A real zero

He’s slow to pick up speed. The off-white hand of the airspeed indicator is creeping up the dial ever so slowly, as if the landing gear were rolling over wet grass, not over smooth asphalt. Huh. The power is good. The Tach reading right where it should be. The roar of the engine steady and strong through the heavy walls of my headset. The runway stripes are zipping toward me, under me, with increasing vigor. The yoke is light in my hand. My senses tell me I’m picking up speed. But the airspeed indicator says I’m only going… thirty-five miles per hour?

Boy, these big, wide runways really mess with your senses. I glace left. There’s a lot of asphalt beyond the wingtip. Santa Fe’s Runway 20 is twice the width of my home base’s widest runway. That’s an extra 75 feet.

Still… Warbler is eating up quite a bit of this wide runway… here comes the north ramp already… and I’m still on the ground. Not that there’s a shortage of runway in front of me, but what’s going on here? Power is good. Engine sounds fine. Still, here we are, more than a thousand feet down the runway and I’m going only 40 miles per hour. How can that be? Think! The plane is light. Quarter tank of fuel in each wing. No cargo… Only me onboard.

Ah, here we go! The nose is finally lifting… But wait. I’m still at 40. He shouldn’t be ready to fly yet. Not in these conditions. There’s hardly any headwind worth mentioning. This is all very strange. Very unusual.

The runway center stripes zip under the cowl with increasing urgency.

Tentatively, I pull back on the yoke and Warbler leaps from the runway, a stone shot from a trebuchet. Holy cow! The wings rock as I pass through an air pocket, I level them and steal a quick glance at the panel. My airspeed is now zero.

Zero?

The airspeed dial’s off-white needle is pointing straight up, giving me the middle finger.

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What.   The.   Hell… ?

They say it takes five seconds for a pilot to recognize when something has gone terribly wrong in an airplane, and to react to it. I don’t know if that’s true. I didn’t time it. But I can testify that there’s definitely a deer-in-the-headlights moment while the brain deals with the unexpected. Before the body springs into action.

Of course, I hardly sprang into action. Actually, I did nothing. In hindsight, I should have chopped power and dropped back onto the runway. Assuming that I had had enough of it left to safely land and stop. I can’t say whether I did or didn’t, because I never considered it. Instead, I simply flew the plane, which is a legitimate response, and one of the first things you’re taught to do when something goes wrong.

At that moment, while I was processing all the conflicting data around me, the tower called, “Ercoupe 116, turn southwest, proceed on course.”

I think not. Time to end this test flight and get back on the ground. I thumbed the mike button, “Uh… 116 would like to return to the field.”

The response was immediate: “Make right traffic, Runway 20.”

Up to this second, I’ve been flying on auto pilot. Not a fancy mechanical marvel, but the martial arts muscle memory of tasks repeated time and again until the body does what’s needed without the brain wasting a neuron on it. But now it’s sinking in that I have no idea if I’m slow, fast, or just right. It’s a perverted aeronautical version of Goldie Locks and the Three bears.

Of course, in the old days pilots didn’t have airspeed indicators. Planes predate all of our gadgets. What was it my forbearers did to judge speed? Oh yes. They listened to the song of the slipstream across the bracing wires, the iconic “wind in the wires.”

No wires on an Ercoupe.

It suddenly dawns on me that rather than being an annoyance, this is a potentially dangerous situation. Sure, unlike most planes, if they get too slow ‘Coupes don’t stall. Not if they’re rigged right. Of course, Warbler has a brand-new tail. That’s what I’m doing today. I’m conducting a FAR 91.407 (b) post-major maintenance test flight to ensure that his flight characteristics haven’t changed. To ensure that he is  rigged right. Still, even perfectly rigged ‘Coupes develop what’s often called “profound” sink rates when they get too slow. Something to be avoided close to the ground like I am.

I’m not scared. Not at all. I’ve got a lot of time in these birds, and a fair bit in this very serial number. But I know I’ve got to think smart. I keep the throttle to the fire wall and hold the nose near the horizon. Screw the climb rate. Screw the pattern altitude. Gentle bank right. Level off. The runway drops behind my twin tails. Now a second turn. Nice and easy.

Should I let the tower know? They already suspect trouble. I told them this was a post-maintenance shakedown when I called for clearance. Should I advise them that I’ve lost my airspeed indicator and have no clue if I’m flying 55 miles an hour or 110? Well, what good would that do? It would seem to them a bigger emergency than it really is for me. For me in this plane.

I’m cleared to land. I’ve stayed high, kept the power up, and held the nose low. I know this makes me fast. Fine. I’ll bleed off the speed when I’ve got asphalt inches below my wheels. Down, down, down I come. The giant, wide runway rises up to greet me. I pull back on the yoke and Warbler skims the runway like a stone skipping over the calm waters of a pond, floating forever as taxiway lights shoot by on either side, then he gently settles to earth, rubber kissing the asphalt, still—according to his airspeed indictor—traveling at zero miles per hour.

 

Happiest of Thanksgivings

Happy Thanksgiving! OK. Yeah, right. I know Thanksgiving Day was really yesterday, so I guess I need to say either happy Thanksgiving +1, or happy belated T-day. Either way, as this is the regular publication day closest to the big day, I decided to use it for my T-day post

Today, of course, is actually the oddly named “Black Friday,” and you might expect that with Tess in the Airplane Hospital for extensive repairs after our October mishap, and considering the fact that there’s not been much flying happening in this flying family over the last year, I might be in a mood to match the name of the day today.

But that’s not the case.

First, for anyone who missed the memo, Tess will fly again. The cost of repairs is nearly as much as she cost in the first place, but given all the upgrades we’d undertaken, I had insured her for more. It was a bit of a drawn-out process, with at one point an AIG insurance adjuster complaining to me that “it’s such an old airplane,” to which I bit my tongue and didn’tsay, “Well we sure pulled the wool over your eyes on the plane’s age when you insured it, didn’t we?”

But repairs are now finally underway, so that’s good news, and a huge relief. Of course, it won’t be fast. As we speak, Tess is back in Santa Fe, looking more a wreck than an airplane. Everything forward of the firewall is gone. The prop and cowl are off, the engine dangles on a crane like the corpse of a hanged convict, and the bent engine mount lies on the floor to one side.

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Next, dozens of rivets need to be drilled out to remove large skin panels between the firewall and the front of her wings on each side, exposing the bent stringers—metal supports that run nose to tail—that need to be replaced. New skins need to be cut and formed to the proper shape and riveted onto the fresh stringers. Then a brand new engine mount must be attached and the engine re-hung, which entails reconnecting all the disconnected plumbing and electrical wires. And of course, her main landing gear needs to be reconstructed, as well. This is going to be a loooooong process.

Adding to the potential triggers of a black mood, the next hospital bed over from Tess at the Airplane Hospital is occupied by my second favorite flying machine—Lisa’s boy Warbler. Ironically, Lisa decided to hangar him in Las Cruces for the Ercoupe Nationals, rather than park him on the ramp. I say ironically, because rather than giving shelter as a hangar should, Warbler got damaged by Lisa’s bid to protect him from damage. You see, the FBO hired a guy to paint the hangar, and the painter guy decided there was no reason to take the planes out of the hangar before he sprayed paint all over the place.

