Mod IV New builder Nga

[bushrod]

I finally closed the deal and purchased a "slightly" built Sky Star Model 4-1200. I was most excited until I saw it in person. Overall, it is not in bad shape. It was stored in a barn that was not weatherproof. Caveat emptor, but it's mine now.
The next kick in the pants was from Ms. McBean from KF, LLC. She stated, "The Model 4 Kitfox was produced by SkyStar When SkyStar Filed Bankruptcy in 2005. The Courts Destroyed all records of Sales and Customers. We did not buy the company, so we were not entitled to any of their Customer or Sales information. So, there is no record of that aircraft or what or who it was originally sold.
I have kit serial# 1816, sold to Mr. Alvin Thomas, who sold it to a person named Bill. Bill passed away in 2015, and the person whom I bought it from procured it from his widow. I added this bit of history and name-dropping simply to see if anybody on this forum recognizes any names. This will be the last time I use names in this forum. It was mentioned in passing that this is a Speedster kit.??


So, I am starting with a fresh, clean slate on an old, unknown airframe. I contacted KF and purchased the updated builder manual(2003). I will be asking lots of questions on this forum.


1. The kit was powder-coated at the factory(I think?). I know weight and drag are not our friends, so I want to pressure wash and re-paint the airframe. Do you have any suggestions on a primer, then a durable type of paint to spray( automotive acrylic, lacquer, polyurethane, or?)?


2. I am starting on the fuselage kit. It states, "Trial fit the floorboards." As the picture below shows, the wood needs to be replaced. Does anybody know the correct type of wood and thickness?


I will have many more once I start this massive project. Thank you so much for your attention and participation! JJ

[avidflyer]

Here is a link to the plywood for the floor boards. Finnish Birch Aircraft Plywood (Metric) | Aircraft Spruce 3MM or 1/8" is used.
I would ask if the plane was ever registered? If so, the FAA will want to see an ownership trail from that owner to you. There is also an option to register an aircraft as 'built from parts" I would say talk to the DAR who will eventually get you the airworthiness certificate once the plane is completed and get his opinion. Better to have him in agreement with your plan at the beginning, rather than at the end say, this is not going to work. JImChuk

[bushrod]

Jim: Thanks for your reply. I plan to try to sand/re-seal the existing ones but I still might have to replace the three pieces.

Any suggestions on painting the airframe? I plan to take LOTS of pictures, dis-assemble what I have, and re-spray the entire air frame some form of "white"

Thanks!
JJ

[jiott]

Many of us have used the white epoxy primer supplied by PolyFiber with good results on bare metal. I'm not sure whether it is recommended on top of powder coating or not.

[atosrider]

powder coating is known to keep the outer layer of paint intact even with rust underneath ..
on my rebuild it was walnut chip blasting then endura 2 part epoxy primer, which is incredibly difficult to remove in the future, such as ground contact points ..
before blasting, braze tabs onto the frame where the plans say drill and pop rivet, such as the canopy, seats ...
anti-corrosion tube preserver, after priming will make any dribbles to the exterior easier to clean up without paint bonding issues ...
check out the reinforcement others have detailed here in the forum after heavy heavy landings ....
are you going to widen the elbow and shoulder room at the doors?
luggage compartment?
all your spare reading time can be devoted to this forum, time well spent !!!!
regards

[bushrod]

powder coating is known to keep the outer layer of paint intact even with rust underneath ..
on my rebuild it was walnut chip blasting then endura 2 part epoxy primer, which is incredibly difficult to remove in the future, such as ground contact points ..
before blasting, braze tabs onto the frame where the plans say drill and pop rivet, such as the canopy, seats ...
anti-corrosion tube preserver, after priming will make any dribbles to the exterior easier to clean up without paint bonding issues ...
check out the reinforcement others have detailed here in the forum after heavy heavy landings ....
are you going to widen the elbow and shoulder room at the doors?
luggage compartment?
all your spare reading time can be devoted to this forum, time well spent !!!!
regards

Thank-you for your response. And YES this is now daily required viewing!

This is a "used kit" Ser# 1816 from Skystar. KFLLC has zero info on manufacture date, since they did not procure Skystar info. I am still in discovery mode of what's on it , and whats not. The person I purchased this kit from "thinks" it might be a "speedster" I guess I have to measure the wings to check.

I think it does have the bumped out doors for the shoulders. How would I , could I, widen the doors??
Thanks again, We will yak again! JJ

[avidflyer]

Here is how I widened my Kitfox 4 by 4". .040" thick 4130 steel sheet under the doors as well. If you are going to be running the cabane style gear, it wouldn't be a bad idea to infill the seat truss to the extant possible as well. JImChuk

[bbs428]

Attn Admin - should we move this thread to Members build logs?

On my 1200 4 build (sold early on for the 5 I have now) I purchased the Wide Body kit from Williams Aviation for a little extra room.
If I remember correctly, the doors did not need to be modified.

Williams Aviation On-line Catalog

widebody.jpg