18th FEBRUARY 2005

The Cook undercarriage has finished its flight testing and the paper work has been sent to the PFA for their approval.

8th DECEMBER 2004

Good news for those patiently waiting for the Cook undercarriage.  The undercarriage has been fitted to G-MEOW and flight testing should start soon.  

Also I believe Danny has just come out of hospital as he also needed some work on his undercarriage, the NHS was providing the engineering support for this one. We wish him well.

21st August 2004
Phrase of the day:       ?

Bella Aviation Ltd 

Yesterday Bella Aviation informed the CAA they wished to put the company exposition on ‘hold’ whilst they evaluated their future plans. The grounding of the fleet and the subsequent delay in getting Shadows back in the air has had a severe financial and emotional impact on all of us involved with Shadows, as all owners are aware.

 We will let you know any useful developments.

3rd July 2004
Phrase of the day: You are not alone!!

The Royal Aeronautical Society - Light Aircraft Group have invited Phil Snowden to give a lecture at the PFA Rally, Kemble at 14:30 on Sunday the 11th. Politics aside, the lecture will give an insight into just the technical, problems, requirements, design, testing, certification and production of the Crosbie undercarriage. There will be an undercarriage on display and some interesting technical footage, all are welcome.

16th June 2004
Phrase of the day: See the argument from both sides and reasoning will get the better of you.

George, Gus and LV have successfully had the hip replacements done and can waddle around again.  
I do know what all you guys and gals are feeling about your Shadows at the moment and am unable to get through my thick skull why their has not been a way to keep the planes flying in one form or another. They are not dangerous.

4th June 2004
Phrase of the day: One bird in the hand is better than two in the bush.

The Shadow Flight Centre is back in the air and flight training as from today.  

We hope to get "GUS" back into the air within the next couple of days and "LV" next week.

3rd June 2004
Phrase of the day: A good night's sleep is worth all the strawberries you can eat.

I have just flown George with Danny Crosbie's undercarriage and gave it a good run for its money.  It is a large improvement on the feel when taxiing or landing or very fast runs down the runway.  It is soft enough yet hard enough and is well matched to the airframe. Not to say that there was anything wrong with the last undercarriage but this one does the job hands down and feels good.  I suppose it is like sleeping on a hard or soft mattress and when you switch it takes time to get used to but I am sure just getting back into the air is all it takes to make us happy again !. 

p.s. I think they can remove the FRAGILE on the shipment boxes (note from Graham Webster) 

Pre-installation. Note that on the dry-fit we did not have the penny washers in place inside the rear cockpit,  for no reason other than we did not tighten the bolts.

Post installation.  The finished job.

3rd June 2004

Phrase2 of the day: George has landed !

We have now fitted the undercarriage to "George" and he may sleep on his feet once again after being on crutches for the last week. Next he gets to fly again with thanks to Phil and Danny. 

Phrase1 of the day:  It is in the post !

We hope to  be receiving and fitting our undercarriage today.  We will let it cure overnight and look at getting "George"  back in the air asap.  

It was mentioned to me by David Cook that people were unclear whether or not they could fit his undercarriage. It all depends on the empty weight of the aircraft and if he gets it certified.  To work this out you will need to know what the current empty weight of your plane is and then add the extra weight allowed, depending on your engine type (aircraft with a 582 can add 2.9kgs,  503 and 447, 1.5kgs). 
 The bottom line is, will your plane still be within this maximum empty weight with the undercarriage you intend to fit? 
So it all depends on the actual empty weight of your plane !

27th May 2004

Phrase of the day:  It will arrive when it's ready.

If it was up to Danny we would have the undercarriage already.  I believe the plating is the bottle-neck at the moment. Danny has also managed to get two welders on the job so i would expect things to start happening shortly.  I will post a picture of GEORGE when he is ready to go. Expect another two weeks??

19th May 2004

Phrase of the day:  Jump!  How high ?