Warbler’s glass was destroyed. All of it. The windshield, side doors, top door, back windows. Thousands of pin prick-sized melted pockets in the plexi.

So there’s plenty to be in a black mood about for Black Friday. But instead, I’ve used the downtime to count my blessings. Other than becoming much poorer since becoming an airplane-owning family (and who’s to say we wouldn’t have just pissed the money away on something else, anyway?), and being occasionally stressed out, the airplane has been nothing but healthy dividends on the investment—at least with the proper perspective.

Tessie has changed all our lives. She’s taken us to beautiful places where we’ve had amazing adventures and met fabulous people. It’s only been a few short years—half a dozen if I’m counting right—but it seems like forever. I don’t really have a clear sense of “pre-Tess.” It seems like she’s been part and parcel of the family forever.

For that, I’m thankful this Thanksgiving season. Thankful for the flights of beauty and fun over these past few years, and Thankful that my future promises many more.

 

Frigid Flight

First the thick T-shirt from Eddie Bauer. Next, a heavy polo-style sweater, also, probably, from Eddie Bauer. After that comes the scarf. Then my deep blue knock-off MA-1 flight jacket. I’m getting ready for a frigid flight. I slide my hands into warm gloves. According to the internet, it’s 17° F at our homebase. On the ground. And the sky gets colder the higher you go up.

I finish by pulling my thick Fly Duluthknit cap down over my ears. They really know how to make hats in northern Minnesota. Of course, my friends in northern Minnesota are laughing their asses off right now if they’re reading this—they wear short sleeve dress shirts at 17 degrees. I’ll bet they don’t even reach for their extra warm, thick, and wonderful artic-proven Fly Duluth knit caps until the mercury goes seriously into the negative. But we Southwesterners have thinner blood, and this is the first real cold snap of the season. So I’m not even remotely acclimated to the fact it’s winter. Heck, the cabin heater hose in Tess is still disconnected.

Luckily, however, I had the foresight to plug in her electric engine pre-heater. I did not, however, have the foresight to bring a hammer with me to the airport. Why would this matter? Because the padlock to Tessie’s hangar is entombed in ice like the alien in The Thing from Another Worldwhen I arrive.

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I get out my phone and amend my flight plan for a later departure. Luckily for me, the ice-clad lock proves less an obstacle than it appears; but my real problems have just begun.

As I push on the left hangar door, it starts to open with a crunching groan, hesitates, then rattles back, pouring cold, blue early winter morning light into my frozen hangar. I push on the right door. It grudgingly moves two feet and then jams solid. I pull back. No go. It’s stuck. Stuck fast.

Great. I can only get half my airplane out.

Debbie starts optimistically sweeping the snow from the short stretch of crumbling asphalt in front of Tessie’s wheels while I hack, swear, kick, and chop at the ice that’s lined the right door’s tracks. A north-facing hangar is only a good idea in three out of four seasons.

At long last, both doors stand open to the frigid world. Time to make ready for flight. Weird things happen to airplane metal and plastic at temperature extremes on both ends, so I do a more cautious than usual preflight. The elevator moves smoothly. The ailerons do not. But that’s a good thing on an Ercoupe. Their ailerons are interlinked to their rudders and their nosewheels. With Tess’s nosewheel planted firmly on the frozen ground, her ailerons and rudders would move freely only if they were horribly broken. The oil level is good. I pull off a glove and reach in to caress a cylinder to ensure that the engine heating system is working. It’s hot to the touch, burning my finger.

I check the fuel levels with a Fuelhawkstraw. They’re much lower than I expect, until I remember that fuel contracts significantly when it’s cold. In fact, in his bid to win the 1946 Bendix Air race by flying non-stop, Paul Mantz dropped containers of dry ice into a fuel truck to contract the gasoline so he could squeeze more of the fuel into the tanks of his heavily modified Mustang, Race 46.

It worked. He took the Gold that year. And the next. And the next.

I, however, decide that it’s prudent to add a few galloons before I take off into the white wonderland that stretches between here and Santa Fe.

Tess ready, I pull her out onto the crunching snow and button up the hangar. Or try to. I’ve carelessly left the open lock dangling from the door latch, and dripping water from the towering hangar roof has sloshed into the innards of the lock, freezing solid, blocking the lock as if it were full of cement. Rio takes the glacial lock to the Jeep and holds it close to the air vent, heater on high to thaw it out, while I amend my flight plan for a second time.

Debs worries that I’ll pick up ice on the wings. She’s been watching Air Disasters with Rio, Grandma, Lisa, and me. Not to worry, baby, that only happens in clouds. The sky is pale blue today, the ceiling of a baby boy’s nursery, with not a hint of a cloud. Even if there had been a cloud, it would probably freeze solid and crash to earth in a shower of broken crystals.

Finally, screaming metal doors closed again, lock thawed, I carefully mount the wing and step into my refrigerator of a cockpit. I’m prepared for a long, cold flight. Fuel open. Master on. Beacon on. Throttle cracked. Mags to both. Two shots of prime. Press the starter.

The prop spins round and round, then she starts with less complaint than I banked on, given the temperature. I taxi across the snow, throwing up less of a blizzard than I expected, darn it, then make my way to the runup area to wait for all the engine parts to come to heated harmony.

Finally, the oil temp in the green, I do my run up and pull onto the runway. It seems that no sooner than I push the throttle forward we are airborne, climbing like a jet fighter, the frigid air turbocharging my engine and airfoils, Tess’s white wings stretching out over a white world below.

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Pilots may not, but airplaneslovecold air.

But quickly I discover that this flight is not the frigid episode of Ice Pilotsthat I expected. In the cloudless sky, the sun filters though my greenhouse of a canopy, and with my newly re-connected heater duct keeping my feet toasty I actually start getting, well, too warm.

So I reverse the winterization process. I take off my headset, and ears momentarily assaulted by 113 decibels of pounding cylinders, pull off my thick Fly Duluth knit cap. Next, gripping a fingertip in my teeth, I slide my warm gloves off my hands. Then I slither out of my deep blue knock-off MA-1 flight jacket. Finally, I remove my scarf.

Liberated from the frozen ground, high in the winter sky, basking in bright sunlight, my frigid flight turns out to be comfortably warm

For body and for soul.

 

One hell of a crunch

The ink was still wet on my Private Pilot’s license back in the spring of 1980 when I rolled the Piper Archer onto final for Runway 03 at KDRO southeast of Durango, Colorado. I was wearing my new headset, the first one I ever purchased. Not a sensible one, mind you. Not one that would help reduce the din in a cockpit installed behind the ultimate noise maker. No. The one I bought was a one-ear, corporate jet pilot-style headset with a skinny boom mike.

It wasn’t practical, but, damn, I looked good wearing it.

It also featured something totally new to me: A push-to-talk switch that attached to the yoke with a piece of Velcro. Prior to that, all my aviation radio experience was using CB radio-style microphones that hung on a clip at the bottom of the panel.

The approach was lovely. The flare simply beautiful. There was only one problem: The runway wasn’t where it was supposed to be. Rather, it was a dozen feet lower. As the plane lost lift, instead of softly kissing the asphalt, it dropped sickeningly from the sky with a rollercoaster/broken elevator/falling out of a tree house kind of feel. I shoved the throttle forward, but it was too late. I gripped the yoke tightly, accidently triggering the new push-to-talk switch and, as the plane hit the pavement with teeth jarring effect, broadcast the word “Crunch” for the whole world to hear.

