rdooley79

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Everything posted by rdooley79

  1. rdooley79 added a post in a topic Wing Tank replacement - ALMOST-   

    Update
    Much further along.
    It's going back together and fabric has begun to be glued and stretched. Poly-system, glue, pinking, silver, paint. A good friend that has covered MANY airplanes is guiding me and making sure it all goes together correctly. We're using this as a teaching opportunity so I can do these repairs myself and also to keep the cost down. Fabric is a new thing for me but I'm very mechanically inclined and just need practice and guidance.
    Yesterday we accomplished a lot. Things are drying now. Hope to make more progress tomorrow.
    Tank is siliconed in place with the special silicone KF sent with the replacement tank.
    New standoffs between the ribs and the tank had to be made as the spacing is slightly different than the old tank.
    New brass fittings set with JB weld. Also new spacing with the bottom cap strip was needed to ensure a nice flat bottom of the airfoil.
    One unfortunate discovery was when removing the flapperon brackets that the backing plates, old glue wasn't sticking any longer and needed to be re-glued in place to ensure the rivets capture the backing plates for a strong mechanical attachment after re-covering the section.
    Below you can see the pictures, worth a 100000 words.




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  2. rdooley79 added a post in a topic Wing Tank replacement - ALMOST-   

    The wing is now off the plane with the strut removed as well. 
    Has anyone used the single shot mix your own spray cans?   http://www.preval.com/
    I have some of these from a past project. Might be a good way to not need a HPLV system with breathers and all of that stuff that's (in my opinion) overkill for a small paint session like this.
     
    Do you have any brush vs. spray pic's? I'd like to see how it turned out.
     
    Geoff, 
    I'm watching your video series on youtube now. I've been looking for exactly this thing on youtube but as you said in your video, there isn't much. We should have your video series as a sticky link for people to watch. Great to see you go through the process. 
    Great Videos!
     
     
     
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  3. rdooley79 added a post in a topic Wing Tank replacement - ALMOST-   

    yea, problem is it's in a buddys hanger and he won't spray in there......My hanger is drafty with no heat. His is insulated with heat. It's consistantly below freezing here in CO so I am stuck with paying to use his space. He is fairly adamant about taking it to an automotive spray booth for any spraying..... That just means a lot of money to me. I hate to be put in this situation, bleeding money.
     
     
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  4. rdooley79 added a post in a topic Wing Tank replacement - ALMOST-   

    We got the tank out! Ended up cutting a lot of it out and then working it back and forth until the silicone started to give way. 
    I don't have a picture of the tank out. but here it is before and after cutting the fabric.
    Next is to install the new tank and then start the covering process. 
     
    I've talked to guys in the past that said they didn't spray their poly-brush/spray on. they just brushed/rolled everything.
    Reading my PolyFiber manual it wants to use a HVLP sprayer and a ton of respirator equipment and a paint booth. While that may be possible, it will increase the cost and time of this project exponentially. I don't want to spend a $1000 on painting that little section of the wing. Plus it would look sooooo good that the rest of the plane would be bad by comparison. I need to match the dull C+ grade paint job on the plane now. Not apply an A+ paint job on the patch for the tank. At that rate it would be better to strip the plane and shoot the entire thing in a booth. Plus the only booth I have access to is at an automotive paint shop that is super high quality and very expensive to set up. This plane does not warrant a very expensive paint job. 
    So can I roll or brush on the paint? The rest of the paint job is fairly flat and dull. There are quite a few blemishes in the paint elsewhere and honestly it's not a "pretty" paint job but it is intact and hard wearing. I really just want to make it good enough to blend in with the rest of the C+ quality paint job. I need a C+ grade paint repair.
     
    Any thoughts? How can I paint this bird with the poly system but not be another $1000 in the hole?
    Thanks!


