy getting things sorted out with the cowlings.  You know, painting preparation takes like 90% of the work, and the actual spraying takes about 10%.  Better to focus on good preparation, which brings good results. 

 Introducing...

Magneto Man!!  I know this doesn't have anything to do with cowlings, but Pete has been slaving away doing magneto overhaul after magneto overhaul after magneto overhaul for us.  He's done a great job!  Thanks, Pete!