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  1. I was asked, off-line:

    ... Do you plan on selling new gear switches and position indicator lights as part of the package?

    Eventually, we hope to have an electrical package as well, but there will certainly be a schematic available for folks to roll their own drive system that includes an Auto-Extend and Backup Battery option.

    --
    Marc J. Zeitlin                      marc_zeitlin@...
                                                http://www.cozybuilders.org/
    Copyright © 2024                     Burnside Aerospace

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  2. Folks:

    Continued from Part 1:

    New Actuator Nose Gear Extension/Retraction System:

    While I know that many folks have designed and fabricated their own electric NG systems, the vast majority of canardians have not and do not have the facility to do so. Nor have the folks that have done so made their systems widely available.

    My goal was to create a system that minimized both mechanical modifications to the F-22 and NG-30 structures, allowing for simple retrofit into existing manual or electrical nose gear retract system installations and minimizing the changes to the design for new builds. I believe that I've achieved that, as I was able to retrofit MY COZY MKIV, which started with a stock manual system and then had an EZNoselift (classic) system for about 20 years, in a few days with this new system.

    The system uses an OTS (Off The Shelf) electric actuator with integral adjustable limit switches, new NG-30 side attachment plates and spacers and a new actuator mounting block. It fits completely forward of the F-22 bulkhead and in between the outer surfaces of the NG-30s, requiring no F-22 mods or hole. It also requires no modification to the two or three side plate mounting holes in the NG-30s. It does require replacement of the existing NG-3/NG-4 brackets, if you're going to re-use your existing nose gear strut rather than fabricate a whole new nose gear strut assembly.

    A CAD image of the new system is shown here:
    image.png

    Pros:
    • OTS Actuator - no actuator modifications required or performed, therefore no weak points from machining or welding as with existing actuator systems.

    • No Spring Cartridge - the origin history of the spring cartridge used with manual and electric actuation systems is unknown to me but in my opinion the spring cartridge causes far more problems than it solves (if it solved any). Removing the spring allows for hard braking on short runways or in emergency situations without the danger of nose gear steering axis angle inversion and extreme shimmy. Removal also eliminates the "porpoising" action of the nose of these aircraft when taxiing over bumps or dips, which can find resonance and lead to tipback or prop strikes, aside from merely being annoying and scary to passengers.

      There are numerous examples of aircraft with the original VE manual gear, - the ones that Ryszard Zadow recently mentioned on the COBA list, as well as Mehran Salamati in his Berkut(s), along with others who've operated safely for many years with no spring cartridges.

    • Limit switch adjustment - adjusting the limit switches in the OTS actuator is very simple and the switches are protected with no connectors between them and the actuator itself.

    • Weight - approximately the same weight as existing electric actuation systems

    • Cost - final cost will be dependent upon quantity of units purchased, but is almost guaranteed to be equal to or lower than existing, available nose gear retraction systems.

    • Eliminated Issues - 
      • Loose/bent side plate attachment bolts
      • Wobbling extension shaft due to poor welding alignment of ball screw shaft
      • Grinding of bottom of actuator to clear NG-4 interior surface
      • Wallowing of NG-3/4 mounting holes due to using bolt as the bearing member
      • Plastic drive gear breakage
      • Poor support

    Cons:
    • No Spring Cartridge - if you believe that the spring cartridge allows for taxiing on rougher ground without breakage, then this would be a "con", but that's not a belief to which I subscribe, so for me, this is NOT a "con".

    • No Mechanical Extension - as with most (if not all) of the currently available nose gear systems, no manual extension crank is possible - only an electric backup in the case of aircraft electrical system failure is possible.

    • 1,500 lb. Load Limit - Currently available (and previous) systems which used the Thomson Saginaw Ball Screw mechanism had a maximum load capability of approximately 3,000 lb. This was required to lift a MGW, forward CG COZY MKIV from a grazing position to a fully extended position (bumper on the ground is the worst case load). Without major modifications to F-22 I was not able to fit an electric actuator that had a 3,000 lb. load capability, and I was not willing to force holes or modifications to F-22.

