top of page
This site was designed with the
.com
website builder. Create your website today.Start Now

Jan - Dec 2016

Well. another year has come and gone.  Hard to believe 2016 is here.  Progress on the Kitfox has been pretty steady this year and maybe a little slower than I would have liked.  I am still enjoying the process and am hopeful that this year will see a completed aircraft.  Over the past couple weeks, I installed a fluid shut-off valve (from Summit Racing) on one of the heater core lines so the hot fluid can be shut off in the summer.  I also have finally installed the side NACA vents on the boot cowl with hysol and used Bondo to do the finish work.  Finally, I painted them with primer & now the boot cowl is pretty much ready for final paint.

2/23/16:  Over the past few weeks I have been working on forming the fuel lines.  The kit came with 3003-O aluminum tubing which is soft and easy to work with.  I used all that I had trying to get the perfect fit so I ordered more.  I am also learning about flaring the 37 deg flare using a special tool provided by an EAA tech advisor (which by the way came out to see the plane.  He really liked the paint).  I also got a tubing bender to bend the tubing.  Steve, from Aircraft Specialty offered to pressure test a couple flares for me and offered to make custom SS flex lines if I wanted.  Since the industry standard are these aluminum lines, I will try to stick with that.  I did a few flares using a variety of turns (4,5,6 half turns) from the flare tool & sent them to Steve.  I also did some reseach on 3003 vs 5052 aluminum tubing.  The 5052 is a little stiffer and is less likely to scratch and dent like the 3003.  The 5052 also has a higher pressure rating.  I ordered some 5052 (comes in 6' lengths) & I like it.  I think I will form the line in 3003 and then use the form to create the installed lines in 5052.  I plan to support the lines with rubber adel clamps at least every 16 inches per the guidlines.

3/13/16:  Well, I think I finally have completed the fuel line routing design, whew!  I ended up using eh 5052 for 3 of the 4 lines.  The line from the one way check valve back to the header tank has lots of bends, so I stuck with the 3003 for that.  Steve, from aircraft specialties pressure tested my flares up to 2000 psi, so I am confident that my flares are ok.  Based on what he told me, I ended up dialing the flare tool 5.75 HALF turns from snug.  This gave me a great flare.  I also learned that you need at least 1 inch of tube prior to a bend in order have enough room for the insert to fit without hitting the flare tool.  I had to remake one line because of this.  I will have 4 support brackets hysoled in place to provide attach points for the adel clamps.  I ordered a bunch of clamps from Spruce & will finish when those arrive. 

 

I beleive I am a couple weeks from ordering the engine, so I started trimming the cowls (just cleaning up the rough edges.  There is some trimming I can do prior to getting the engine, then the rest will need to be done with engine and prop hardware in place).

5/3/16:  Ok, been a little slow lately but today my engine arrived!  Also, I attended Sun n Fun in Lakeland Florida last month and ordered both my prop and radio.  The radio is here and the prop is a few weeks out.  I also cut out the inspection holes in the bottom of the fuselage and one wing.  I beleive I have completed all the interior fuel lines and fittings.  I also did the final riveting of the control horns on both flapperons.  Now, its time to get busy studying all thats required to install the engine.  What fun!

5/15/16:  Its been a great weekend.  Jared flew home this weekend and he and Kyle helped get the engine installed.  Also had help from our neighbor Josh.  We attempted to get the nose wheel on first, but had some issues with getting it fitted, so on Saturday we got the engine mounted, then on Sunday, Jeremy and I resolved the nose gear issues and completed the nose wheel installation.  Jeremy borowed the engine lift from a friend. 

6/20/16:  Good progress over the past month.  I ordered and received my Airmaster 3-blade constant speed propeller and spinner.  Below are some pics of the blades, spinner and the controller.  I needed the prop to properly fit the cowling.  So, after alot of aligning, sanding, and more sanding I finally took that deep breath and drilled the holes for the camlocs and attach bolts that go through the firewall flange.  It took alot of time, but worth it.  I still have some fine detail fiberglass work to do and I need to install the lower NACA duct.  I also shaped, cut the hinge and drilled the mounting holes for the oil door in the upper cowl.  Next will be install of the radiator and oil cooler/oil thermostat and all the associated lines that go with that. 

7/5/16:  Over the past couple weeks, work continued on the cowl.  Not sure if it will ever be done.  I began to fit the NACA duct onto the lower cowl that then defines where the radiator will be.  So, with that determined, I began the install of the radiator which involves the fabrication of retention straps.  One on each side, then a rear one that attaches from the back.  I then installed the overflow bottle and then cut the coolant hoses & installed them,  Note the T-fittings that feed hot coolant to the cabin heater.  Next is the oil cooler.  I removed the radiator so that the oil cooler could be attached to the radiator via 4 brackets (2 on top, 2 on bottom)..  Once installed, the oil thermostat and oil line planning will begin. 