Nigel has been testing David Cook's undercarriage and they have successfully completed the preliminary tests.  They need now to submit their test results but things seem favorable for the Cookie undercarriage.  As far as I can tell and depending on the empty weight of each aircraft, that aircraft with a 582, 618 and 912 fitted should be able to fit this undercarriage once the testing results have been approved.

Danny is waiting for the first batch of welded stub axels to arrive and then he will be sending them off for plating. So the first batch should be rolling off the production line next week and hopefully all being well he should be able to deliver the second batch of 15 by the end of the month. I would expect the first two weeks next month that he will have reached about number 50 for those of you whom have ordered.

14th May 2004

Quotes of the day:  
"no worse off than before", 
"occupants being seriously or fatally injured"
"actively considering the possible solutions to this unsafe condition"

Both the PFA and the BMAA have completed the paper work with regards to the undercarriage modifications. All we need to get flying again is Dannys' undercarriage.  We expect to get our undercarriage next week some time and hopefully our trainer will be flying that weekend.  My guess is that the undercarriages will start rolling out of production in about two weeks and then we can all get back into the air, one by one.
The main thing to report is that  all the aircraft with a 582 will save 2.9kgs,  503 and 447 will save 1.5kgs due to the reduction in fuel quantity needed for certification and thus getting round the problem that a hevier undercarriage brings. 

The BMAA MAAN no. is1762 and this will allow the slipper tanks to be reconnected.

Also just to let you know that all the current undercarriage backing plates will need to be replaced.  I have looked into the time it would take and estimate a good mornings' work for two people, about 4hrs x 2 plus the paperwork. 

Both Bella and David Cook are still actively pursuing their alternate undercarriage solutions. 

6th May 2004

Today we have received notice of suspension of Permit to Fly for a Shadow C-D to prevent "occupants being seriously or fatally injured" . 
" The BMAA and CAA are actively considering the possible solutions to this unsafe condition."
We ask why the aircraft is now unsafe when it hasn't been so in the last 14 years and trained may a pilot. During these 14 years the aircraft configuration has not changed.

  
 No news from the BMAA of Danny's undercarriage or weight allowance although it seems we may be able to adopt the same ploy as other 450kg microlights with regards to the fuel consumption to trade off weight. 

30/04/04

From Phil Snowden and Danny.

News from the CAA that the PFA "has approved this modification (PFA MOD No. 11121) for PFA aircraft and we (PFA/CAA) will be issuing an MPD today to mandate this modification for PFA aircraft"

Basically the PFA have accepted and approved Danny's undercarriage.
 Thank you Francis for doing your utmost to help us, what would we do without you!.

We do not have any info from the BMAA.

We have also checked the CAA website at 17:20 and found no Letters to Owners, MPDs or Emergency MPDs referring to the Shadow undercarriage.  

          29/04/04          
Until you receive a letter from the CAA we may continue to fly!

David Cook's undercarriage is still in the process of application and testing.

News 28 April 2004. The final certification test of the Crosbie undercarriage was carried out very successfully last night, a full scale Drop Test. An unserviceable fuselage was loaded with sand bags to an axle weight of 392.5 Kg, (target 388.7Kg.) this is equivalent to the axle weight for an aft CG 430 Kg. MTOW aircraft. The fuselage was then dropped 219 mm whilst being videoed and an additional local digital video camera recorded no tyre bottoming. The exceptional energy absorption of the tailored carbon glass spring configuration meant that the impressive test was benign, so the drop height increased to 276 mm (120%) and the test rerun for good measure, again without tyre bottoming and without concern. By default this limit load test is already conservative as no wing lift is considered to act throughout the impact.

            As the certification submission has been accepted by the authorities the Modification will receive approval by Popham and be flying on the priority, training aircraft within 3 weeks. The BMAA have always proposed an increased empty weight requirement for aircraft on their upper weight limit to allow fitting of the slightly heavier Crosbie undercarriage (about 1.2 Kg.) Due to the outstanding success of the design testing, super-factored ultimate strength, single wheel cases and energy absorption, it is unlikely that an alternative solution will be able to achieve these results, especially within the tight weight constraints. You are therefore encouraged to let Danny know if you require an undercarriage so that he can make production provisions. The undercarriage will be on show at Popham probably around the BMAA stand.