      With the new system's 1,500 load capacity, you will be required to lift the nose to 18" - 24" off the ground before loading the front seat (the amount of load will determine required height - these #'s are approximate).

      Since raising a fully loaded aircraft from the ground is contraindicated due to the fact that the NG-1 strut was not designed for such loading, I believe that the advantage of not having to modify the aircraft structure outweighs the disadvantage of having to raise the nose prior to front seat loading.

      (As an aside, electro-hydraulic actuators that DO fit forward of F-22 are available with 3,000 lb load capabilities, but they can draw upwards of 40A and would require major, heavy electrical modifications to make them work. This MAY be an option in the future, if folks believe that the nose height loading restrictions are onerous - I do not. There would also be a 14 week lead time for procurement and then a month of testing, after another month of design, so would be delayed substantially over the electric actuator).

    New Components (Not Including Hardware):

    These are parts required for mounting the new actuator, and would be provided with the actuator "kit".
    • NG-25B - Actuator Side Plates
      These replace the side plates to which existing actuators mount via trunnion - these provide for the end pivot mounting of the new actuator

    • NG-14B - Side Plate Spacers
      Shorter spacers than the current NG-14s to account for thicker side plates

    • NG-26B - Actuator Mounting Block
      Connection between the new side plates and the actuator

    • NG-27B - Actuator Mounting Block Pin
    • NG-17B - Bracket Spacer

    Actuator Mounting Brackets on Nose Gear Strut:
    • NG-3B - Large NG-1 Bracket - ONLY FOR USE WITH NEW ACTUATOR SYSTEM
    • NG-4B - Small NG-1 Bracket - ONLY FOR USE WITH NEW ACTUATOR SYSTEM
      These come match drilled with a 1/4" hole (which will be drilled out to 5/16" after assembly to the NG-1) for a perfect fit.
    These are both wider and taller than the existing NG-3/4 and NG-3A/4A brackets, and will NOT work with the EZNoselift or Wright electric nose gear systems, nor the original manual nose gear extension system.

    As with the previously mentioned new components, the tentative plan is for me to work with Nate at 3:23 Composites to source and supply these parts to the canard community - the exact relationship and sales/distribution methodology is still to be worked out.

    For now, my goal is to gauge interest in this system, as purchasing components from vendors in onesie/twosie quantities is not cost effective. Once we get to 5 - 10 piece part orders, costing decreases tremendously and becomes cost effective. Please make the assumption when gauging interest that the costs will be equal to or less than the existing available parts/systems that these will replace, with substantially higher quality, repeatability, usability and aesthetic level, not to mention actual support.

    If anyone has questions or comments that might be of interest to all, please post them to the list.

    If you're interested in procuring a system, please respond directly to me at the email listed below with an indication of how likely you are to purchase one (25%, 50%, 75%, 100%). I'll keep a record of who's interested in what and whether this becomes a financially viable option.

    Thanks.

    --
    Marc J. Zeitlin                      marc_zeitlin@...
                                                http://www.cozybuilders.org/
    Copyright © 2024                     Burnside Aerospace

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  3. Folks:

    General Discussion:

    For many years, many of us have been concerned about both the quality of the current nose gear parts that are available to the community, as well as the availability of these parts to the community moving forward. I procrastinated doing anything about it, though, hoping that other vendors would begin shipping parts again and replace the existing poor quality parts with higher quality parts. But that hasn't happened, nor has anyone else (other than Nate Mullins at 3:23 Composites) provided any new nose gear components. 

    While I know that EZJets is working on an electro-hydraulic nose gear system, my understanding (and someone can correct me if I'm mistaken) is that one has to have EZJets perform the installation of this system. Other than that, I know nothing about it.

    Alan Thayer's catastrophic EZNoselift failure in September, 2023, which resulted in $25K worth of aircraft repairs, prompted me to start the design, testing and fabrication process of new systems. The EZNoselift Side Bolt Clamp system, which approximately 80 of you have purchased and installed, was the first step in that process - make existing installations as safe as possible by correcting known failure modes.

