Geek's STi Build

[bbs428]

Glad you found the issue with your engine Gary. I knew it wouldn't set you back to long!
Funny how we know so much about trons and we can still get some things wrong! It's the same issue as I have... ME! Lol.

To be fair, as we get used to the software and work through the various squawks, the more it all makes sense, and it is getting easier to find the problem without a call to the Garmin/Rotax tech wizards.

This forum continues to be a wealth of information, and the members are real lifesavers when we are hitting the wall they have already climbed over.

[Geek]

Doing some small stuff while awaiting parts and getting some 'honey do' off my list. Finished off the oil level access door on the upper cowling with the Dzus fasteners. Decided that I wanted to improve the seal around the cooling radiators so I added a seal strip around them. (Sorry pic #3 is upside down) I have read that some people put a wooden spacer around the flaperon control rod to protect it should the fiberglass seat collapse. Haven't actually heard of this happening but thought it would be a good insurance step so I made and installed a couple spacers.

Cowl Door 12.JPGNaca Duct Seal 2.JPGNaca Duct Seal 3.JPGSeat Brace.JPG

[bbs428]

Seals and oil door look great Gary. The seals are something I haven't thought about tbh.

I still have to add my wooden spacers, thanks for the reminder!

[alexM]

I've read about some seat collapse scenarios. Several things might have contributed to those stories. On the series 5 the seat pan is secured to the cross tubes (top and bottom) with slots and zip ties, which can stretch/break over time. Maybe you trim off too much along those edges trying to make it look nice. Maybe the flight crew is more graviationally challenged than a standard FAA 170 lb pilot.

Those storage compartments under the seat used to be optional. They not only stiffen up the seat pan, the help support the pan if it should flex further than it is supposed to.

Now the fuselage comes with those steel tabs on the top/bottom tubes, and you use mechanical fasteners. Don't skip out on the fasteners and inspect your seat pan occasionally to make sure cracks aren't forming between the fastener holes and the edge of the seat pan. The extra blocking probably isn't required but it certainly doesn't hurt.

[airlina]

Back in the olden days when I was building my Series 5 , there where several reports of seat pan failures and a few wrecks , and that got my attention in a hurry. I had a hard time imagining how the Skystar folks thought zipties where a good idea to hold such a critical component in place (or not). I took the belt and suspenders approach and used high quality rubber cushioned SS hose clamps in place of the zips, added aditional layers of reinforcing fiberglass in the mount critical areas and used old seat belts under the seatpan and mounted to the front and back support tubes as a last save. Trust me , i've tested the integrity of my work over the years with some dynamic arrivals and all is good 1000 hrs later. Bruce N199CL

[Geek]

.......... Maybe the flight crew is more graviationally challenged than a standard FAA 170 lb pilot.

..........Trust me , i've tested the integrity of my work over the years with some dynamic arrivals and all is good 1000 hrs later. Bruce N199CL

So first off - you two are guilty of some classic quotes. I got a good chuckle out of both of these. Thanks. As for the braces, I too had read some stories about the seat pan but think when I had read them, wasn't smart enough (read - the start of my 18 month waiting period after ordering my kit) to know the difference between a 4, 5 or 7. Probably still can't quote confidently about the differences. But I did make notes back then on things I wanted to make sure I did with mine and those braces were there.

Gary

[alexM]

You know we all expect you to paint those to perfectly match the fuselage tubing, right? Maybe some superfill to smooth them out?

Surely you wouldn't leave those hideous bare wood blocks there after the whole world has seen them.

[rv9ralph]

That was my observation... and the motivation of posting after seeing the Hysol, that modification will not be seen on the exterior is a good thing ... and I agree with the unpleasantness of working with composite. However, there is no way to replicate the results with aluminum. (My skills with an English wheel are non existent)

I am currently working on the cabin vents NACA ducts. Cowl is coming soon.

[rv9ralph]

I am certain that engine will flex the motor mounts a bit (Kitfox calls for a half inch of clearance between the exhaust pipe and the cowling due to that)

That is a concern Gary. However, the muffler stinger is further from the center of rotation than the valve cover, reducing the amount of clearance needed.

I love your glass work. HAHAHA!!!

But seriously. Your progress looks great. Keep plugging away.

[bbs428]

Nice catch Gary. These things happen and it's how you deal with it that counts. Looks 1st rate.
Nice strut rotisserie!