Sunday 25th April 2004
Phrase of the day:   ?~#\>|+~~#

We have halted the composite undercarriage and will only continue developing if we are sure that we can make a lighter one.  We are also replacing all our undercarriages with the Danny Crosbie model.  I would think that he will start delivery coming the second week in May.  As at the moment we do not know if we can fly in May and have no information.  I guess it will be a call  to the CAA again because communications has not been very good up to now.  I will let you know if i get any more info.

Thursday 15th April 2004
Phrase of the day:   If it don't move, paint it.

15/04/04 Danny has completed the bench tests and has passed as from last night !!.

Danny let us know this morning that his tests have been accepted and that one final drop test will finish the job. He is preparing Nick Hart's Star Streak for flight and has invited me to do some of the flying with the new undercarriage.
No doubt he will start the production asap.

BELOW A NEWS FLASH DIRECT FROM DANNY & HIS TEAM
Crosbie u/c     15 April 2004

The undercarriage passed the super-factored two wheel, landing test on Easter Monday, witnessed by John Tempest. The undercarriage sustained a load of 6678lbf. Equivalent to a 430 Kg. Shadow at a ground reaction factor of 3 with an ultimate factor of 1.5 and a composite super-factor of 1.5. The carbon/glass/epoxy legs were component tested and are over twice the strength of the original however the springiness vs. the existing design has been maintained by extending the legs, the track is increased by 19mm per side, the undercarriage is now fitted to a Streak and taxies well. Many additional modifications to the steel-work have been made with the inclusion of now two cross braces, the mass increment is circa 1Kg.

The single wheel landing configuration test was carried out successfully on 14/04/04, again witnessed by the PFA, with flight testing to start on Friday. We expect the drop test to be carried out next week. Certification and the start of production will be achieved at the end of April.

picture 1 shows 10% over normal ultimate two wheel landing case, subsequently tested to 1.5 times normal ultimate for composite super-factor.

picture 2 shows Limit load one wheel landing case, subsequently tested to ultimate 967Kg.

DAVID COOK

Guy is looking into David's undercarriage but we have no confirmation of the actual status.

Quote received via email today from Brian Johnson:
 David's U/C has been accepted by Guy Gratton subject to an acceptable
'drag' test which has taken place and was successful. All the paperwork is winging
its way to the BMAA [Guy G] and the PFA [John Tempest]. Upon acceptance of
the tests, manufacture will start immediately. Bearing in mind the test U/C was
delivered within a week, it shouldn't take long to start shipping.

Wednesday 14th April 2004
Phrase of the day:   Sorry for the lack of info.

I have just spoken to Danny and it is going to be his undercarriage that most of us will be fitting.  John Tempest from the PFA was there on Monday and said that the numbers are good.  The new tension cable has been repaired and has taken the load satisfactorily. They possibly will be completing the tests tonight and hopefully that will be it. 

At the moment we can fly till the end of the month.

The composite undercarriage has been causing a problem due to the modifications made to suit production. Nigel and his father will be able to repair and test undercarriage and test their ideas in the next weeks. It may seem redundant to do so with Danny's' near completion but having come this far it could still be worth it.     

Here is a picture of the composite undercarriage under load.

17:00  I have just had news from Nigel that the new composite undercarriage configuration has taken the ultimate load for the B and C series. They are working out where to go from here, as there are still a few options and a new undercarriage needs to be made to complete the tests.  The reason for a new test model is because the undercarriage has had a tension cable added and that changes the whole approach to the design and hopefully make it lighter and stronger. 