    Since October, I've been designing, fabricating and testing a new electrical Nose Gear Retraction system for canards. But before discussing the new system in Part 2, I've also created new versions of many of the existing nose gear parts, including:


    Top of Nose Gear Strut:
    • NG-6B - Long-EZ, Varieze, COZY III, etc. Nose Gear Pivot
    • NG-7B - Spacer for NG-6B
      These are single piece, machined (not cast) replacements for the original NG-6 cast, bushed parts; the original NG-6A cast, tapered roller bearing parts and the current NG-6E multipart pivots with tapered roller bearings.

      The NG-6B pivot uses the same tapered roller bearings for smooth, no wear operation and comes with predrilled holes for attachment to the NG-1 strut and the NG-5B Clamp Plate.

    • MKNG-6B - COZY MKIV Nose Gear Pivot
    • MKNG-7B - Spacer for MKNG-7B
      These are single piece, machined (NOT cast) replacements for the original MKNG-6 cast, bushed parts; the original MKNG-6A cast, tapered roller bearing parts and the current MKNG-6E multipart pivots with tapered roller bearings.

      The MKNG-6B pivot uses the same tapered roller bearings for smooth, no wear operation and comes with predrilled holes for attachment to the NG-1 strut and the NG-5B Clamp Plate.

    • NG-5B - Clamp Plate for NG-6B and MKNG-6B
      1/4" thick replacement for the original NG-5, pre-drilled with matching holes for the NG-6B and MKNG-6B. It uses MS24694 screws at for the two top holes and AN-3 bolts for the two bottom holes

    Bottom of Nose Gear Strut:

    Nate Mullins (3:23 Composites) supplies very high quality, machined nose gear forks (NG-15X/MKNG-15X) assemblies - I highly recommend that any replacement forks or forks for new builds be sourced from Nate, not any other vendor.
    • NG-2B - Nose Gear "Foot"
      This unit fits the original VE/LE NG-15, the later VE/LE NG-15A and Nate's (MK)NG-15X

    • MKNG-2B - Nose Gear "Foot"
      This unit is ONLY for the original COZY MKIV MKNG-15 and MKNG-15A - it will NOT fit the 3:23 Composites MKNG-15X

    The tentative plan is for me to work with Nate at 3:23 Composites to source and supply these parts to the canard community - the exact relationship and sales/distribution methodology is still to be worked out.

    For now, our goal is to gauge interest in any/all of these parts, as purchasing them from vendors in onesie/twosie quantities is not cost effective. Once we get to 5 - 10 piece part orders, costing decreases tremendously and may become cost effective. Please make the assumption when gauging your interest that the costs will be equal to or less than the existing available parts that these will replace, with substantially higher quality, repeatability, usability and aesthetic level, not to mention actual support.

    If anyone has questions or comments that might be of interest to all, please post them to the list.

    If you're interested in procuring some or all of these components/systems, please respond directly to me at the email listed below with an indication of which component you'd like to acquire and how likely you are to want that particular component (25%, 50%, 75%, 100%). I'll keep a record of who's interested in what and whether these become financially viable options.

    Thanks.

    To Be Continued in Part 2:

    --
    Marc J. Zeitlin                      marc_zeitlin@...
                                                http://www.cozybuilders.org/
    Copyright © 2024                     Burnside Aerospace

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  4. Excellent rant and very true. You see this in so many ways, just look around where ever you go. The sad thing is, its the result of over indulgence, plus I think its also the additives that are in our foods these days. I know when ever I have traveled out of country for any extended time, I like to eat native, and I feel so much better. The young are also suffering from being overweight. Lower or no Physical activities, gym class seems to be gone, as well as shop classes from the schools.   (My Rant).

    Jack Mulqueen



    Is this still about nose gear strut fairings? 

    Recently the son of a VariViggen builder donated his fathers builders log to RAFE. When it arrived, we were sitting around the break room table at JetGuys enjoying looking at it. At the end there were lots of comments but one stood out. The builders log was circa early 1980s and the comment was "Did you notice there's no fat people in those pictures".

