Carrier IV Build

[fathom]

Greetings,

I posted this on the Facebook group last night but figured I'd share it here incase anyone has an interest in seeing it. My wife and I started a blog to log the build of our Model IV. Our decision to do it outside of the forum environment was due to that fact that of the many forums I have used over the years lose embedded images and some threads become archived in a difficult to read format as site updates occur. We wanted a clean, consolidated source that someday we could have professionally printed and bound in a book, both for ourselves and for the aircraft if/when we have to sell it. We will keep it updated as often as possible with many photos and thorough documentation. I'd like to use this thread as well to throw out questions that we may have as they come. It's very inspiring to see how helpful everyone is in the Kitfox/homebuilt community and we've learned a ton just lurking on other's build threads. Feel free to comment or subscribe and recommendations are always welcome. Thanks!

David
https://carrieraero.wordpress.com/

[HighWing]

David,
Welcome to the forum. I have built and flown 2 Model IVs and confess that this old guy thinks it is the best of the bunch. Looking at your build site, the thing that impresses me most is your youthful appearance. Most of my Kitfox friends are graybeards or worse. Excited for a new generation of enthusiasts.

[fathom]

Haha, thanks, Lowell! You all are the wisdom that's making our job as "youthful" builder's easier, and for that, I thank you! It's great to hear that you loved the IV so much that you built another, I'm sure we'll have questions coming your way soon. Thanks again!

[efwd]

be prepared to get "serious" with your build. Lowell has probably got more skills than most of us and to follow him would be quiet the accomplishment.;)

[avidflyer]

David, Just looked at your website, and see you've moved to Pensacola Fl. I will be in Gulf Shores for a while this winter. Maybe I can meet up with you sometime and have a look at the progress. I've been rebuilding a Kitfox 4 over the last couple of years along with other planes. I do know of one other guy in Pensacola who also has a Kitfox 4. He flys out of Feguson apt. Take care, JImChuk

[Greg79]

David,
Welcome to the forum. I have built and flown 2 Model IVs and confess that this old guy thinks it is the best of the bunch. Looking at your build site, the thing that impresses me most is your youthful appearance. Most of my Kitfox friends are graybeards or worse. Excited for a new generation of enthusiasts.

Hello Lowell, I've already been talking with David about his IV and I am picking up a partially built model IV this weekend. Your only a few hours from me. I'm south of Fresno. Some friends were just talking about a strip in the Placerville area. Do you ever come down this way?

[Bryan]

Enjoy the build guys and you will enjoy many hours of flying as the IV is a great airplane. So many decisions along the way and this forum is a great help. Enjoy.

[HighWing]

Thanks guys.
Hello Lowell, I've already been talking with David about his IV and I am picking up a partially built model IV this weekend. Your only a few hours from me. I'm south of Fresno. Some friends were just talking about a strip in the Placerville area. Do you ever come down this way?

I have not been flying much lately. Mostly due to some minor health issues. It is good to hear of the two new IVs being built. We have three IVs in our airpark where we live O61. Thinking of near Fresno, the second one I finished was purchased as a partially built kit out of Fresno. It would be great to get together.

[fathom]

This seems to be an topic on the Facebook group with a lot of disagreement.
To lay out the scene, I am installing the brake cylinders to the brake pedals at this time but having issues with the recommended hardware from the manual.

As an example, the manual calls for using an AN3-6 bolt, washer (AN960-10L) and castle nut in conjunction with the aluminum clevis for the brake cylinder rod attachment to the pedal.
Following the assembly configuration required in the manual, I am unable to insert a cotter pin unless I tighten it so much that it begins to deform the aluminum clevis.

If I remove the washer I have no issue inserting the pin.

I don't want to file down the clevis and I also don't want to file down the castle nut as it removes the protective coating. Best option is probably upgrade to an AN3-7 and go forward....but the topic as a whole has me curious...

Given these are used for shear forces, is the washer really necessary in this application? The same logic could be applied to installing the bottom of the cylinder to the rudder pedal brackets.

[HighWing]

Given these are used for shear forces, is the washer really necessary in this application? The same logic could be applied to installing the bottom of the cylinder to the rudder pedal brackets.
Remembering the inspector from the FSDO who was a former helicopter mechanic and had an eye for cotter pins, I dont think he would notice the missing washer. I think I would simply omit the washer. As you say, torquing the bolt is a non issue given that it is in shear only. I suspect you could get away with a clevis pin, washer and cotter pin.