It’s one of those things people never let you live down.

Fast forward to last week. After an hour or so of flying Tess for the pure joy of plying the sky, I was returning to my home base. It was late morning as the clouds were lazy and didn’t want to get out of bed, hanging low to the ground for hours after the sun rose. But now they were small, widely scattered, and high. The wind was light from the south. There were a few bumps, but nothing to write home about.

I rolled onto final for Runway 19. The approach was lovely. The flare simply beautiful. There was only one problem: Someone had moved the runway.

At least that’s the only explanation I can come up with. After more than 782 hours flying this airplane, I somehow set up my worst landing since 1980. Instead of softly kissing the asphalt, Tessie dropped sickeningly from the sky with that rollercoaster/broken elevator/falling out of a tree house kind of feel. I shoved the throttle forward, but it was too late.

She slammed down on the pavement with teeth jarring effect. I heard a double crunch from the landing gear, left and right. Felt the punch. Up the gear strut, across the main spar, up into the seat, and through my spine. Then Tess sprang back into the air before dizzyingly falling to earth a second time, for a second pair of crunches. A second pair of seismic shocks. Again, I was catapulted into the air. Power now fully up, she wallowed for a moment, then regained her airplane pride and shot down the runway, slowly gaining altitude. I banked wide and slow, coming back over the runway to reassure myself that I hadn’t left any parts of my landing gear behind, then came around into the pattern and landed again. Which, with two bounces, I guess was the third landing of the day. This time the runway was where it was supposed to be and Tess kissed the pavement softly.

I taxied to the apron and shut down. The latent reverberation of the pair of heavy hits still quivering in my spine, I thanked the ghost of designer Fred Weick for his decision to build the ‘Coupe with robust trailing link landing gear. I slid the door down into the belly, climbed out onto the right wing and dropped to the ground. I ducked under the wing and inspected the gear. It looked fine. Irrationally, I looked up at the bottom of the wing. Nope. No dents in the wing from the gear. I moved around to the other side. It was fine, too. Then I looked to the nose gear.

It was not fine. Not fine at all.

I stared dumbfounded at my nose wheel faring, which appeared to have been nearly shot away by Arab terrorists.

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What… the… hell…?

But that was only the beginning. The big story wasn’t the blown-out back of the faring. No, the big story was at the other end. The very tip of the nose faring was chipped away. Hardly damage worth looking at, it took me a few minutes to process the cause: My own propeller had taken a bite out of the faring.

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I stood to one side and studied the back of my spinner. It wasn’t parallel with the nose, a sure sign of an issue with the engine mounts. Over time, the rubber mounts tend to compress from the weight of the engine and need to be replaced, but these are only six months old. Still, I popped open the cowl, and sure enough, the engine mounts had collapsed. I guess the impact of the hard landing squashed them like bugs. I could feel my wallet getting lighter by the moment.

I had no idea.

The prop now clear of the nose faring, I taxied back to my hanger and emailed my mechanic, who in addition to being an A&P, holds the prestigious IA, or Inspection Authority. I let him know what happened and sent him photos. Then more photos. Then more photos still. He judged the plane safe to ferry. Two days later, I delivered Tess to the two men I had been hoping not to see for a few months, and they got to work. They meticulously inspected the inside of the engine compartment, looking at the firewall for wrinkles (none), each joint of the engine mount for cracks (none), and who knows what else. Then they got to work changing the mounts, discovering in the process that I’d managed to bend the robust pair of bolts in the bottom mounts.

Quite the crunch.

When it was all done, the spinner back still wasn’t perfectly parallel to the cowl, suggesting one of two possibilities: Either it never was, or the entire engine mount had been bent. My guys told me to fly for a while and see if the trim, handling, or speed had changed.

I flew home.

Now we have to detour into envy for a minute, before the rest of the story unfolds. My hangar neighbor, Lisa, has a very different hangar from mine. My hangar has a largely gravel floor, with only a small square of concreate for the plane’s landing gear to perch on. I have some power plugs. But no lights. None of this ever bothered me.

Until Lisa moved in next door.

You see, her hangar has wall-to-wall concrete, and bright, wonderful lights on the ceiling. It’s also insulated. Apparently, at some point in the distant past, NASA used to launch weather balloons from our airport, and they upgraded one of the hangars. NASA is now gone and the upgraded hangar is Warbler’s nest.

I never needed lights until I spent some time in Lisa’s hangar. But not wanting to attempt to install many banks of fluorescent tubes twenty feet off the ground (I know my limits… sometimes), I purchased some work lights on a tripod from Home Depot while the guys were changing the engine mounts on Tess. After landing, I set up the tripod, attached the lights, and plugged them in. My hangar was filled with soft, warm, wonderful halogen-fueled light. It was so stunningly beautiful I decided to pull up a chair and simply soak in the view.

And that’s when I saw it.

Actually, at first, I thought it was just a trick of the light. An artifact of light, shadow, and reflection. Forward of the wing root was a perfect triangular depression in Tessie’s aluminum skin.

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Eventually, concern trumped entropy, and I rose from my chair, aided by my lightened wallet, and made my way to the plane. I softly ran my fingers along her side and sickeningly felt them side deeply into the depression. This was no trick of the light.

More emails. More photos.

The diagnosis: Structural Damage.

 

The triumphant return of Warbler

“You warned her,” said Debbie.

“Seeing all we’ve been through up close and personal, you’d think she’d have known better,” said Mom.

“This is what she gets for buying an Ercoupe,” said Rio.

My family is lacking in, you know, basic human compassion. Sure, I knew that sooner or later—probably sooner—Lisa’s Warbler would suffer his first breakdownon her watch. But still, I felt badly for her.

Now, you may recall that the consensus from all the experts we phoned, after pushing Warbler almost a mile across the airport to get him back to his nest, was that he was suffering from a stuck valve; albeit one that was manifesting in a way that no one had really heard of before, what with the prop stuck fast turning one direction, and freely spinning in the other.

But they were all wrong.

This is the Tale: The very next weekend Lisa’s mechanic drove over from Santa Fe with a trunk load full of tools. He did some tests, poked, prodded, and basically did all the stuff that airplane doctors do to sick airplanes. Rio and I hung out in the back of Lisa’s hangar, rocking back and forth in her rocking camp chairs, staying out of the way, and pretending to surf the internet on our iPads.

Really, we were eavesdropping—drinking in every word.

After a bit, her wrench-turner decided to fire up the plane. We helped pull Warbler out of his hangar and he fired right up. Lisa was in the cockpit, the mechanic, Rio, and I arranged in a loose ring around the plane, heads cocked, ears aimed at the engine. It sounded, well, not quite right. Or did it? I’d rarely been outside of Warbler listening to his powerplant sing.

This was followed by a comic series of hand signs and pantomimes between Lisa and her mechanic. It became pretty clear that they weren’t speaking the same language. The various finger pointing, hand swirling, and gestures mimicked two drunken deaf people leaving a bar and arguing in sign language over whether or not to call a cab. She was saying that in the cockpit, the noise was back. He was saying that outside, it sounded fine.

Rio looked at me and shrugged one shoulder. At least he and I were talking the same language.