Wednesday 8th April 2004
Phrase of the day:   It ain't finished till the fat lady sings

Both Danny and myself were testing undercarriages yesterday.  The composite one we were testing ran into some problems and another way of going about it has been determined.  This one is going to be lighter and uses another way to take the load.  Danny's testing had the tension cable release and he is in the process of making a modified one.  He will be testing again on Monday.  Nigel will be testing his concept within the next two weeks.

Thursday 2nd April 2004
Phrase of the day:   With a little help from our friends

This is the new test undercarriage received yesterday. Bonded the stub axels last night and here it is ready to go to Nigel's for testing.  At the moment it looks like it is about 1/2kg extra compared to the standard one.  Nigel also picked up the bits from Ron and is preparing the test-bed.

Wednesday 31st March 2004
Phrase of the day:   Information is a necessity and not a gift.

We can still go flying tomorrow! 

I have called the CAA with regard to an explanation of where exactly we stand.  The CAA are taking the viewpoint that as we are in the process of getting the issue resolved that no action will be taken by the end of today.  We can continue to fly as normal and only when the owners of the aircraft receive individual letters of suspension or revoking that we are only then officially grounded with regard to the undercarriage. I will shortly be getting an official comment and will post it here asap.

The CAA Official comment 

"  For the attention of Raymond Proost.     Raymond,  Following our telephone conversations on this topic today, and having looked at the correspondence on your web site, I should like to summarize the current situation.

Guy Gratton's letter of the 25th March 2004 is essentially correct when it
says that the LTO is an advisory letter. It contains information on the
situation but does not contain instructions. Instructions concerning the
operation of the aeroplanes would be promulgated by the CAA using Mandatory
Permit Directives (MPDs) or by individual letters to Permit to Fly holders
detailing any necessary restrictions. The CAA is currently reviewing the
situation with regard to the availability of approved replacement
undercarriages and depending on the outcome of the review may take further
action to safeguard the airworthiness of the Shadow aeroplane fleet. 

I hope that answers your concerns.   Kind regards   Nigel Davis   Design Liaison Surveyor   CAA

Thank you Nigel Davis for getting back so swiftly !

Bella have had a meeting with the CAA and the initial A1 approval step has been done.  Later this month they will have an audit and then if all is well the will have their full A1 approvals again.  This means that we will have Shadows and parts back in production..
Bella are also in the process of acquiring a beam of fibre-glass foam-filled to simulate the materials for their new undercarriage.  They will be running some tests and then maybe take the plunge.  The supplier is the well known SP Systems from the Isle of White.  

Danny is putting together three undercarriages.  One for testing, one to fit onto Nick Hart's Star Streak and one reserve.  The one for testing has been assembled whilst the other two have been sent for plating.  As you know Danny is using pulltrusion rods and then he is adding aa outer carbon-fibre sleeve to give it extra support.  Here is Danny's quote for the day,  
"Why do the east thing when with a little effort you can make it difficult for everybody".

Here are some pictures of Nigel and his facilities. Nigel as you know will be testing the Mick Newman composite undercarriage.  Nigel's father and Ron Woolley are both backbone helpers and I would like to thank them enormously.  The actual test undercarriage is on its way today which will need the stub axels fitted and then off to Nigel's. Ron is turning up some bits (quite a few ! Thanks Ron) and then the fun can begin.

In the meantime I have also received some pictures of the David Cook design which needs to be tested.  They are speaking to the PFA because a similar type and composition has been in use in the UK for some time and could possibly be accepted on its merit.

Thursday 25th March 04
It's how it ends and not how it begins.
(see the last paragraph!!)

Below a letter from Guy Gratton

Dear colleagues,

This letter is posted initially on the microlight eGroup to put into the public domain what is happening with regard to the Shadow undercarriage. Please feel free to copy or re-post it anywhere that Shadow owners are likely to read it - could I just ask that you copy it in it's entirety so as not to confuse anybody.

The Crosbie undercarriage project is proceeding well, but not quite as fast we might prefer. My current best guess is that we'll be flight testing a suitably modified aeroplane early in the week commencing April 5, and (all going well) issuing approval on it at about the end of that week (that is, at Easter). As all Shadow owners should know, Danny has quoted a maximum price for this undercarriage of £900+VAT but hasn't released a final price.