[Ronin]

I myself would not file any hardware down. Longer bolt, thinner washer, or no washer. Three washers in any combination per fastener is acceptable.

[fathom]

I'm reluctant to post this, because I feel like I already know the answer....but I'm going to see if any of you experienced builders have a recommendation... This kit is 21 years old, so are the gear, but they have never even had the weight of an engine on them.

I took a 7447 maroon Scotchbrite pad to the lower bracket yesterday and some aluminum polish to see how it looks and I'm less than impressed with what I'm seeing. I've read through the 43.13 and see the acceptable methods of corrosion removal but am wondering what others thoughts are from personal experience. Is this set of gear beyond repair saving? Anything I can do to try to save it and ensure that it's airworthy? Thanks in advance..

16625
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[avidflyer]

I guess I would wonder about how deep the corrosion goes. That thick of aluminum would be maybe more inclined to bend then break under enough pressure I'm guessing, but it is a guess, so take it with a grain of salt (or 3) I'm down in Gulf Shores for a bit, if you decide you don't want the gear, I'll come and have a look at it and maybe take it off your hands. JImChuk

[Geowitz]

If it were me I would run that gear with never a second thought. A little alumiprep to clean it up beyond what you did on the sample maybe, but only for looks. The corrosion that would have to exist to be of any real concern on our grove gear would have to be massive.

[Dave S]

Fathom,


A little reluctant to make any suggestion pro or con from a photo. Can't tell and don't know if there is any filiform or intergranular corrosion going on from a photo. Also not sure what the gear was coated with...paint? powder coating?.....zits under a coating often go deeper than the surface.



My cautionary comment would be to consult Grove about the condition of the gear - they know their products and have likely seen just about anything you can imagine. - even if that means shipping it to them if they want to look at it. If Grove says OK - then I would trust it. Not a cheap part so worth some investigation IMHO.



Sincerely,

[David47]

Fathom, the corrosion in the bearing blocks can be removed by machining. It sounds like it’s reasonably deep and hand linishing won’t do it. That might be outweighed by the cost of buying new - don’t know, but worth checking. Either way, better to be rid of it. The spring leg is another matter. I’d contact Grove as previously suggested and ask them what limits there are on thickness. Machining would be the better option there as well. FWIW.

[Northof49]

If it was mine , I would blend a small area on the top surface, to completely remove the corrosion, no deeper than necessary ,then measure it with a depth gage to find how much material was removed . Then consult grove . They should have some allowable damage limits. What ever the outcome you cannot leave the corrosion. Corrosion can look a lot deeper than what it actually is.
Mike

[Sagebrush]

Hello Lowell, I've already been talking with David about his IV and I am picking up a partially built model IV this weekend. Your only a few hours from me. I'm south of Fresno. Some friends were just talking about a strip in the Placerville area. Do you ever come down this way?

Hello Greg, I recently have the opportunity to buy a fuse for a model 4. I would like to talk to or visit someone who has experience with this model. I live in the Fresno area
at the Sierra Sky Park. I am new to this forum and would like to get some contact info for anyone near my area that has knowledge or is flying a model 4.

Thank you for your help.

Dale

[HighWing]

Welcome to the IV club Dale. So many thoughts going through my mind - all positive. Back in the day after the Skystar bankruptcy a friend and I began making tooling to maybe help the existing fleet with some parts. We made jigs for the wing ribs. I still have the jigs if you think you are inclined to fabricate to save a few $$. Tools needed a table saw and a bench router. Hopefully in the near future, I will be doing more flying - adapting and getting used to a Cochlear Implant - and being in the airpark makes your place a favorable target.
Lowell

[Sagebrush]

Welcome to the IV club Dale. So many thoughts going through my mind - all positive. Back in the day after the Skystar bankruptcy a friend and I began making tooling to maybe help the existing fleet with some parts. We made jigs for the wing ribs. I still have the jigs if you think you are inclined to fabricate to save a few $$. Tools needed a table saw and a bench router. Hopefully in the near future, I will be doing more flying - adapting and getting used to a Cochlear Implant - and being in the airpark makes your place a favorable target.
Lowell

Hi Lowell, I recently flew into Cameron Park to give some tailwheel instruction. Good luck with that implant, I understand its very successful. Your welcome to stop in at any time.
Thanks for the offer on the jigs, thats nice to know. I checked out some of your videos, nice road map of the Idaho back country airports!

Dale