Eventually Lisa throttled up and then we all knew something was amiss. In Warbler’s tongue, he made it clear that something was very wrong with his engine. The mechanic moved his hand quickly back and forth across his throat and suddenly he and Lisa were speaking the same language. She cut the engine.

I was secretly relieved. Airplanes sometimes behave themselves for their mechanics, only to act up again as soon as the “parent” is out of the room. I was afraid the man would find nothing, leave, and suddenly Warbler would be back to his antics. At least—no matter what the problem might be—the mechanic was now witness to it, could hopefully figure it out, and then fix it.

The sun beating down, we pushed Warbler back into the shade of his hangar. The mechanic started rocking the prop back and forth when some movement in the engine compartment caught his eye. I missed what he said, but a moment later his head was inside the engine compartment on one side, and Lisa’s head was inside the engine compartment on the other side.

Now, if you don’t already know this, the latest and greatest in airplane engines is about as technically evolved as a 1932 gasoline-powered lawn mower. They haven’t changed much in eons. Of course, Warbler’s engine is only one year younger than Warbler himself. He was born in 1946, and his current engine rolled off the Continental assembly line a year later in 1947. I guess engines can’t really roll off of assembly lines, now can they? Well, however it was moved off, it was originally bolted onto the nose of a brand-spanking-new Cessna 140. That airplane later got an upgrade to a more powerful engine, and the cast-off original engine from that plane somehow found its way to Lisa’s plane in the following decades.

And you think your family history is complicated.

But back to engine tech: An airplane engine generates power from controlled explosions of a gas and air mixture in each cylinder, which drives the piston downwards. The match for these explosions is the spark plug. Airplane spark plugs get their sparks from spinning magnets called magnetos. If the magneto were to stop, the pulses of electricity they make would stop, the spark plugs would stop sparking, and the airplane’s engine would stop. Which would be bad.

Accordingly, airplanes have two magnetos. Just for in case.

The magnetos are bolted to the back of the engine and are driven by gears inside the crankcase. Once the engine is running, itis spinning the mags that keep it running. It’s really quite clever. At least until one of your two magnetos comes completely apart.

And that’s what happened to Warbler. All four screws that held the two clamshell halves of the right magneto together were missing, the case had come apart, and the mechanism was shredded and stripped.

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Luckily—if these kinds of breakdowns can have any luck about them at all—the damage was to the outside end of the mag, not the part where it attaches to the engine. Those gears were all fine.

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The solution was ordering a new mag. Well, returning the half-demolished “core” and purchasing a refurib’d replacement. “What’s this going to cost me?” Lisa asked her mechanic.

He shrugged, “I dunno. Probably a thousand bucks.” Then after a few beats of silence he added, “All airplane parts cost a thousand bucks.”

Of course, add to that two house calls, as Warbler isn’t flyable with one mag off, and the innards of his engine exposed to the elements…

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Her mechanic wrapped up the damaged mag in a small blanket, like an orphan baby, and drove away in a cloud of dust. Tess still broken down in another city, there was nothing left to do but break out the bourbon.

Now I know what you are thinking: How the heck could all four screws work loose? Did someone forget to replace them after working on the mag? We’ve asked ourselves that; over and over and over again. But like the question about whether or not there was a second shooter on the grassy knoll, this is one of those questions we will never likely learn the answer to. On the surface, it looks like a maintenance failure. Like someone forgot to put the screws back in. But looking though the logs, the mags hadn’t been worked on for a looooongtime. So on the one hand it seems unlikely that all the screws could fall out, but on the other hand, if they were never there, how could the plane have flown so long?

Before every takeoff, pilots independently check both mags by using the ignition key to run what is called a mag check. Lisa was religious about doing hers. The right mag always ran rougher, as one or the other of the pair often do in airplanes, but the darn thing was always running. Heck, it was running when she did the engine runup for her mechanic right before the whole mess was discovered. We spent a lot of time talking about the flight hours and the various maintenance log entries from before and after Lisa took over as caretaker of Warbler.

In fact, we spent the next two weeks doing nothing but that until her mechanic came back to SXU with a shinny “new” mag. He bolted it on, then fussed around with the prop and a small beeping box, adjusting the timing of the mag so it would spark neither too early nor too late.

When he was done, it was out into the sun for Warbler, for an engine test. He sang his throaty song, clear and bright. Even on the right mag alone. Problem solved, right?

Not necessarily. The problem with the mag didn’t rule out the possibility that there was alsoa valve problem. One that wouldn’t show up until after the engine had been running at full power for a while. A test flight was needed.

Now, Lisa’s mechanic is a pilot, too. Some flying mechanics insist on test flying their work, others don’t. He’s one of those that don’t.

As we hadn’t broken out the bourdon yet, I pulled up my big boy pants, pulled on my Chuck Yeager boots, and climbed into Warbler’s cockpit.

“Stay within gliding distance of the runway,” Lisa’s mechanic told me.

Roger that.

I spent the next half hour circling the field by myself, bored to death. It was bumpy as the dickens. Finally, fuel running low, Warbler and I returned to earth. There was no valve problem.

Lisa paid off her mechanic and he disappeared in a cloud of dust. She turned to me and said, “I really need to fly. You know, not train. Just. Go. Fly. Understand?”

I understood. We climbed in, belted in, and headed out. She carefully checked her mags and ran up her engine. The takeoff on Runway One-Ninner was smooth and as she turned and flew down the Pecos River Canyon south of the airport the choppiness I’d experienced in the atmosphere over the airport disappeared.

I turned and looked at Lisa at Warbler’s helm, and watched a metamorphosis take place. For the last two weeks, Lisa had been a woman of stone. Her eyes narrow, scowling, dull and flint-like. Her jaw tight, the usual smile absent, replaced by a horizon-straight slit. Her shoulders hunched tight to her neck. Now that all began to melt away. Her shoulders relaxed and dropped, her eyes widened and lit afire anew, and a smile danced at the corners of her mouth, slowly spreading like the growing dawn until her entire face was a picture of pure joy.

The magic of flight was erasing the stresses of doubt, fear, and expense that had hung over her like a dark shadow for the last two weeks.

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Yeah. They have their challenges, but this is why we own airplanes.

 

One spare isn’t enough

“This day is really improving,” said Lisa with a big smile on her face as I rolled Warbler’s wings level and entered the downwind for Runway 8.

But that ear-to-ear smile was not to last.

Now, for background, you need to know that Tess, when it comes to maintenance, has become nearly as much trouble as a Warbird. Yeah. She’s “down.” Again. I would’a thought that for a woman of her age hot flashes would be a thing of the past, but just days out of that killer annual earlier this summer, she began to overheat. Big time.

I’ll spare you the pain of the details, and myself the PTSD of recounting this latest woe, but the bottom line is that two of her four nearly-new cylinders have to be pulled off. According to my logbook, I took her to her new shop about six weeks ago, and it’s likely to be several more weeks before she’s back in my hands (or I’m back in hers, as the case may be).

But that said, my logbook is hardly empty of Ercoupe time since. In fact, I’ve been flying a lot. How can that be? Well, the “family” has a spare airplane.

IMG_7312

Yep. I’ve been flying with my buddy Lisa as the safety pilot in her plane, helping her polish her skill set prior to her next round of formal training. Actually… Come to think of it, Lisa’s skill set has become so polished that I haven’t had to touch the controls in… well, I can’t remember how long it’s been. But each time we fly, she’s kind enough to let me take the controls at some point so that I can feel like a real pilot again.