Given that this design is (almost certainly) satisfactory and imminent, and the supply of undercarriages should be only a matter of time, I have written (with the support of PFA's Chief Engineer) to CAA asking for an extension of their grounding deadline to the end of June. So far they haven't given us a decision on that.


There are several other options being pursued to my knowledge and it is worth mentioning them. 

Bella Aviation, under the supervision of their Chief Engineer Dr. Paul Welsh are pursuing a composite undercarriage design. I know that they suffered an initial false start which set progress back somewhat, and at present BMAA hasn't seen details of what they propose to manufacture.

Phil James, of Cloudbase Aviation at Redhill has submitted a proposal for a 3-leg version of the current undercarriage. However, no reports have been submitted with that proposal to show compliance with Section S, and I suspect that the project is for the time being shelved.

RCS Engineering (John Wighton) was known to be pursuing a composite undercarriage of a similar design to that which fitted to CFMs demonstrator, G-8525 which many people will have seen. No detailed information on this has been submitted to the BMAA, and I can't offer any opinion on either it's viability or state of progress.

A one-off Carbon Fibre undercarriage was designed several years ago by Michael Newman, a Shadow owner and yacht designer from Suffolk. This design has been picked up and is being pursued by the Shadow Flight Centre; they have been working with PFA Engineering on this, and I understand hope to be testing at about the same time as the final testing of the Crosbie undercarriage. From our previous experience of the Newman undercarriage, I would consider it likely to succeed, but can't offer any indication of cost or timescale.

David Cook, the original designer of the Shadow, chose to involve himself in the issue originally by publishing a public letter dated 9 February. This letter I found personally quite unhelpful and offensive, coming without any prior attempt to contact the BMAA or PFA engineering departments asking for authoritative details of what was happening, and referring to me personally as a "technical incompetent" as well as questioning whether I was qualified to hold the title Engineer; for the public record I have twice asked Mr Cook to retract those statements, which has hasn't yet done. Nonetheless he has since written to me on 22 March, stating that he has redesigned the undercarriage in aluminium, andasking for advice on how to go about approving an undercarriage to the current version of BCAR Section S; this information he has been provided with and we'll see what he's able to come up with. 


So, that is the position at the moment? Going back to the Crosbie undercarriage, which at present seems the best developed solution, the CAA recently asked for my views on the position of this and after consulting with PFA I told them that "I've about 85% confidence in approval being on time, and similar on the production timescale, and about 99% confidence in a successful outcome, irrespective of timescale." That remains my position, on-time being approval at Easter.

There is one final thing to mention to everybody, the CAA letter threatening grounding on 31 March was just that - an advisory letter. No aircraft is grounded unless it receives a formal notice from CAA, BMAA or PFA saying so. If CAA can be persuaded to change their mind, they may be less quick telling everybody that than if they don't, so no-news is good news.

G²

Guy Gratton
Chief Technical Officer
British Microlight Aircraft Association

The Bullring
Deddington
Banbury
Oxon, OX15 0TT

Wed 24th March 04
If it ain't broke, don't fix it!

OK there is more news.  Firstly Danny is off to get the his undercarriage framework welded this morning. David Cook is in the process of acquiring an aluminum undercarriage which has no welding and should be in the country in the next few days. Bella are still in the process of testing the materials.  Nigel is getting our bits together for the test bed and next week the newly built composite Mick Newman undercarriage is due to arrive. This should coincide with the completion of our test bed.  Ron is looking into a gas strut option.

The big question is will we get an extension ?!??!!

