bbs428 Build

[bbs428]

Was really satisfying to walk into the garage and see the plane slowly coming together.
I have my coffee and look everything over... and plan the days work. Very enjoyable.

After a few days I finally worked out all the bugs with the pitch servo install and the trim
assist. With a few minor modifications, it meets all the conditions of the kit. No interference issues
and there is always tension on the spring.

The pitch servo bracket ended up very strong and light but grew complicated and required many
adjustments to the cutout areas. The assist spring had to be positioned a bit different but the
function and effect is still the same. My pitch servo arm had a conflict with the spring in it's normal
placement.

Since this is a model five I had no lightning holes on the flap weldament on the mixer
assembly. So I drilled two holes one inch apart where the measurements looked to be the best. The lower
hole on the mixer is lower to compensate for the diagonal crossing of the spring. It also provides the
lightest amount of assist. At this setting the elevator is about neutral with the H. Stab. with zero flaps.
The upper hole provides noticeably more assist which seemed a bit to much as the elevator was up
substantially with zero flaps.

I was thankful that I worked on this prior to covering. Would even be more of a pita.

This was my first effort...
auto pilot pitch servo2.jpg

And the second...
auto pilot pitch servo2.jpg

And the last.
auto pilot elevator at lowest setting1.jpg

auto pilot elevator at lowest setting3.jpg

Elevator relatively neutral at zero flap.
auto pilot elevator at lowest setting.jpg

[airlina]

Brett, your project is coming along well. Looks like some nice workmanship and quality control. And you are right , much easier to accomplish these tasks early in the build before cover. I added an autopilot to my Series 5 Outback after the plane had been flying for many years and it reminded me of playing the game "operation" (you have to be of my generation to remember that one) with a lot of contortions and tight quarters. Sounds like you are enjoying the process, which is the proper mindset for homebuilding an airplane. Bruce N199CL

[Meyer]

Looks great. You are ahead of me so I am taking notes. I also remember the game Operation!!! I am too big for that!

[atosrider]

I like the longer stringer that ramps up the vertical stab. Where you trying to create an off-set that would reduce the need for a fixed trim tab? I'm rebuilding a model III and would like to eliminate any tacky add-on ... but the tail surfaces are all single plate on the III, so it would be tricky to make it streamlined instead of kinky. Anyone tried this fix?

[bbs428]

Thanks for reading my thread and commenting!

No, tbh I wasn't trying to reduce the need for the trim tab at all. I will be adding a small fixed trim tab block on
the lower side of the rudder that I saw on one of the builds. Small, simple and effective. I will fabricate some
threaded inserts so I can experiment with the size of the block easier.

My build incorporates most of the series 7 mods. Larger elevator, longer motor mount and smooth cowl among
many other minor changes. This tail transition offered a cleaner look and it ties the tail in better imho.
I have read from previous build threads that the base of the tail was a bit tricky to cover. So I hope this helps, not
aggravates that.
For lack of a better term I'll call it the razorback mod, lol. Looks a lot better imho and is very light and strong.

[bbs428]

BRRRRRR it's cold! 7 deg atm.

Not to anxious to work out in the non-heated shop today. But prior to the deep freeze, we were able
to get the wings drilled and all our measurements remained constant, yay! Nerve racking to say the least.
I'm glad That part is done! Now we need some warm weather to attach the chrome-moly reinforcements
to the spars and set our butt rib and #1 rib in place. Thinking about the epoxy under 32 deg.
I need to see 50+ deg for me to be comfortable with the glue.

Received an AE three stack relay board, Garmin G3X gap 26 pitot tube/tubing kit and GSA 28 connector kits.
The relay will be for the "hat" switch for trim and a third for a spare.
I'm still looking at nav/pos/strob wing lights, and wing mounted taxi/wigwag lights. Not sure which way to go.
No night flying for me these days but I would like the plane to be night flight legal.
Any Suggestions?

Working on the paint scheme was fun. It was nice to sit in the warmth of the fire and color away. Stumbled
onto a distinct color scheme that I liked. I was going to plagiarize the Legend super cub scheme that I
absolutely love but it irked me that I was going to copy another plane. Last thing I wanted to hear was there's
the "little legend" or god forbid a "There's the "mini legend"... but only in his own own mind",
no matter how true/untrue the statement was! lol.

Still playing around with some ideas. This one is a little busy but fun.
My favorite colors from my favorite flag!

wing settup5.jpgparts delivery ac spruce.jpgresized americub.jpgpaint scheme.jpg

[RV6flyer]

Did you varnish the ribs so they would not be damaged when you washed he spars?

[bbs428]

Did you varnish the ribs so they would not be damaged when you washed he spars?

I used the Stits EV-400 epoxy varnish on all the ribs prior to the alodine treatment.

[bbs428]

Best weather window for painting in years. 70 - 80 deg. Low humidity. Just perfect. Might go on another week or so...

The plastic painting cups are nice to use and the tops have a built in filter. You can store your leftovers with a cap and clean up is easy too.

When I sprayed the Poly-Spray, I knew what the Stits manual said was true.... "All your sins will be revealed." Some pieces turned out very good - others not so much. I have spent a lot of time fixing little bug-a-boo's.

Haven't worked this hard in years.

[bbs428]

A lot of work preparing the wings for their rig and attachment to the fuselage and subsequent work. It's time
like these I wish I had just ordered a new kit instead of resurrecting this old, grungy sad sack of a kitfox.
The quality of the kits these days are so much better. I just drool at the pic's of all the new kits. Skystar built
some nice kits, but John, Debra and the kitfox crew are building great kits. The parts they have sent me have
been top notch. Their help and patience with me in this project cannot be stressed enough.

Those of you who do find an older kit as I did... Don't fool yourself. Unless it's pristine, stored in a rodent proof
box, you will be facing much of the same. Dirty, gnawed on and missing parts. Corrosion and rust issues and
older airframe and parts that have since been updated. And of course the time to overcome all of these challenges!
Lot's of Time...

I wonder sometimes if the $$ I saved was worth the trouble!

Well... of course it's worth it! lol. The savings paid for the engine upgrades and avionics!!

Enough of the pity party. Back to work!

Here are the wings after a week of scrubbing, inside and out. I alodined the spars, inside and out.
Painting or 2-part epoxy primer I felt would just add to much weight. The white vinegar is a cheap mild acid
that not only cleans but prepares the aluminum for the Alodine. You have to flush everything with fresh
water between steps. An amazing amount of scrubbing is needed and the alodine treatment still came out
blotchy. Thank goodness the wings will be covered! I'll topcoat the root ends of the spars with the gloss white
urethane. Perfection can be attempted later with the covering and paint!

At least they are treated and I can live with myself knowing they will be safe and corrosion free in the decades to come.

wing wash.jpgwing wash3.jpgwing wash4.jpgwing wash1.jpgwing wash7.jpgwing wash8.jpgwing wash9.jpgwing wash6.jpg