7/24/16:  Good progress lately on finishing the install of the radiator and oil cooler.  I elected to install an oil thermostat to reduce engine warm up time.  Below is a picture of it.  As a result there are a few more oil lines that have to be installed.  I wrestled with using hose clamps vs pinch clamps.  Unfortunately, I could not get the hose ends off to put on pinch clamps on, so it looks like hose clamps it is until the 5-year rubber replacement.  I also have been working on getting the lower cowl NACA duct in place.  I got it as close to the radiator/oil cooler as I could and left about a 1/4" gap once I was done fitting it.  The pic below was taken before I got the cowl to fit around the oil cooler.  I now need to paint the cowl inside before I hysol it in place.  I dont think I could get it painted well once its in place.  Next is wiring.  I installed the battery/tray, the starter & master solenoids and the engine control unit (computers).  I am now working on the #6 wires that run to engine ground, master and starter solenoids.  And of course, I didnt have a crimper that would crimp #6 wire, so off again to the tool store I went (cant have enough tools!). 

8/17/16:  Spent alot of time trying to figure out how to route the radiator line on the left side because the most obvious routing has it very close to the exhaust pipe.  So, I bought some heat shield, stainless steel tie wraps and tied it back as best I could away from the exhaust pipe (thanks to Ross from the forum for that idea).  Next was working on the FWF wiring.  All the #6 wire is now complete after getting a hydraulic press designed to crimp this large wire.  There was an initial problem with the starter solonoid showing continuity between the two main contacts.  After bumping it and energizing the solonoid, it appears to be working ok.  Next was to fit the exhaust pipe.  After getting it on the muffler, it took some careful measurement to figure out where the hole needed to be.  Its further outboard than the guide would have you cut it.  I think I will take it to my auto mechanic to cut the 45 deg cut at the end of the pipe.  I also installed the cam-locks on the lower cowl.

9/18/16:  Work has been a litlle slow lately.  Finally got the oil door installed and ready for paint.  I also spent lots of time working the cowl to ensure proper fit.  Working with Superfil is really nice, I highly recommend it.  I also broke out the paint gun and painted the inside of the lower NACA duct, then hysoled it in place.  I thought it might be hard to get the paint into the scoop once it was attached to the cowl.

10/5/16:  Over the past couple weeks I completed the fine sanding and superfil on the boot cowl and upper cowl.  So, then it was time to prime them.  I decided I wanted a landing light mounted in the lower cowl to improve visability in the air, so after some research I decided on the Rigid SR-Q2 six LED driving light.  This light is built for off-road vehicles and its very bright and well built.  I designed and cut out the opening, then finished the hole with some rubber siding material.  I built a mounting bracket, then used hysol to attach it to the cowl.  In addition, I plan on using 100 deg countersunk screws through the cowl and into the mount just in case the hysol lets loose.

10/15/16:  Since I didnt have large parts left to paint, I set up a paint booth in my workshop with 3 fans blowing fumes out.  It works really well.  I have completed the white desothane on the wheel pants and all three cowls.  Next, I applied the design stencil to the wheel pants and have so far completed the purple part of the design. Next will be blue.  Then, it will be time to apply the stencil to the cowls & then paint them blue.  10/25/16:  Added pics of the completed wheel pants.

11/06/16:  I had to have Aerographics re-do the cowl stencils because the first attempt was not right.  The stencil was not long enough to stretch around the front of the cowl.  So, they were nice enough to redo them and send them to me.  This weekend I applied the stencil and got the purple color on.  So, I believe I am now complete with the purple color.  One more paint session with blue should complete the painting!  I also have sent my panel data to Aircraft Specialty.  They created the panel layout diagram & will be helping to plan, cut, powercoat and label the panel.  I also ordered my MGL EFIS on Friday & it should be here this week!

11/13/16:  Its been an exciting week.  I have finally finished painting the cowls and therefore I believe I am now done with paint (famous last words, right?).  Anyway, I am pleased with how it turned out and have dis-assembled the paint booth in the basement.  My wife is glad she will no longer have to smell paint! I also had the spinner powdercoated in gloss white to match the landing gear.   I also have ordered and received my EFIS, electronic compass, engine data sender (RDAC) and Electronic circuit breaker kit (ECB).  Now the real fun begins as I continue planning the panel and how this beast will be wired.

bottom of page