20/03/04
No news is good news

Unfortunately this is not the case when your Shadow is at the doctors for a major operation.  
Bella were getting in some components to test the material strengths etc. They are going to need a mould which takes time and money. In my view they are not going to jump in with both feet because it is a very lengthy process if  you discover that your mould does not have the right shape or design. This is what I understand is the current situation with their progress and will obviously change it if I get any more information.  
Danny has completed the preliminary stage and is in the process of putting together all the bits to fit on the rig. We are all holding our breaths just as I suppose Danny will be when the pressure gets applied. We will not call Danny up in the next few days as we know his is working overtime to keep to schedule.
Below are two pictures from the test Ron Woolley did on our standard pulltrusion rods.

17/03/04
Every journey starts with a single step.


Picture of the initial test model from Mick Newman
Test model number two is in the process of being made as we speak, estimate of about 2 weeks.

Nigel Townsend and myself went to the PFA offices to discuss the testing of the composite undercarriage. Nigel will be in control of the testing procedures together with Mick, John Tempest and myself.  The procedures were discussed with John and all the necessary was discussed including possible pitfalls when it comes to what calculations need to be done and which ones not to leave out. Nigel is finalizing his paperwork and has a clear view on how to go about it.  Unfortunately time is against us but the important thing is that all people involved with the testing and ideas continue working until the problem is solved.  We will have to test the fuselage and the attachments and they will need to be modified. The test rigs are being modified and with the help of some of our good friends like Ron Woolley, a current SFC student, helping in making this all possible.  Bella are now updating their website.  So for their latest news go to http://www.bellaaviation.co.uk.  I am trying to contact Danny , his phone is RED hot, to find out how things are going and as soon as possible it will get the current info here. I have just managed to speak to Danny and he is picking up the rods today and will no doubt be burning the midnight oil!

12/03/04
Never look a gift horse in the mouth.

I have just spoken to Danny as we also have had the letter from the BMAA.  He is taking deposits of £100 and will refund if he is unsuccessful.  All the tests have been simulated using computer graphics which are giving a positive result.  He is just waiting to get the new rods in and then he can make up a couple of test undercarriages.  I believe that the computer results are good enough tol allow him to put the undercarriage on a plane and start flight testing as well.  The practical tests hopefully will commence next week and then the final conclusion drawn up.  We wait in anticipation.  In the meantime we will continue with the composite undercarriage as a back-up. 

I have found out why we have a slight delay in receiving the damaged composite undercarriage.  The link has now been restored and it is under way.  I would think next Tuesday or Wednesday we will be able to put up some pictures of it. Tests will then be conducted on any useful bits and information gathered.  We are in the process of determining what tests are going to be done and how.  A nod was given over the phone to say we are on track.  We have decided to go to the PFA for the testing as the first tests on the Newman undercarriage were carried out through the BMAA.  I feel using the PFA gives us a fresh start and clean slate to begin with, let's see where we end up. 

11/03/04
More haste less speed.

We are still waiting for the undercarriage. This is due to Mick also having to run his business which obviously is very understandable.  He has also already put in an enormous amount of work and will get us moving asap.  We have now got our test schedule prepared and will be having a meeting next Monday on discussing it in depth.  We will let you know then.

06/03/04
Don't put all your eggs in one basket.

We will shortly be receiving a damaged composite undercarriage which we intend to do some material tests on.  As far as we know it has been severely damage the intension is to investigate.   Maybe that it was just not up to the job, we obviously don't think and hope so.  The first prognoses is that  aiming for the 374kg AUW would be the place to start.  In theory this would cover the B and C series Shadows. Until the tests are underway we will have to decide as we go if we have any choices.

In the meantime Danny and Bella and some others are all still gunning for glory and at the end of the day we want to keep flying, so the end result counts and all support should be given to those that are investing there time and efforts.   Just to let you know that one of our students is also busy with another alternative project and we wish everybody success. 

05/03/04

A picture says a thousand words.

I would like to announce that we have decided to get a copy of the Mick Newman design and run some tests of our own!   We will keep you informed and show you how we get on. The reason for this action is that we do not like being in the dark! 
1.) we do not yet have a delivery date for the first test model (expect a week or two)
2.) we are working out the testing procedures  
3.) you will get some pictures and true results, even if we do crack it !