Most days, after Lisa flies, Rio takes over the left seat and we go up and polish the maneuvers that his flight instructor is teaching him as well. We had been doing Rio’s training in Tess, but with her in the Airplane Hospital again, Lisa loaned him the keys to Warbler.

We all started joking that it’s a good thing we have a spare airplane. But as it would turn out, one spare Ercoupe isn’t enough. And that’s why Lisa lost her smile.

So much for background. Now on to today’s Plane Tale…

 

We rose early—me from the master suite and Lisa from the guestroom—and met at the coffee pot, bleary-eyed. We aren’t morning people either of us, but the early morning sky favors flight training. Winds tend to be light, and thermal turbulence from the sunbaked landscape hasn’t started to form yet. But today, it was clearly a waste of blissful sleep. A quick look out the window showed that the weather was not as forecast.

You can’t trust weathermen and psychics.

Still, we’ve learned that the weather at my house (which is 20 miles closer to the field than Lisa’s, hence the use of the guestroom on flying days) and the weather at the airport can be so different as to be in alternate universes, so properly caffeinated, we headed out.

Headed out into weather that grounded the crows that live on the airport beacon tower next to the hangers.

So instead of pre-flighting Warbler, we dumped the trash in the terminal, restocked the fridge and the snack baskets, and looked to see how many new pins had been placed in the large flight planning chart on the wall, the one that visiting pilots are invited to mark their home airports on. Then we hung out in Lisa’s hangar, mine being empty. She also has windows that look out to the East, allowing me to keep one eye on the weather while surfing the internet on my flight pad.

As the sky began to lift the wind came up.

“You know what?” said Lisa, “this isn’t happening for me today. But if you want to fly for a change, I’d be happy to come along for a ride.” She dangled Warbler’s keys in front of my face.

If there’s a pilot who can turn down an offer like that, I’ve never met him. Or her.

I had planned to do a toilet paper chase after Lisa’s practice. That’s where you fly up to around 10,000 feet, chuck a roll of (fully biodegradable) toilet paper out of the plane (over and empty area) then dive on the streamer and try to cut it with your wing as it flutters to the ground. It’s easier said than done, but every bit as much fun as it sounds. And I’ve actually succeeded at doing it.

The ceiling was starting to break up, so I chucked a roll of toilet paper in the back and up we went. It felt strange to be in Warbler’s left seat.

But as we climbed into the murky air, it was clear that this was not a day to venture up to 10,000 feet. I opted for barnstorming instead. Low and slow down on the deck we zipped between sandstone buttes, circled the ruins of abandoned ranch houses, and did lazy S-turns up and down empty dirt roads to nowhere—soaking in the view and the feel of flight.

Our RMP was acting up a bit, first high, then low. I didn’t give it much thought. Warbler has a new throttle and I figured that we didn’t have the friction lock set right yet.

I figured wrong.

“Thanks for letting me take the left seat,” I told Lisa.

“Actually,” she said, “I’m enjoying being a passenger for a change. Over here is where I fell in love with flying.”

Finally, gas running low, it was time to head back to the nest.

“This day is really improving,” said Lisa with a big smile on her face as I rolled Warbler’s wings level and entered the downwind for Runway 8.

On base it seemed like I needed a lot more back pressure on the elevator than normal, and we also ended up landing long. But the touchdown was smooth, the moment between flying and rolling almost undetectable.

Then the noise started.

Or maybe it was there all along and we just couldn’t hear it over the roar of the engine. It was a flapping-type sound. I cocked my head to one side. “Do you hear that?” I asked Lisa. Then I pulled one ear cup away from my head, trying to hear it better, trying to process what it might be. As Warbler rolled down the runway, it seemed to get louder.

We needed fuel, so I headed for the far end of Eight, where Taxiway Charlie leads to the terminal and the pumps.

I should have turned tail and headed back to the hangars. Hindsight.

As we crossed One Niner, the noise was really distinctive. It sounded like a loose cowl banging in the slip stream. I decided to shut down right where we were. Nearly a mile from either the hangars or the ramp.

It never occurred to me that the engine would never restart again.

I pulled back the throttle and the mixture, then turned off the mags. With an abrupt shudder the prop snapped to attention, stopping at 12 o’clock, not making the lazy spin down we are used to. With trepidation, I slid the top of the three-piece canopy to the right, climbed out onto the wing, dropped to the ground, and came around to the front of the plane.

Everything looked normal. No loose cowl pieces.

For some reason, I reached up to pull Warbler’s prop down to the normal position.

It was stuck fast. Excalibur in the stone. My mind couldn’t process what my hands and eyes were telling me. One moment the engine is running; the next moment, after shutting it down myself, the prop is stuck fast.

I didn’t know what to do, but attempting a restart was out. I looked far to the West at the distant Lego block of the hangar. Then I looked far to the South at the distant Lego block of the terminal. This was a stupid place to shut down.

So like hippie college students who ran out of gas on the way back to the dorm, we pushed Warbler back down the taxiway, across One Nine, and back along half the length of Eight. Well, Lisa pushed. I pulled on the stuck prop, using it as a combination tow bar and steering tiller.

It was a long haul, helped by a friendly couple from Arizona headed home from AirVenture, who added some horsepower to the pushing on the last half of the journey.

The slow roll to the hangar seemed to take longer than the flight that proceeded it, but eventually we got Warbler back in his nest, where Lisa collapsed into a little puddle of DNA in the corner. Not to say she reverted to sucking her thumb, or anything—which I probably would have—but there are some things in this world you just can’t do for yourself, and a good example is calling your mechanic to discuss a very expensive-sounding repair on an airplane you really couldn’t afford in the first place, so I offered to make the call. That’s what friends are for.

I got the man on the phone and described what had happened. The prop would turn backwards as much as I wanted it to, but going in the normal direction of travel, when the blade reached 12 o’clock it stopped cold.

The mechanic said he’d never heard of anything like that before.

He had me check the oil. It was fine. Then one or two other things. Finally he said, let it cool down, then see if the prop frees up.

As we had time to kill, I starting calling various experts we knew in the Ercoupe community. The first guy thought it sounded like a broken crankshaft, about the worst thing that could happen. But I didn’t think so. Sure, if the prop were totally frozen, or totally loose. But half and half? Of course, all I know about airplane breakdowns is things that have broken down on mine. I was in uncharted territory here.

The next three guys I called had never heard of such a thing, either. Great. But all three of them instinctively felt we were seeing a bizarre manifestation of a stuck valve, a serious but not fatal mechanical issue.

Hours later, the engine cool, the prop spun freely again.

The next step? Lisa’s mechanic will have to make a house call. That will happen next weekend. And in the meantime, even with two Ercoupes, we have no plane to fly.

One spare, apparently, is not enough.

 

Officially not good

If you’ve ever been out to a small airport, you might have noticed that there are always a lot of pilots hanging around talking to each other about flying, and you might wonder why they aren’t just out flying instead.

It’s probably because their planes are in the shop, where it seems ours spends half her time recently.

To recap: In July of last year we put in a new engine. Well, three new engines. That took until late November to straighten out.

Then we spent all of December pitching, un-pitching, and re-pitching the prop so it would work with Engine III.