     When I hear people taking about cutting open their fuel tanks to install fuel gauges because they can't twist to see their sight gauges or how they can't get in and out of their Ezes anymore I get very frustrated. So here goes my rant and I apologize in advance to those who will allow themselves to be offended. What I'm about to say is motivated by one thing and one thing only:

    - I do not want to see anyone not enjoy their love of flying because of their physical fitness.-

     I'm not taking about medical issues. I'm taking about what you see when you look into the mirror. I'm 64. I can almost still hop into an EZ like I did when I first got my VE in 1983. I can still twist around to see my sight gauges and I've had major back surgery from a broken back and a knee replacement. I'm not bragging, I'm making a point that I can still do these things only because I WORK at it. It's not easy. I stretch. I go to the gym. I try to keep my weight down, which is a huge struggle for me. 

    My ONLY motivation to do these things is because I know too many people that have quit flying because, excuse my bluntness, they're too overweight to get in their airplane or they can't function enough to get in and out. I love flying so much that I WILL NOT LET THAT HAPPEN TO ME. 

    Obviously age and medical issues
    happen and again that's not what my focus is. Too many let themselves succumb being physically unfit WILLINGLY and then expect sympathy for their plight or rely on excuses. If you're taking my comments personally all I can hope for is you get offended by my words enough to take ACTION and start changing your lifestyle. Trust me, only positives things will come from it. Unfortunately I know some will instead get defensive and sadly the only action they'll take is type a lash out response to this, which will only prove my point. 

    Your physical fitness is your own responsibility. If you can't get into your EZ anymore, you can't blame the airplane. You did it to yourself. The good news is you can undo it too! Never forget that old cliche: you don't quit the game because you get old. You get old because you quit the game! Be "fit" to fly!! It's way more fun that way. 

    RyZ 


    You have received this message as a member of: Canard Owners and Builders Association
    Change preferences (including opt-out): Online Profile. Click on 'Forum Memberships' to change your settings for this forum, or 'Forum General Preferences' for all forums.

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  5. Joe Polenek wrote:
     
    Wilhelmson's noselift instructions warn about a 700 lb preload in that tube, so I don't want to start messing with things I don't understand.

    Hell, that's basic human nature, Joe. Where would we be if we didn't mess with stuff we didn't understand? That's probably a little deeper than you were probing, I'm guessing...
     
    What exactly does this setscrew do?

    That's a question that does not have a clear answer (and won't unless Jack responds here).

    Will removing and replacing it change anything inside the tube assembly?

    The answer to that we do have, since a number of folks have done exactly that, and the answer is no - it does not maintain the preload or keep the spring tension and removing and replacing it does not harm anything.

    And just for the record, here's what my unit (and 3 other units that I've worked on in the past week or two) looked like wrt that screw:

    IMG_2110.jpeg

    I THOUGHT that's what they'd all look like - silly me, for thinking there was consistency in the build, or a list of revisions, or...

    Apparently some have counterbored the holes and others don't. In any case, a low profile, smaller diameter screw is acceptable as long as it doesn't extend further into the unit than the one that's in there now. Some have used button head screws and ground down the diameter to fit the clamp hole.

    It would also be acceptable to drill or grind out out the hole in the clamp halves for clearance to fit a larger diameter screw head - it's only the height of the screw that interferes with the clamping bolt.

    --
    Marc J. Zeitlin                      marc_zeitlin@...
                                                http://www.cozybuilders.org/
    Copyright © 2024                     Burnside Aerospace

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  6. Michael Baker wrote:

    That looks just like mine and it kinda works. The set screw on the drive is taller than shown in the instructions. So, only 3 of the 4 bolts will work. So, should I trim off the top of the set screw or leave one bolt out?

    Do NOT leave out a clamp bolt. Either cut down or replace the screw that's interfering with the ability to install the clamp bolt.

    --
    Marc J. Zeitlin                      marc_zeitlin@...
                                                http://www.cozybuilders.org/
    Copyright © 2024                     Burnside Aerospace

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  7. Folks:

    I received this question from a few folks who've purchased the EZNoselift Clamp system and wanted to reply to everyone. Most installations have gone smoothly, with no interferences or issues, but some units are different.

    The actuator set screw is too tall. See pics. Should I cut the top of the set screw off?

