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Thread: Rock Fox Build

  1. #21
    DMMeix's Avatar
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    Default Re: Rock Fox Build

    I thought a recalled a 2022 date when we last spoke. That definitely makes things get 'real' real fast!
    Student Pilot
    Here to absorb everything about building a KF.

  2. #22
    Dean_aeroleds's Avatar
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    Default Re: Rock Fox Build

    Have fun! One of these days I hope to be able to do a build...

    Dean

  3. #23
    Senior Member rv9ralph's Avatar
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    Default Re: Rock Fox Build

    Have fun! One of these days I hope to be able to do a build...

    Dean
    We are having fun. I need to post some updated pictures as we have progressed quite a bit further in the build than what I have posted so far.

    Seeing as you are not too far away, send me a PM if you want to drop by sometime.

    Ralph

  4. #24
    Senior Member rv9ralph's Avatar
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    Default Re: Rock Fox Build

    Another joint work session. Shaped provided foam for tips of HS and Elevator, bonded the foam on after that set, then buttered on a coating of micro. After the micro sets, will shape and ad SuperFill to take to final shape. Below is the prices in picture. There were several replications of ... apply Super Fill, sand/shape, Super Fill

    I like the results, easy to sand and shape and very little added weight.

    Ralph

    IMG_7018.jpgIMG_7019.jpg


    IMG_7021.jpgIMG_7023.jpg


    IMG_7024.jpgIMG_7025.jpg

    Not quite there but almost. Didn't get a good picture of final results.


    IMG_7030.jpg

    Ralph

  5. #25
    Administrator DesertFox4's Avatar
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    Default Re: Rock Fox Build

    Ralph and Victor, hope you are both doing well.🤞 Haven’t seen a recent update on your Kitfox project.


    DesertFox4
    Admin.
    7 Super Sport
    912 ULS Tri-gear


  6. #26

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    Default Re: Rock Fox Build

    Quote Originally Posted by DesertFox4 View Post
    Ralph and Victor, hope you are both doing well.🤞 Haven’t seen a recent update on your Kitfox project.
    We're doing great. We're way behind on posting updates! We have finished all the preliminary work on the right wing and are starting on the
    left wing. This, of course, has provided and endless stream of jokes from me since Ralph and I are on opposite political teams We'll leave it
    a secret as to which team each of us plays for.

    We had a unique method for adjusting the fit of the wingtip and we'll post more info on that later.

    During installation of the right wing flaperons we encountered some resistance to movement after getting everything clecoed in place but we finally
    realized that it was due to sag in the wing since it was only being supported on the ends. Turning it 90 degrees up solved the issue.

    The left wing will have the magnetometer and pitot so it'll be a bit more work but it's going faster overall since we've already done it once.
    IMG_1159.jpgIMG_1187.jpg

    We'll try to post more often!

    Victor
    Building SS7
    915iS
    Garmin G3x

  7. #27
    Administrator DesertFox4's Avatar
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    Default Re: Rock Fox Build

    Good progress and happy you are both well.


    DesertFox4
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    912 ULS Tri-gear


  8. #28
    Senior Member rv9ralph's Avatar
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    Default Re: Rock Fox Build

    As Victor said, we are making progress but not posting much.

    I thought I would share the process we used for fabricating the tips of the flaperons. Here are the pictures in sequence.

    First, I bought a sheet of 1" thick extruded foam from the local hardware provider, I needed 2" thick so I cut a 2" wide strip and laminated to get a piece 12" long and 2" square. Note, I used a spray adhesive to keep from having a hard glue joint.
    IMG_0413.jpg
    Next, I cut the airfoil to fit inside the flaperon and the tip profile. I had about a 1/2 inch of the foam inside the flaperon.
    IMG_0414.jpg

    Next I used the disk sander to round it to a desirable shape.
    IMG_0415.jpg
    I did the final shaping with sandpaper. The size at this stage is slightly under the finished product.
    IMG_0416.jpg
    To do a 1 layer fiberglass shell, I put the tips on skewers in a board to hold them for this stage.
    IMG_0417.jpg
    Next was laying on the fiberglass and letting it cure.
    IMG_0419.jpg
    After it cured, I trimed off the excess glass. At this stage, the weight of one tip was .4 Oz.
    IMG_0421.jpg
    To adhere the tip to the flaperon I used a slurry of epoxy and microballoons thickened to peanut butter consistency, this also filled the glass weave and brought it to the desired profile. I used 20 mil plumbers tape to protect the skin of the flaperon while I shaped the cured micro down to the final shape, the filled in any low areas with SuperFill.
    IMG_0431.jpg
    The finish product set aside until final prep for paint.
    IMG_0446.jpg

    Victor and I were very happy with the finished product, light and sturdy.

    Ralph
    Attached Images Attached Images

  9. #29
    Senior Member Kitfox Pilot's Avatar
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    Default Re: Rock Fox Build

    Looks like the tips turned out very nice. I enjoy watching your build.
    Harlan and Susan Payne
    Sold Piper Archer
    Flying FarmFox STI Kitfox N61HP
    Rotax 915is, Airmaster prop
    https://www.youtube.com/channel/UC5A...oCVUP15G0uB-Yw

  10. #30
    Senior Member rv9ralph's Avatar
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    Default Re: Rock Fox Build

    I has been a long time since our last update. Since then we have finished everything we could do before cover, so ... we started on covering. I did a short video on our first surface cover. Here is a link to the video on my YouTube channel. I hope you enjoy it.

    https://youtu.be/ycxu_cG0rto?si=QSOWDOei0ey_19SE
    Ralph
    Kitfox 3 flying
    Building Kitfox SS7 (RockFox)
    915iS Engine
    Building Partner Victor V

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