January Tess developed oil incontinence; and in February the header tank sprung a leak. Into the cockpit.

March it was throttle issues. Now in April, one month before our annual (Again? Seriously?) this happened:

Yeah, the exhaust pipe isn’t supposed to move like that. Actually, it’s really not supposed to move at all. In this case our muffler has come loose, and as it flaps around, it’s torn the carb heat connections loose, too. What does all that mean?

It means at least a theoretical risk of carbon monoxide poisoning for anyone in the plane when the engine is running, and a more than theoretical risk that the carb heat system will fail when it’s needed most. And those two things together add up to mandatory maintenance.

And as I could see that the cowl would have to come off to work on this newest problem, it made more sense to me to move the dreaded annual up a few weeks than to pay for two rounds of maintenance within a month’s time.

So off to the shop I must go, and then, because I won’t be flying for a while, I guess I’ll just hang out and talk with the other pilots.

The one’s whose planes are being worked on, too.

 

 

Paint tale

“What on earth happened to your paint?” asked our league photographer in her heavy English accent, pointing to several naked places about the size of a dime on Tessie’s left wing

“Oh, I accidently plowed through a flight of baby peacocks at the last race,” I replied, being careful to keep a poker face.

There was a long silence while she processed this, then she said, “I was under the impression that peacocks didn’t fly very high…?”

“They don’t. And your point?” I asked.

I think I told someone else I ran down some baby flying squirrels. In truth, I have no idea where the paint went, or where, how, and when the dozens of other missing paint flakes disappeared. All I know is that Tess is beginning to shed paint like a cat sheds fur in the spring. And that can only mean one thing: Her paint job is reaching the end of its service life, expiring, dying; and that means there’s a new paint job in my future.

Which is both scary and exciting at the same time. But mainly scary.

An airplane’s paint job is more than mere decoration. It’s protective. It keeps the metal from being damaged by the elements. So it’s important, and beyond some point, it’s not something that can be safely put off. But getting an airplane painted is nearly as much work as buying an airplane in the first place, and in our case might cost nearly as much. Why scary? Well, for one thing, there are hundreds of paint shops to choose from, and the offerings and quality vary a lot. As do the prices and the potential for disaster. I’ve read several articles on the whole process, a couple of which—focusing on all that can go wrong—sent me into a nearly cationic state with worry.

But done right, as I understand it, the process goes something like this: First, all the old paint needs to be stripped off. Based on what I’ve seen, I don’t think this was done on Tess’s last paint job or two. Under that pretty blue and white is buff yellow, and in some places green is peeking through. Some shops use chemical strippers to remove the layers of old paint, others use high pressure water, while others still use something called “vacuum blasting.”

Once down to the bare metal, any damaged skin discovered lurking under the paint needs to be fixed, along with any dents and dings, much like auto body repair. Naturally the control surfaces need to be removed to get the old paint off the edges and get the new paint on, as well as all the inspection ports and the like. I read one case where the plane was put back together wrong and crashed right after leaving the paint shop!

Once all of that pre-paint work is accomplished, the new paint is applied, sometimes many layers of it, depending on the design, plus whatever top coats you choose. As you can imagine, protecting the interior and glass requires much taping and paper.

So much for scary. What about the exciting part? Well, that’s scary, too: What paint scheme do you choose? Getting a paint job opens up a universe of possibility. An overwhelming universe. It used to be that airplane paint was pretty pedestrian: White with a stripe. What color would you like your stripe? Tess’s current paint job is actually higher end than that, but now planes come airbrushed with artwork resembling show cars, tattoos, and more.

I’ve seen some pretty drool-worthy paint jobs in my travels. Check out this paint job of the inner race plane shedding its warbird skin like a snake:

DSC_7621

So what to do? Tess is sort-of a famous plane. She set a World Speed Record that still stands, and is a well-publicized two-time National Champion race plane. Does that obligate me to simply re-do the livery she sports now? Maybe use a sparkly white instead of gloss? Or should I update the scheme? Or can I let my imagination run wild? I mean, really, what would the perfect Ercoupe paint scheme look like? When I look at the Coupes gathered at our national fly-ins, I’m not that impressed with most of their paint jobs. That’s sad. They are cool-looking airplanes. They deserve cool looking paint jobs. But what would that look like, exactly? And what if I were wrong? I’d hate like hell to take a chance, try to design something, then detest the way the plane looks every time I open the hangar doors.

Not sure what I wanted to do, at AirVenture this last summer I prowled the paint vendor’s booths and talked to many of them, and I also attended a few workshops on the painting process. One of them was led by a scheme designer.

What on earth is a scheme designer, you ask?

It’s not some sort of con man, as the name implies. Think of scheme designers as architects. They are part artist, part draftsmen. They create designs for airplane paint jobs and translate them into precise instructions for the paint shops. One, named Craig Barnett, particularly impressed me. He runs an outfit called Scheme Designers, which does paint jobs for airlines and aircraft manufacturers—and he’s even designed the paint schemes for many of AOPA’s sweepstakes planes. And Craig had an offer for me I couldn’t refuse: For a flat rate, he’d create an unlimited number of paint schemes for our plane, letting us explore the “entire universe of possibilities.” I figured if AOPA trusted him, I could trust him. I hired him on the spot.

Unfortunately, so did a lot of other people, so it took a looooooong time until I saw any exploration of my universe.

Anyway, at AirVenture, Craig looked at photos of Tess’s current paint job, which he declared to be 1970s Mooney-esqe. Fair enough. He asked what I wanted and I said I had no idea, which was why I was hiring him. He said he needed a little more to go on than that, and suggested I send him pictures of planes I liked. Or even cars. I didn’t have anything that visual in mind, so instead we talked concept. For starters, I asked him to create a modern, updated version of Tess’s current livery. Then I wanted something race-themed with checkered flags. He told me that he hated the checkered race flag look, but OK. Then I said, perhaps a muscle car look. I told him to avoid art deco or warbird, as there are a number of Ercoupes that have gone that way (successfully) and I wanted to do something different. I also told him to design one scheme completely based on the lines of the plane.

The first thing he did was send us out paint chips of aviation paints. Dozens of colors. The rainbow and more. As a family, we decided to stay with cool colors, leaning toward the blue and white we are used to (and would match the interior), but we threw in black and a kick-butt sparkly silver as options. In fact, most of the colors we chose were sparkly.

After that, we didn’t hear from Craig for a looooooong time.

Half a year after I hired him, just about when I was ready to abandon any hope we’d ever see anything, we got our first look.

This is his update of Tessie’s current look:

1-1

I especially like what he did with the rudders, as I always felt that little triangle back there didn’t fit the rest of the design scheme very well. Filling in the area in front of the triangle really tied it in for me. I also like what he did with the nose pant, making it two tone. So that’s Tess, as we know her, updated.

He also created a slightly more whimsical version:

6-2

And playing up the “Herbie” race number theme he submitted this Love Bug meets Ercoupe scheme:

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I like it, but wouldn’t use it, though I might consider it in different colors:

4-3

The grey isn’t grey. It’s the kick-butt sparkly silver. From any distance it would look like polished aluminum. But the paint job that blew my mind was this hotrod racer one:

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I love the silver and black race flag motif. I adore the way it follows the gill-like edge of our cowl and wraps up onto her back. For a man who hates the race flag look, Craig sure nailed it. And the subtle flames licking down the side from the engine compartment completely blew my mind, as did the perfect placement of the bold race number on her flank. I miss the two-tone nose pant from the updated design, but I can see that it would be just too much if we did that, and I’m not sure about the bars on the rudders. Still, this is just a first draft. Any and all details can be tweaked.