    Apparently, EZNoselift has used multiple versions of screws in the location noted by the red arrows in the pictures below. I've only seen low profile screws here that barely rose above the surface, so my design did not take into account that some units were differently equipped.

    It is acceptable to replace the large, hex head cap screw with a low profile screw and it's also acceptable to slightly grind the outer diameter of the new screw head so that it fits in the recess. This has been done by more than one user successfully, so far.

    I wish (If wishes were horses) that there had been some - any - consistency in the design, fabrication and shipping of the EZNoselift systems so that these types of modifications weren't necessary

    Clamp1.jpg
    Clamp2.jpg

    With respect to my last message regarding the NEW version (belt drive, large black mechanism housing that looks (and is) homemade), apparently there's substantial variation in the fabrication of those as well - SOME folks have been able to get the clamp system to fit between the motor housing and the ball screw mechanism, and some haven't.

    As stated before, if anyone cannot use the clamp system due to lack of ability to fit and would like to return it for a refund, I'll happily refund the paid amount, or hook you up with a person on the waiting list who would like a set.

    Thanks.

    --
    Marc J. Zeitlin                      marc_zeitlin@...
                                                http://www.cozybuilders.org/
    Copyright © 2024                     Burnside Aerospace

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  8. Alex Liedl wrote:

    Maybe a dumb question.  How can one tell?  I’m waiting on pulling the nose gear till the new machined fork gets delivered so haven’t looked at my gear yet to see if it fits.  I purchased mine about 5 years ago.

    That's the old style, and it will work fine. If the top of your unit is a large, black housing, then it's the new style. I don't know how many of the new style EZNoselift Jack has shipped - hopefully not too many, as many users seem to have quality problems with the assembly of them.

    I wish I had known that the clamp system wouldn't work on the new system - hopefully not too many folks will get screwed - I'll refund the purchase price for anyone that can't find a waiting list person to swap with.

    --
    Marc J. Zeitlin                      marc_zeitlin@...
                                                http://www.cozybuilders.org/
    Copyright © 2024                     Burnside Aerospace

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  9. Folks:

    So far, I've installed 4 of these on customers' planes and many other reports of successful installations have come back to me.

    However, I'm informed by a user of the NEW version of the EZNoselift (the one with the belt drive head) that the clamp system doesn't fit between the motor and the shaft housing.

    So, if you are a user of a new version of the EZNoselift and cannot use the Clamp system you purchased, let me know and I can hook you up with someone on the waiting list (since I've sold all the units I had made). Kill two birds with one stone.

    --
    Marc J. Zeitlin                      marc_zeitlin@...
                                                http://www.cozybuilders.org/
    Copyright © 2024                     Burnside Aerospace

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  10. Folks:

    This is a followup to the message I posted to the three mailing lists back on December 5th. A total of 77 units were ordered by 62 individuals, and almost all of them were shipped yesterday to each recipient.

    I have additional units available at $100 + shipping (which has been running approximately $25 domestically and $50 internationally) so if anyone else has an EZNoselift and would like to remediate the side attach bolt issues, this system does that.

    Here's an updated version of the original announcement:

    ----------------------------
    As many of you know, the EZNoselift system used in many canard aircraft has a number of  basic design flaws, one of which leads to the unit attempting to unscrew the trunnion pin attach bolts (the AN5-12A or AN5H-12A bolts through the side mounting plates) every time it's actuated. Sometimes, the unit succeeds in unscrewing the bolts completely and sometimes only partially, which then sometimes leads to bent bolts and/or the unit damaging the mounting plates and trunnion pin, as well as possibly causing collapse of the unit. In any case, mounting bolts unscrewing themselves is bad. Also, the mounting of the bushings in the side plates puts the bolts in bending, rather than pure shear (which is why they bend sometimes).

    Dave Ronnenberg has developed a support system that eliminates the bolt bending and some of the unscrewing issues and has fabricated a few of these for select customers. All who have it have been pleased, I am told. I attempted to install one of his units on my EZNoselift system but it would not fit, as there are multiple versions of the EZNoselift that are out there and there are tolerancing issues as well. So I designed my own clamp system that can be retrofitted onto ANY EZNoselift system of any vintage, without any changes to the aircraft structure or EZNoselift side mounting plates.

