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Builder Report — Mark Gaffney

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05/01/2023 — My Teenie Two project falls last on a long list of must dos. Family, home, farm, and our Cessna 172 comes first. Many of you know that Anne and I are also finishing our cabin project. Yep, started in 2016 with a cabin kit from New Hampshire, but like the Teenie Two, almost done. We sold the Christen Eagle, so that has freed us up a bit, but finding the time is still hard raising a teenage daughter.

Currently I have multiple projects that I’m working on N589TT. In December of 2021, I rigged up a temporary gas tank so I could start my engine for the first time. I tied the airplane to my pickup truck and hand propped the engine. It popped once. I propped it again and it roared to life! As I revved it up, I could feel the power of the engine tugging at the plane. She may only have 83 horsepower, but the airplane is a light weight at 450 pounds empty! I’m guessing she will climb like a homesick angel and I’m hoping to get 130mph cruise. (that’s with an open cockpit)
The gas tank is almost ready to be welded. I made the gas tank as big as I could with limited space. Because the gas tank is above my legs, I didn’t want to go with tin or fiberglass. I wanted a tank that could take high impact loads, God forbid. The gas tank is made out of H50, 0.05 inch aluminum. Once the tank is welded, I will be able to find out how much it holds. I’m hoping for a 7-8 gallon tank. With fuel burn only 2 1?2 to 3 gallons per hour, that would leave me with a two hour range with VFR reserves.

I’m also finishing up the stabilizer and elevator on the tail. The elevator and ailerons I made years ago with an 8 foot bending brake that I rented from Home Depot. The rudder is close to being done. I have some control attachments to finish, as well as some painting to do. I’m holding off on engine cowling until after I have a flying airplane. I may go for the Harley look and not cowl it. The engine is bigger than the firewall!

I rigged up a temporary paint spray booth in my garage’s third stall last fall. With all of the plastic and the bright LED lights at night, a few of my neighbors said it look like a “Breaking Bad” episode. I was able to finish the paint on both of the outer wings as well as the stabilizer. With the garage being climate controlled, I can paint any time of year. In the past I would time all of my painting in the fall with mild temps and low humidity. (I could also safely park Anne’s auto in the driveway with no chance of hail) With this setup, I was painting in the middle of January this year!

So what’s left to do? I’ll need to make the wing tips out of fiberglass, something I’ve never done before. The panel above the gas tank needs to be made and painted. I have the template for the windscreen, but cracked the plexiglass while attempted to make a year or so ago. I’ll need a final inspection from the FAA. I have been informed that I won’t be able to get hull insurance on the airplane, only liability. With less than $10,000 in the airplane, I’m fine taking a hull loss. FYI, underwriters don’t like plans built experimental aircraft. As a bonus, I fit in the airplane wearing my emergency parachute! The picture (next page) is of Veronica wearing her custom made kiddy parachute that we had made so she could do aerobatics in the Eagle with Daddy. We are all hanging on to our chutes because we are still looking for an RV8 to replace the Eagle. The good ones have been going for north of 200 grand! Like everything else these days, I should have bought one a few years ago.



03/13/2021 — I first attended the “EAA Fly-In” in 1985. I was amazed that people were building and flying their own airplanes. I fell in love with the idea and promised my then 12 year old self that I would someday build my own airplane!

While a student at the University of Iowa, I started to research what I wanted to build. I wanted something that I knew I could finish regardless of my income. (I was driving a $500 car at the time) Because of the expense, I wanted to stay away from a certified engine. I also wanted a metal airplane. I really liked the VW engine as an aircraft engine. It is air cooled and runs at a low enough RPM not to need a reduction gearbox. Parts are inexpensive and the engine is relatively simply and reliable. The only problem is a VW doesn’t produce a lot of power. So if you want metal and a VW, you are most likely looking at a single seat airplane. (this was prior to the Sonex)

In the early 90s there were only 4 experimental aircraft that were metal and incorporated a VW engine. The Plazamany, the Hummel Bird, the Mini Coup, and the Teenie Two. The Hummel Bird with its ½ VW was too small for me. The Plazamany was too complicated and planes were costly. I don’t think I could even get plans for a Mini Coupe at that time. So, in February 1995, I purchased plans #15-2635 from the designer Calvin Parker. (now deceased)

I started to build N589TT around 2000. By then I was a professional pilot, something I didn’t see happening 5 years earlier. I was working for an airline based in Minneapolis and Detroit, but was living in Lincoln. Because I had to “commute” to work, a lot of times I found myself jump seating a day early, so as not to risk missing my trip. This left me with a lot of time on my hands, which was a perfect opportunity for me to file parts. The ribs for example I would transport between two pieces of cardboard about 30 inches long. Once I remembered bringing ribs back from Minneapolis to Lincoln. I put the ribs on the TSA belt. The belt stopped and the look on the screener’s face was priceless. On the screen it looked like a medieval Worf like killing blade! And yes, it was post 911. He asked what it was and I said an airplane part. He said model? And I said yes, because I don’t think he would have understood. I always did that in uniform, just in case.

I know it’s been 20 years, but that doesn’t bother me. If you are thinking about building an airplane you need to ask yourself a question. Are you building to build? Or are you building to fly? If your building to fly than get a fast build kit, a project that has already been started, or purchase a completed home built. I was never building to fly, because I did it for a living. I have enjoyed the building process tremendously!

Anne and I built a new house last year. (2020) So, I haven’t worked on the N589TT for 9 months. I am currently finishing my new shop where I will finish the airplane. It is heated and air-conditioned, so I have no excuses! I hope 2021 is the year that I finish and fly the little bird to Oshkosh in 2022!











































03/06/2021 — Here are a few pics of N589TT being built. By the way, I soloed in May 1989 and I’m building a Teenie Two. N589TT.

Pictures in no particular order…