I’d love to fly a low pass in this baby, and taxi into the race parking in it. It would be the ultimate racing Ercoupe look. Heads would turn, jaws would drop. We’d be the envy of every racer, even in our humble Ercoupe.

I couldn’t wait to show Rio. I was sure he’d love it as much as I did. His reaction? He shrugged one shoulder and said, “It doesn’t do much for me. I don’t think I want a race flag look.”

I was crushed.

Why does his opinion matter? Well, because, in point of fact, it’s his damned airplane. Or nearly so. The title to the family airplane is currently held by Grandma Jean. I sometimes (well often, actually) refer to Tess as my plane, but she isn’t and never will be. Mom has willed her airplane straight to my son Rio, bypassing me completely. It wasn’t that I’m a bad son, she helped her other grandchildren with their college, but Rio is the youngest and she didn’t think she’d still be around. It was her way of making things even. But the end result for me is that despite all the blood sweat and tears I’ve but into the little beast, I’ll never own her. Now, if mom dies before Rio’s 25… or maybe it’s 23, I can’t remember… then I serve as the airplane’s trustee until he comes of airplane-owning age. But that’s it.

So while I could talk the current owner into a paint scheme that I like that he doesn’t, or could, in theory, acting in my role as future trustee, paint it any frickin’ way I want, it would be a mean butt-head thing to do. Given the cost and complexity of painting an airplane, Rio will need to live with our choice a long time.

Of course, I’m still the only licensed pilot flying Tess, and I’ll be damned if I’ll arrive at a race in a pink plane with purple polka dots—not that he’s suggested any such thing—my point simply being the two of us have to agree on a paint scheme. And I’m finding that now that Rio is becoming a young man, he doesn’t see eye-to-eye with his old man very often. Serves me right for encouraging him to have a brain of his own.

Luckily Tess doesn’t need paint tomorrow, because this is going to be a looooong process. Poor Craig. He really has his work cut out for himself this time.

My family lives in a big universe.

 

Next week: Rio and I finally agree on something.

The third time is the charm… Or maybe the fourth…

Yay! The plane is done. The day is beautiful, and this afternoon Rio and I launch on a four-day adventure. We’re flying the Route 66 Air Tour, joining a fleet of 20-30 airplanes following the historic “mother road” across New Mexico and into Arizona. We’ve just been through a major maintenance event, but I’m confident the one-hour solo flight home will serve as an adequate test flight to ensure that all is in order.

Debs, Grandma Jean, and Rio are at home assembling chicken salad sandwiches for a pre-Tour party at our airport (more about that next week) so Lisa is driving me the hour and a quarter over to Santa Fe to pick up the plane. It’s my second trip over in as many days. She’ll drop me off and head to SXU by car, where we’ll rendezvous in the late morning. My job is to prepare Tess for her adventure and to get the giant silver quasi-antique 40-cup coffee pot brewing. Once Lisa shows up, and I’ll easily beat her to Santa Rosa, we are to lay out the cookies that the city council authorized the airport manager to buy onto trays in an attractive and creative manner.

After the required small talk with my mechanics, the giant hangar doors rumble open and my chief mechanic uses his fancy-pants multi-adjustable tow bar to grab Tess’s nose gear and pull her out into the sun. It’s a perfect flying morning. Not a breath of wind. I do a quick walk around, and assured that all is as it should be, I mount the wing, step down into the cockpit and settle in for the flight.

My only real worry is the flow of fuel between Tessie’s three tanks. I plan to watch the fuel gauge on the new header tank like a hawk to ensure its being kept full by the engine-driven fuel pump as designed, and that the excess fuel is properly overflowing and draining back into the conjoined wing tanks; an invisible process that can only be monitored by proxy, using the compass-style float gauge on the floor of the plane.

If all goes well, I’ll be back to my homebase in a little over an hour. If all goes poorly I’ve got plenty of time, and fuel, to get back to Santa Fe.

I reach above me and button up the canopy, then secure my lap belt, attach the shoulder belt, cinching it down tight, but not too tight. I set a pen and a piece of paper on the seat next to me to copy down my taxi clearance, then plug in my headset. As it’s been a few weeks since I last flew Tess, I pull the engine start checklist from the right-hand side pocket and follow it.

Parking brake engaged. Check.

Fuel cutoff open. Check.

Master switch on. Check.

Beacon on. Check.

Crack the throttle a quarter inch. Check.

Push the mixture control full forward. Check.

Ensure the carb heat knob is full forward. Check.

Turn the ignition switch to both. Check.

Clear the “add fuel” warning message from the engine monitor. Check.

Give her two shots of prime. Check!

“Clear prop!” I shout, and press the starter button.

The propeller starts spinning and the engine coughs to life, its roar filling the cockpit as the spinning prop dissolves into a pale grey blur of motion. At once the new-old tachometer goes crazy, the needle jumping up and down like a seismograph station when the big one hits the San Andres.

Well, that’s not right. I fiddle with the throttle, advancing it, and retarding it to no avail.

Well, crud.

I shut the engine down. Close the fuel valve, and one by one shut off the heavy satin metal “bat switches” (so called because they look like miniature baseball bats) that run all the plane’s electronic systems. Each has a satisfactory solid movement as it’s flipped downwards to its off position. Radio: Thunk. 12-volt power: Thunk. Navigation lights: Thunk… I unlatch my seatbelt, slide my shoulder out from under the shoulder belt and unbutton the canopy, sliding it downwards into the belly of the plane. I hoist myself up on the seat back, step out on the wing, then drop to the ground behind the wing.

I walk back toward the maintenance hangar. My mechanics heard the engine start, then stop again, and are waiting for me. “Hi, guys, long time no see,” I joke. Then show them the quick loop of video I shot on my iPhone of the new-old tach.

“It worked fine when we tested it,” they say.

The new-old tach is the one that was originally in the plane, but was removed when we (foolishly) purchased a modern digital engine monitor, which has been nothing but a pain in the ass as far as I’m concerned. I decided to get it to help us better protect our expensive new engine, but it added to the delays that cost us the last race season, plus I find it hard to read in flight, I miss all of my simple old gauges that told me in a half-glance the status of my engine, but most of all I miss the tach.

The engine monitor has a tach, but it’s small and hyper sensitive. It jumps around a lot even when the throttle is rock solid, and I’ve found it impossible to use to get the right power settings for landing. I tried for some time, and finally decided to just re-install the analog tach to make landing operations safer and easier.

But now, in its maiden re-installation, it has gone crazy. Tony, the number two mechanic, heads out to the plane with a flashlight and a handful of tools. He climbs up on the wing and drops into the cockpit backwards, his feet dangling outside, so that he can see under the dash.

I text Lisa: Short delay on this end. Keep driving.

After a few minutes of grumbling, he emerges and reports the problem likely fixed. “What happened?” I asked.

Tony shrugs, “It’s a pretty simple system. I just disconnected it and reconnected it. Let’s test it.”

