Bearhawk Aircraft Update Spring 2024

Source: 2024 Q1 Beartracks, Virgil Irwin
For those of you who don’t know yet, my wife Mackenzie and I purchased Avipro, the kit production company behind the Bearhawk Quickbuild kits. Mark Goldberg offered the company to us last July at Oshkosh, and after six months of due diligence and number crunching, we decided it was something worth investing our future into. We have been very grateful for the support and encouragement from the community as we begin this new venture. I’m sure everyone has lots of questions and many have reached out already with their thoughts and concerns. We have a to-do list about a mile long, but we are doing our best to get everyone’s parts out the door and questions answered as we continue to work on our new advancements in the company.
First, the manufacturing will be staying in Mexico. The guys at the factory are exceptional craftsmen and I have always followed the motto of if it’s not broken, don’t fix it. There are still lots of parts manufactured here in the US, and as we move things forward our goal is to bring everything we can in house, this helps to keep costs down and ensure the highest quality product at the end of the day.
As we prioritize the tasks that need to be accomplished, the one task that sticks out the most is build manuals. Starting in April we will be constructing new build manuals that will be of a hybrid nature. There will be a written step by step manual with parts schematics, pictures and instructions. To go along with these written manuals there will be an overview video that goes with each section, giving visual guidance and tricks to accomplish each task. For years the task of building a Bearhawk has been very daunting simply from a project management point of view.
My goal with these manuals is to close the gap for the builder, increase completion rates, and decrease completion time. We have to start somewhere and currently there are the most people building the Five. After the manual is complete for the Five, we will start into the other models. The most likely order will be the Five, Patrol, Companion, Four, LSA.
The Web Store. What is it? What will be available? The store will be a complete one stop shop for you to get everything Bearhawk. Seatbelts, lights, avionics, tires, wheels, electrical, batteries, cables, fabric, paint, spare parts, merch, etc. For the scratch builders, there will be major assemblies available for purchase such as landing gear, shock struts, engine mounts, seats, etc. Wing kits and Fuselage kits are still available individually if desired. We recently got the warehouse moved and are working hard on new OEM
partnerships to provide the most complete product offering at the most affordable price. Recent new partnerships include Whelen, Desser, Garmin, E-mag and many more. We will begin adding products shortly and we are excited to offer this service to the community.
Thank you to everyone for continuing to support Bearhawk and the community that surrounds this company. Aviation truly brings some of the best people together and the Bearhawk community is by no doubt the best community to be involved with. Continue reading

Bob Barrows Begins a Bearhawk Companion Build Spring 2024

Source: 2024 Q1 Beartracks
So far only one example of the Bearhawk Companion is flying, though a few others are close! When it came to the Bearhawk 4-Place, Patrol, and LSA, Bob built the first prototypes and completed the flight testing and validation himself. The Bearhawk Companion worked out differently, and once Bob got to see and fly the first completed Companion, he knew he wanted to build one. Being that a Quick-build kit was available, it didn’t make sense to build the same way he made his prototypes. His kit arrived on January 26th, 2024, and he went right to work. As of press time he has the fuselage on the gear, the boot cowl and firewall installed, and the wings finished. He says, “Building an airplane is a lot easier when this much of it is already done!” Bob’s grandson Erin has also helped occasionally with the kit. Erin is half way through A&P school and is excited about airplanes.

Bearhawk 4-Place N316BH First Flight

Source: 2024 Q1 Beartracks, Scott Hoover in Alaska
N316BH, serial number 1266, is a plans build 4-place original model with some B model upgrades. I purchased the plans and many of the materials from a local man in Alaska who decided to go another direction with his build. It was built with a fair number of parts purchased from Bearhawk Aircraft and the VR3 Engineering tubing kit. N316BH has the original wings and tailspring but I upgraded the horizontal stabilizer, the door formers, and I re-enforced and strengthened the aerodynamic gear shock-struts with an internal round tubing. A skylight was added and lowered to match the wing across the top. I also reinforced the frame and welded a float kit along with ski cable attachment points.
The interior is simple and light with painted fabric. I kept my panel simple as well. I went with the MGL Xtreme EFIS and EMS along with a panel mounted iPad mini and two AHRS units that provide ADSB and air data to the iPad. All said and done I was pleased with my empty weight and CG. With the Bob Barrows O-540 and a metal two blade 84″ Hartzell propeller installed the empty weight came in at 1420 lbs. The CG is just aft of the forward limit with a pilot in the seat and empty fuel tanks. This leaves the entire CG envelope available for cargo, fuel and passengers. Impressive design for sure! My initial impression after just a few flights is WOW!!! What an incredible airplane! Very few things in life can beat that first flight! This was my first build and my first flight in a Bearhawk. After a couple of engine runs per the Lycoming instructions and a couple of taxi tests I was ready for the big event! After one more detailed inspection and one final run up I lined up on runway 20R at the Birchwood airport in Chugiak Alaska. It was a perfect day: 28 degrees, clear skies and little to no surface wind. The pressure altitude was well below sea level so I suspected great performance. Once on the runway I pushed the power up to 1200 RPM and let the plane slowly accelerate while taking one more concentrated look at the EMS, satisfied, I pushed the throttle on the untethered engine up to full power for the first time. She roared to life! I was thrown back in my seat with far more pressure than I have ever felt before in a single engine piston aircraft, it was at that moment that the smile came on my face and lasted for the next hour. The plane literally leapt off the runway before I even got the throttle to it’s stop. To my relief the airplane felt perfectly rigged and I rocketed to 3000′ at my planned 100mph climb speed. The first flight was all about engine break in and basic controllability checks. Fortunately, there are no issues other than some avionics problems that I’m still working through.
My overall impression of the Bearhawk is that it is perfectly designed for mechanically inclined individuals to build, even from scratch, with little experience in building aircraft. The great majority of the airplane is constructed using very basic metal working skills. The project took me nearly 7 years to “complete” as a hobby with many distractions along the way.
The plane feels light and even sporty in the air. It is wonderfully powered with an 0-540 and stable at high and low speeds yet still extremely responsive to flight control inputs. I look forward to exploring the entire flight envelope as I work through my flight test profile.