Its not the end result that is the goal, its the journey...
Colorado Kitfox
Jan - Dec 2017
1/10/17: Wow.....Another year has passed. It is my sincere hope that 2017 will see this airplane take to the sky. There is still lots that need to be done. Just when I think I'm getting close, I go out to garage and see all the parts still in the bins and bags. Over the past few weeks I have received the sample panel from Aircraft Specialty that is made of a fairly flexible lexan plastic. Its purpose is to test fit the instruments, switches, etc to ensure when the final panel is cut, it will all work. I have 5 or 6 changes I will make as a result, therefore I believe this is a really great idea. For example, I plan to move the radio to the right just a bit and also move the ELT remote slightly to the right. A few other mods will be made to better accommodate structural supports in the back of the panel. Below are the pics.
1/22/17: Been working lots with Steve at Aircraft Specialty. We are on rev 11 of the panel design and have decided to cut the main panel and subpanel from one piece of aluminum the same thickness as the original panel. So, now I will have an extra panel and sub-panel, but that's ok. We think it will look really nice. Also, I decided I wanted the Dynon pitot tube because it supports the AOA function that I can hook up to the MGL EFIS. So I had to figure out how to retrofit the single 1/4 aluminum tube pitot design with the new Dynon and do it all in a covered wing. Luckily, the inspection hole in the wing provided the necessary access to install an additional plywood support needed to mount the larger mast. The next challenge will be to run the additional tubing needed for the AOA pressure port and get it zip tied in place.
2/19/17: Over the last couple weeks, I finished mounting the Dynon pitot probe into the mount. I had to thread the threads into the probe, then screwed it in place. Next, more panel work. I received the aluminum panel from Aircraft Specialty. The next steps was to mount an L-shaped brace into the bottom of the panel then cut and mount braces for mounting the radio. The bottom brace had to be cut to match the instrument cut-outs. Next was to install the panel braces that attach to the front structure. Next will be to create the mounting brackets for the glare shield.
3/1/17: Tonight I completed mounting the glare shield brackets to the panel. The manual called for 5 brackets, but I made 7 just to ensure a better fit of the glare shield. Over the past week, I finished installation of the map box. Steve, from Aircraft Specialty made me a new map door since I neglected to account for the space the hinge would take up and therefore the map box opening was too small by 3/16". So rather than trying to enlarge the door cutout, Steve made me a new, smaller door. It fit just fine. So, the panel is now ready to ship back to Steve at Aircraft Specialty. I boxed it up and will get it in the mail tomorrow.
4/23/17: Its been a month and a half since my last post. In that time period, the panel was completed by Aircraft Specialty and I have it installed with most of the instruments now mounted. The planning for the wiring has been one of the most challenging aspects of this build. The 912Is adds lots of wiring. For example, there is a connector that requires a very expensive tool to crimp, so Kitfox was kind enough to crimp them for me. Crimping and cutting all the wires for the Harness Interface Connectors (HIC's), 2 of them, has been a chore. I created a speadsheet with a list of each wire and I am over 60 right now with a few more to add. I ordered some labels and labeling kit so I can print out a label for each wire and wrap it around each wire. I also built a custom cable to provide GPS data to the ELT. Also in this time period, Becky and I have picked out the fabric for the interior kit and have placed that on order. It should be here by late May is my guess. Also completed is the install of the comm antenna (red tail from DeltaPop Aviation) and coax cable (RG400 from fieldcomponents.com)
5/7/17: Wiring of the panel continues and continues and continues....whew. Seems like there is always more to wire. So, I have most of the instruments all hooked up except the radio wires which are next. The challenge has been to get all the wires in place, then find a good way to dress it up so all the wires are adequately supported and have some slack. In order to mount the extender, ELT buzzer, USB power outlet, GPS antenna's and ADSB-IN unit, I build an accessory shelf and mounted it between the panel supports. I also installed the clamshell wire pass-through and all the wires and the throttle seems to fit just fine although there is not much room for more wire. I also created a plywood mount for the electronic compass that will be installed in the left wingtip. I had to use brass screws since only non-ferrous metals could be used. I applied power to the system with just the EFIS and ECB hooked up. Worked fine. Now I need to start testing the rest of the system.
8/14/17: OK, well its been a while since I posted new pics but its not because I stopped working, its just that I have been spending a lot of time completing the wiring. Not too exciting from a picture point of view. In this time period I also completed wiring the headset mounting bracket. I also attended Oshkosh 2017 with my friend Jeremy. We had a great time. I purchased 2 Bose A20 headsets and a fire extinguisher. I also received my interior kit with the new Kitfox logo. Very cool. Also, today I completed the paperwork for the aircraft registration and got it in the mail It says that it could take up to 3 months!
9/05/17: Over the past couple weeks, I have completed install of the interior kit including the seats, center console and glare shield. Using the 3M spray adheasive worked really well. Contact cement is a must have for securing the edges. I have also been securing more wires and I secured all the fuel and oil line fittings (either 1/4 turn past seated or per torque spec). Tonight, I installed the map box, so now the entire panel his installed!
10/10/17: I covered the cargo bay floor with Black 500 Denier Nylon Cordura Nylon Fabric Fire Retardant & Water Repellent material I found on Amazon. I then mounted the fire extinguisher to it. Also, working with Aerographics I had them design a Kitfox logo that was designed to cover some paint damage on the left side. I put the logo on both sides. I also designed and had them build a placard for the trim switch and flap adjust handle. Below is the design. The final design made the hole for the trim switch smaller (1" x 2") so the placard would slip under the switch instead of going around it. I also mounted the SP-6 compass in the right wing tip and completed the wiring for the compass and wingtip lights. I also mounted the required "EXPERIMENTAL" sticker and added American flags to both sides of the rudder.
12/03/17: Well, its been a bit. I have spent a while looking for a hangar out at Meadow Lake airport. After about 3 months of searching, my friend Jeremy and I secured a brand new hangar and we moved my plane into it this weekend. Now the real fun begins! Over the past few weeks I have also completed the wiring on both wingtips and installed the fuel placards. I also have to cut a wedge out of the map box so that the glare shield would fit properly. That was fun!
As part of getting the hangar, I also had to get a builders risk policy that protects my project and also provides liability insurance. So, now that is out of the house, I am covered if something happens to the hangar.
12/10/17: Jeremy and I spent a day installing the prop and the wings. Its amazing what a difference that makes! We had a blast seeing it take shape. We tested the prop movements and all worked as it was supposed to. Greasing the prop was real fun. Below is a short video clip of the wingtip nav and strobe lights in action.
Solo Flight Day