I climb back into the plane, pulling the canopy halves partway up to protect myself from the prop blast, then double check that the parking brake is engaged. Fuel cutoff open… master switch on… beacon on… crack the throttle a quarter inch… push the mixture control full forward… ensure the carb heat knob is full forward… turn the ignition switch to both… clear the “add fuel” warning message from the engine monitor… give her half-shot of prime for a warm engine…

“Clear prop!” I shout, and press the starter button. The propeller starts spinning and the engine coughs to life, its roar filling the cockpit as the spinning prop dissolves into a pale grey blur of motion.

The tach behaves itself. Oh well, what’s one little glitch? After all, they had to pretty much disconnect everything in the plane to get the old tank out and the new one in. I give Tony a “thumbs up” and he heads back into the hangar.

I reach above me and button up the canopy, then secure my lap belt, attach the shoulder belt, cinching it down tight, but not too tight. I put on my headset and dial up the Santa Fe ATIS, which stands for Automated Terminal Information Service, a pre-recorded audio loop that gives pilots basic information on airport operations: The wind conditions, the active runway, and more.

I’m greeted with complete silence.

Well, not complete silence, with the engine running there’s always a dull roar in the cockpit, even with the best of headsets. But I’m not receiving any radio signals. I double check. Yeah, I’ve entered the frequency right. I poke at the intercom buttons. I fuss with the volume button on my headset. I pull out the head set plugs, and push them in again.

Well, crud. I shut the engine down. Close the fuel valve, and one by one shut off the heavy satin metal bat switches that run all the plane’s electronic systems. Radio, 12 volt, Navigation lights, Thunk… thunk… thunk… I unlatch my seat belt, slide my shoulder out from under the shoulder belt and unbutton the canopy, sliding it downwards into the belly of the plane. I hoist myself up on the seat back, step out on the wing, then drop to the ground behind the wing.

I walk back toward the maintenance hangar. Again. My mechanics heard the engine start, then stop again, and are waiting for me. “Hi, guys, long time no see,” I joke.

It’s not quite so funny this time.

Once again Tony heads out to the plane with a flashlight and a handful of tools. He climbs up on the wing and drops into the cockpit backwards, his feet dangling outside, so that he can see under the dash.

I text Lisa: Another short delay on this end. Keep driving.

After a few minutes of grumbling, he emerges and reports the problem likely fixed. “What happened?” I asked.

Tony shrugs, “I think the plug was loose. I just disconnected it and reconnected it. Let’s test it.”

I climb back into the plane. No need to start the plane to test this problem. I flip the master switch on, then the radio control switch. I hold the headset up to one ear and hear, “Santa Fe information Papa, time sixteen forty five Zulu…”

I nod to Tony and give him a thumbs up again.

“Now don’t be coming back here again,” Tony teases me.

I reach above me and button up the canopy, then secure my lap belt, attach the shoulder belt, cinching it down tight, but not too tight.

Parking brake engaged, fuel cutoff open, turn the master switch, flip on the beacon, crack the throttle a quarter inch, push the mixture control full forward, ensure the carb heat knob is full forward, turn the ignition switch to both, clear the “add fuel” warning message from the engine monitor, give her a half shot of prime…

“Clear prop!” I shout, and press the starter button.

The propeller starts spinning and the engine coughs to life, its roar filling the cockpit as the spinning prop dissolves into a pale grey blur of motion. Time to get this party started!

I call ground control and get permission to taxi, then I engage my Cloudahoy App to record the flight and start to taxi. I notice the GPS link in the App hasn’t turned green yet. I also notice that on my Garmin Pilot Navigation system I’m not moving. I slow down and look at my transponder.

It says “MSG.”

That can’t be good. I call ground control and ask for permission to return to the ramp.

I pull back up in front of my mechanic’s hangar and I shut the engine down. I close the fuel valve, and one by one shut off the bat switches. Thunk… thunk… thunk… Unlatch seat belt, slide shoulder out and unbutton canopy. I hoist myself up on the seat back, step out on the wing, then drop to the ground behind the wing.

I walk back towards the maintenance hangar, and pull the heavy door open enough to slip in.

“Seriously?” they ask me.

I text Lisa: Third time, assuredly, will be the charm. Keep driving.

This one is more complicated. The coaxial cable has pulled out of its plug. My guys don’t have the magic tool needed to fix it. I text home to tell Rio to search the flight lounge cabinets for our old dash-top GPS unit. I’m not going to let a little thing like no navigation system spoil our adventure. In the meantime, my guys call the avionics shop on the other side of the field, who agree to send someone right over.

I pass the time in my mechanic’s office, in out of the cold late morning air, surfing eBay on my iPad. After what seems like forever, once again, Tess is pronounced ready for flight.

Parking brake, fuel cutoff, master, beacon, throttle, mixture, carb heat, ignition, fuel warning, give her half shot of prime…

“Clear prop!” I shout, and press the starter button.

The propeller starts spinning and the engine coughs to life, its roar filling the cockpit as the spinning prop dissolves into a pale grey blur of motion. Third time is the charm!

I call ground control and get permission to taxi. Everything is working fine. The new-old tach is behaving, I can hear and talk on the radio, and my nav system is alive. I taxi back toward the runway again, scanning the instrument panel for anything out of the ordinary.

Everything looks good. I do my run up and tell the tower I’m ready to rock and roll. They advise me a larger plane is on long final, but the tower controller clears me for takeoff, adding, “Do not hesitate, early turnout approved.” Hell yeah, I’ve just been given permission to have some fun.

I throttle up to full power as I turn onto the runway, foot never touching the brake. Tess surges forward, she has fuel to get home and nothing else onboard. As she leaps into the air I bank left, and barely higher than the tower, fly up over the south ramp, studying the planes parked in neat rows.

It’s good to be back in the air, even if it’s a few hours later than I expected. It’s surprisingly calm air, the engine sounds strong and smooth, and all the repairs seem to be holding. I reach up to the engine monitor and scroll to the secondary screen. Amps and volts good. I scroll to the fuel computer. It shows me that I have fuel enough to reach Hawaii.

Non-stop.

That seems improbable.

I check the fuel flow. The gauge is reporting one gallon per hour, not our usual five and a half. I know this is wrong. But what could be causing it? I lift one earphone clear of my head. A blast of sound assaults me. Nothing wrong with the engine. If I were venting fuel above the sensor, the engine would be starved. I look at the fuel gauge on the floor. It’s steady. The float gauge in the new header tank is riding high. Like most of the rest of the repairs today, it must be a wire not hooked up right.

Do I go on or go back? A deep sigh. I’m only ten miles out; I’m going to have to take the plane back to the mechanics at some point anyway. It might as well be now. I bank into a right-hand 180 and dial my radio back to the Santa Fe tower to tell them I’m coming back.

I land, taxi back to my mechanics and park right in front of their hangar doors. Engine shut down. Fuel valve. Bat switches. Seat belt. Shoulder belt. Canopy. Up and out.

I walk back towards the maintenance hangar, and pull the heavy door open enough to slip in. They guys aren’t happy to see me.

“Each time you come back it takes longer to fix,” sighs Tony. I tell him the problem and he gathers his tools and his flashlight.

I text Lisa: Wouldn’t you know it? More trouble. Keep driving.

She replies: I can’t. I’m already here.