Project 5 build thread

[bbs428]

Looking mighty fine! Organization will save you untold hours of frustration.

I'm in Eddie's camp as no matter how "organized I try to be, my kaos nature kicks in and my workspace turns to doggie doo. I always replace my tools prior to quitting time so tools can be found, however my trick is to pick up a vital part/hardware and then put it down in the most unlikely place. Then I spend hours looking for said part/hardware! When I'm having a bad day I clean the shop and go thru all the boxes and cubby holes. I usually find what I'm looking for BEFORE I order new hardware... most of the time!

[Jerrytex]

Great thread. I just sold my KF 4 and I am in high gear now on my model 5 build, which means the aircraft spruce boxes are going to start piling up.

I'll be following your thread closely.

I am sure you probably have already researched this but in case not, it would be wise to do the rudder pedal assembly reinforement now since everything is still disassembled.

[Shadowrider]

Nothing I hate more than looking for tools!

[alexM]

Thanks for the replies. This garage is the most organized I've ever had. I can relate to the shops in disarray because it is in my DNA. My dad's mode was that if it would keep for 6 months and you might have a use for it, it stayed. His last shop looked like Russian soldiers ransacked a hoarder's garage. I used to only sort of joke that every time I got a decent tool box it was stolen shortly after that. About four years ago I had to rebuild the engine in a Porsche, and damn was I organized for that project! It went so much smoother being able to see a missing wrench from across the room. At the end of each work session I took the time to put everything away, and it more than made up for time spent searching for a missing tool/part.

Good call on the rudder pedal reinforcement. It is part of my current work.

Yesterday was the first time I felt like I accomplished direct hands on work on my Kitfox. With the new rudder pedal brackets in hand I got to practice surface conversion. My project came with Bonderite C-IC 33 Alumiprep acid deoxidizer and M-CR 1201 Alodine. I printed out the data/instruction sheets, mixed my chemicals and did an initial cleaning of the parts with acetone. I got dirt on my rag so that was a good idea. I used the temperatures and times suggested and was quite surprised at the fizzing away as the parts were etched. I rinsed thoroughly to see the very shiny parts, and then it was straight to the Alodine. I'm used to Alodine treated parts being a little splotchy but these came out beautifully as if they were gold anodized. Rinsed again and dried.
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The other thing I did was head to my local Wesco auto body supply store to get a can of custom enamel to match the red powder coating of my steel parts. While I was there I inquired about a product I had never heard of before: two part epoxy in a spray can. My uncle was doing some work on the SNJ recently and started talking about it. I thought he was losing it but it's a real thing. Maybe I'm just late to the party but I got a can of epoxy primer yesterday. You use part of the cap to break something inside and it mixes the catalyst. Then you have 8-12 hours to use it up.
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I've got the two part Epoxy from Kitfox but as of yet I haven't mixed or sprayed any. I'm guessing there is a learning curve and I don't want to make my freshly alodined parts ugly. I have some prep work to do on the fuselage still so I'll wait until I can justify cracking open that can. I pick up the can of red this afternoon. It's single part so not as life limited as the epoxy.
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Regarding the rudder pedal reinforcement: Last night I used the pattern depicted on the Service Bulletin to make a 1:1 paper doll and test it on my rudder pedal torque tubes. I didn't love the way it fit or looked, so I used the pattern as a basis for a new one. I'll be mocking that up before I cut any stainless steel. The one I made is slightly asymmetrical in order to work with the rivet pattern already established on the torque tube. I'll post pics when I get there.

[bbs428]

Great job on the alodine parts!

[airlina]

Alex., do you have the name of that two part epoxy primer in a spray can? I wasn't aware of it either and would be nice for small jobs that I have. thanks Bruce N199CL

[Delta Whisky]

I'm curious as to why you are cutting the gussets out of SS? (I'm not familiar with the SB - if that is what it calls for.)

[alexM]

Alex., do you have the name of that two part epoxy primer in a spray can? I wasn't aware of it either and would be nice for small jobs that I have. thanks Bruce N199CL

Bruce
That's the stuff right there. Check with your local auto body store.
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I left one of my non Puka pedals with the paint shop so he could match my custom rattle can. One of these two pedals was used for a test and the other came out of my tub of parts I'll never use. I would say I'm pretty happy with the results