    This system works by clamping on the exterior of the upper tube and supporting the shear pins so that they cannot stress, bend or deform the bolts, nor is tension on the bolts required to prevent the bolts from loosening. The purple washer shown below is a Nord-Lock washer that will retain the bolt, which is never under torsion trying to unscrew it.

    This is an exploded view of the system (3D CAD):

    image.png

    Here is a link to the 3D models, 2D drawings and installation instructions for the clamp system on the EZNoselift mechanism:

    https://drive.google.com/open?id=1rMJIQisEFLaIl3FPSzKRr4XMNvXrHdL6&usp=drive_fs

    The instructions have many pictures showing the install methodology. Feedback on the instructions is welcome - this is Revision 3.

    In any case, I've tested this clamp system on my plane (a COZY MIV) and on two customer's Long-EZ EZ's noselift and I'm happy to say that it works well in all three. It's by no means perfect and it weighs about 1 lb., but to me, that's a small price to pay to eliminate the bolt unscrewing (and bending) problem, which has led to system failures and could lead to nose gear collapses.

    I'd like to make this clamp system available to anyone with an EZNoselift in their aircraft (or anyone installing an EZNoselift system in their aircraft build). It takes 45 - 60 minutes to install.

    Each clamp system will ship with all machined components as well as all required hardware for installation (bolts, nuts, washers).

    If you are interested in eliminating potentially catastrophic failure modes as well as eliminating continuing maintenance headaches (frequent attach bolt checks) on your aircraft, please email me directly at the address below (please don't clog any of the lists with order emails, but questions regarding the system are welcome on list if the answers would be of interest to everyone) and let me know you are interested in acquiring this system.

    Thanks.

    --
    Marc J. Zeitlin                      marc_zeitlin@...
                                                http://www.cozybuilders.org/
    Copyright © 2024                     Burnside Aerospace

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  11. Folks:

    Mike Busch has a great primer on borescoping here:


    for those of you who believe in science :-).

    --
    Marc J. Zeitlin                      marc_zeitlin@...
                                                http://www.cozybuilders.org/
    Copyright © 2024                     Burnside Aerospace

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  12. Hi Pat, long time no meet-up.


    I reported this when the same happen to me a few years back. Due, as you point-out, to having made the bend, as plans, too sharp, - too small a radius.


    The replacement I made has a much larger bend radius, say, >1/4" so it will never cause me any trouble again.

    Still gives a good 'twang' on closure - although I always visually check.


    Instead of re-filling the access holes I just put speed tape over them - despite hopefully never needing access again.


    Best wishes to you and Linda,


    Mike T


    (Still no access to my safety-latch photos. Recovery data from failed HD is awaiting new comp - due today but darned delivery guy didn't bother to call !) Too far/cold to visit Eze for new picis.




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  13. Hello all.


    Just wondering if any canardians might have in your "spares" chest a SC-1 safety catch for a Long-EZ?

    After 15 years of flying the EZ the catch has cracked/split along one of the 'arms' close to the canopy frame.                                                                                                                                         I guess all those times when I would bend it back after opening the canopy has work-hardened it to the point of fracture.                                                                                                                    Shame and for some reason I don't think I have installed it as per the plans but have buried nuts in the frame rail, using machine screws through the catch part.                                                     Bet it's going to be a pig to remove but we'll see!

    Hoping someone can help, but if not I'll be getting the tools out again to make one.

    All the very best for a good flying season to come.

    Patrick Elliott, Surrey, England.
    G-LGEZ

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  14. It appears to be N656TE. There's a thread going already on the Cozy mailing list and a couple of the canard-related Facebook groups.

    On Monday, January 15, 2024 at 06:47:12 PM CST, Steve Rothert via groups.io <swrothert@...> wrote:


    Does anyone have more details??  Looks like a Cozy

    https://www.newsnationnow.com/us-news/west/coast-guard-suspends-search-for-survivors-in-half-moon-bay-plane-crash/

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