Since I have been getting more aggressive, pushing the boundaries as I work on the list of maneuvers, just found something that could have come out to bite me the next flight.

Was doing the final fitting for the cowl and went looking for a sound that has been bugging me from day one. There has always been a bit of a rattling sound coming in flight, something along the lines of a couple of pieces of wood colliding. Had mostly come to ignore it, concentrating on trying to tame the rich midrange on the Saito and thinking it had to do with the more pronounced power pulses of the 4-stroke. Last Sunday the friend I had been teaching to fly brought it to my attention again, so this time tried to find the source. Only thing I saw was a bit of play between the forward cabane attach and upper wing. Pulled it apart and was thinking of adding a bushing when I noticed the tab extremely weak. One more slight flex and it broke off! The rear was not far behind, so glad I made the effort.

Pulled the entire cabane assembly apart and will bring it to work tonight to bead blast the joint area and look into making more substantial tabs with holes that more closely fit the C/F rod I use to pin it together. Was always leery of how thin and weak those tabs were, (why, with such heavy rod they opted to use something so thin and soft?) so hopefully this will eliminate that one complaint. Now if I could only find a stronger main gear that fits the last of the buggaboos would be flushed.

Phew!