Flight Testing Homebuilts
Joe Gauthier
860 635-4058
The Opportunity to build and fly comes with a responsibility to do it safely and carefully.
Professional testing involves a team; you are a team of one...
Test facilities, Equipment and support availability
Technical Counselors
EAA Flight Advisors
FAA Advisory Circular 90-89
Designers Recommendations
Other EXPERIENCED Builders
A&P Mechanic
Airport
Low Traffic
Unpopulated
Hand Held Radio on the ground
Emergency Facilities
Flight test Area
Chase planes and pilots
Introduction.....
First Homebuilt a BD4 in 1973, had a mentor
Built BD4, Davis DA2A, Lancair 235, Thorp T-18,
Taylorcraft and Cessna 140
Maiden flights 26
Homebuilts 78, Kitfox to Glasair III, Stewart 51, Midget Mustang Favorite
CFII Airplane ME Com’l
Tailwheel Stick and Rudder
FAA Safety Counselor
Tech Counselor, Flight Advisor
A&P Mechanic
Qualified Test pilot
Current in Make and Model and other types
Know the plane
Knowledgeable Mechanic/Pilot
Experiencedflight testing
Do it yourself ? Rent, Borrow, try it out with guidance in unfamiliar airplane
Conventional or Unique Design?
Builder/ Owner Conceived design Changes
Engine Certified?
Canard, Pusher designs
Tandem Wing (Quickie)
Unique CG Situations with Canards
Conventional Landing Gear
Trust your "Eye Ball" TLAR..
Size, big and small BD5 and Stewart 51, Questair Venture
Delta Wings, Glasair III
Airframe knowledge Design/construction Compliance with Plans?
Flight Test Plan
Small graduated steps toward the overall Goal
Each part defined, Switch tanks, retract the gear, Flaps/no flaps? Etc.
Engine condition, new, overhauled, mid-low time?
Fuel Flow test, who made the hoses? Debris in the hose?
Flight test CG Determination, fuel loads and ballast
Stick to the plan
Weather requirements
Weight and Balance for Fight test
Runway (Abort Point, takeoff and go around)
Support crew, essentials only,
Note taker near radio, pen and paper, well briefed.
Communication plan, don't call me, I'll call you
Emergency Plan and equipment
Parachute and Hard Hat
Fly the Plane, don't stall
Test Pilot performs the EXTENSIVE preflight check the daybefore planned flight
Checklist, develop, fine tune and use one
Seating environment (Sit High)
Ergonomics, are things where you would expect them?
Conventional Panel Layout
Labels and Placards, test flight parameters (Masking Tape & Magic Markers)Seat Belts
Canopy, cockpit security, latches
Engine, Prop Controls, function
Fuel system, controls, quantity, and indicators
Boost pump during runup?
Control System; Trim operation, proper direction and operation
Brakes, feel and function
Radio test, communication capability
Emergency cockpit egress
Magnetos, Idle mixture cut off, Primer function
Temperatures and pressures
Inoperative equipment/placards
All required paperwork, Certificates and W&B, POH, Placards
Engine run up and leak check prior to flight
Cowling off inspection
Fuel System
Engine Controls
Cooling components
Taxi Testing
Reasonable Speed, controllability
Visibility FOV
High speed Runway flights
Throttle response
Brakes, controllability
Traffic surveillance
The Big Day
The plan, Step One
Repeat the preflight and runup
Checklist use
Repeat the taxi operation. No High Speed Taxi
Close attention to temperatures and pressures
Checklist use
Traffic
Clear the area
Alert the ground crew
Takeoff
Radio Communications
Full power
Abort point V1
Evaluate control feel, instrument indications
Smooth lift off above stall speed, note IAS
Adequate control, 3 axes? Trim Feel?
Positive but shallow? Climb angle, speed and power
Climb configuration, Flaps? Power settings
Checklist use
Circle overhead the airport
Monitor instruments and controllability
Maneuver to return to the landing runway if necessary
Report to the ground crew
Low cruise power at 3,000-ft overhead
Checklist use
Remember the plan
Slow flight, flaps, landing gear, boost pumps
Monitor Instruments and relax
35 or 40 minutes max
Checklist use
Report to the ground crew
Landing
Perform landing aloft
Explore Approach Speed 1.3 Liftoff IAS
Execute go-around
Landing plan, power, flaps, approach profile
Power off approach, glide, sink rate etc
Checklist use
Monitor traffic
Report to the ground crew
Radio Communications
Go around plan, Approach Window
Stop straight-ahead on the runway
Add power and clear the runway
Congratulations and de-brief
Expanding the Flight Envelope
Write a plan, stick to it.
Work some relaxation time into each flight
25 Hours is barely enough
Required Crew
Ground Communications plan, take notes, voice recorder
Airspeed Calibration
Propeller qualifications
Engine Cooling
Climb test, VX, VY
Glide Test
Altitude loss in a turn
Stability Testing
Additional weight
Trim performance
CG configurations
Landing gear, cowl flaps and wing flap operation
Minimum, Maximum speed
Flutter
Aerobatics
Stall series
Spin avoidance, Use CFI as a refresher if needed
Limit the testing, results in limits on the envelope
Documentation of results
Phase One/Phase Two Operating Limitations
Joe Gauthier
9 Kowal Drive
Cromwell, CT06416
860 635-4058