109JB stumbled on another Kitfox IV project

[efwd]

Mine is open to the cabin. I have an avionics shop do the verification. No problems.

[109JB]

Thanks for the responses on the static port.

I got a bit more done yesterday but momma had a honey-do list. I did have time to get a friend over to get the wings off and also got some patching done on the wings and stab.

[109JB]

Got more done this week. Tubing finally arrived and I got the longerons fixed and side covering on.

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Also had a crack at repairing the busted upper cowl. To fix this I simply used a cutting wheel on a dremel to open the cracks and allow the pieces to be pulled back into position. From there I used bits of tongue depressors and hot melt glue on the outside to hold the cowl in proper position. Then a right angle air grinder with roll-loc disks to grind down to bare clean glass and layed up glass on the inside. Used mostly 2 layers, but sometimes more depending on the area. Amazingly a trial fit shows it worked.
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[109JB]

Well, I met my goal of having fabric on the fuselage by this past weekend. The fabric was attached using Ekobond and I'm using the latex paint method on the patches. I decided to do this after checking a spot of old fabric by cleaning it with acetone. There is obvious darkening of the paint over the years so even though I know the polyfiber color, new paint would not match well. Anyway, I've now got the weave filled and starting on color. Before anyone says anything the color on it in the picture below is too dark. This was a computer color match but doesn't match. Since I'm using latex I went to the paint store and rather than refund my money, I got them to sell me another quart at 1/2 price that was tinted too light. I've been experimenting with different ratios of dark and light paint and am pretty close to a perfect match using 2/3 light and 1/3 dark color. I'll get the exact ratio I need after a few more tries. In the meantime the dark paint is on as a base since yellow is such a pain to cover.

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I also moved on to enlarging the vertical tail to match the size of later model 4s. I didn't know the fin leading edge tube was 0.049 wall thickness, so I had to order a new piece. Rudder was enlarged and instead of rounded corners I went with squared off corners.

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[109JB]

Tail modifications are done and fabric and tapes applied.

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[Kitfox Pilot]

John I am very much enjoying your work on this rebuild. Very nice work. What kind of a seal is that between the windshield and the cowling?

[109JB]

I'm not really sure exactly as the previous owner installed that seal. A little searching on mcmaster carr and it appears it is an edge type wiper seal. I think it is about 3/4" overall width but will get you a close up picture and a measurement next time I'm out there.

https://www.mcmaster.com/edge-seals/...l-style~wiper/

[109JB]

Getting close. Fuselage is pretty much done. Had to pull the engine and de-carbon the pistons and also split the case to replace the crank seals but I got it back together, back on the airplane and fired up that mighty Rotax 582 today. New flaperons coming this week. Once those are on it is ready to go.