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  5. rdooley79 added a post in a topic Installing Rotax Ricks 670 Muffler on a 670   

    I have a 670 installed on my KF 4. Mounting the muffler was the most difficult part of the installation. It required cutting and re-welding the "arm" to get it to fit in the cowling. it also required some mounting brackets. 
    The work was definitely worth it. The 670 has 70+ hours on it now and is running great. The performance increase over the 582 is remarkable. Flying in CO from a field that is 5288 above sea level in the summer with the 582 is a bit lacking, especially with two guys. With the 670 the climb and speed increase is much much much better. 
    The picture below is not my plane but is the reference for how my exhaust is installed. Works very nicely. 
    You're going to love the 670 once you get the jetting and prop pitch set correctly. Rick is always pushing to run these engines over rich. That's the only thing I disagree with him on. I have my 670 tuned to be right on at field elevation but remember as we climb up, the mixture will be more rich. Just tune it like a 582 with the next size jet up. I ended up with that and the plug color is a nice light chocolate color, with minimal carbon buildup. The RAVE valves that everyone complains about is not a problem with Rick's engines. He uses the HO spades and they hardly move anyways with the power band we are running the 670 in. Prop it for 6350 ground static. On take off you'll hit 6500 and that's almost perfect. 
     
    one last thing, ONLY RUN AMSOIL INTERCEPTOR! it's not that expensive especially if you find an independant amsoil dealer. The cost is 40% less than their stated retail price. 
    My buddy became a dealer and re-sells to the 6 guys on the field. He makes enough to cover the dealer fee and we all get awesome oil for a reasonable price. 


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  6. rdooley79 added a post in a topic Wing Tank replacement - ALMOST-   

    I tried lifting the tank up but it is very secure. whoever put this tank in definitely did not want it moving or coming out. The problem is that the spar seems to be twisting with the force of the tank. The tank is long enough to be a large lever. 
    I'm just wary of doing anything that may even be close to damaging the spar. 
    Fishing line is recommended and a good to try next. no risk of damage either.
     
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  7. rdooley79 added a post in a topic Wing Tank replacement - ALMOST-   

    Fishing line may be possible. I'll grab a spool of that and see if it works, can't hurt. 
     
    What solvent would you try? MEK and Acetone are neither effective at breaking down the silicone. Xylene is the only thing that seems to soften the silicone but that's just what some people on the internet are saying, so who knows what that's worth. 
     
    Cutting the tank is the obvious answer but is too risky being so close to the spar. Not going there. The last thing that I want it to nick the spar. Just too critical to even get close to with a cutting device. I can't pry on much, again the spar is the only thing there to leverage against. If I damage the spar the whole wing is wrecked. 
     
    Fortunately I have a good A&P helping with this project but he's stumped as well. Just way too risky for all the obvious solutions. the caveman approach is not the way to go here. As Matt Damon said, "I'm going to science the $#!t out of this." 
     
    What solvent will break down Silicone?
    I'll get some close up pics soon.
     
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  8. rdooley79 added a topic in Technical tasks   

    Wing Tank replacement - ALMOST-
    Hey Guys,
     
    I almost have my old wing tank removed. Only problem is that the tank has no gap between the tank and the front spar. The rear spar had a lot of room and I was able to use some safety wire to work through the silicone and it's separated but the front spar is so close to the fiberglass with no gap that I can't fit even some .020 safety wire to cut the silicone. I definitely don't want to pry on the tank because I don't want to damage the spar. It's very tight and I can't use a screwdriver or a paint scraper, only a razor blade is able to slide between the fiberglass tank and the spar but there is no mechanical leverage to persuade the tank in to coming loose. I don't want to go at it with a dremmel because if I nick the spar, it's done, replace the spar and rebuild the wing. As much as I want a nice shiny set of freshly covered wings. My bank account doesn't.....
    It seems that the only solvent is Xylene (Strip-Rite @ HomeDepot) that will soften the Silicone. 
     
    Has anyone had a tightly fitting wing tank? What did you do to get it out?
     
    TLDR; silicone adhesive and a tightly fitting wing tank won't budge. How do you remove a tank without damaging the spar?
     
    Thanks Guys,
    R
     
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  9. rdooley79 added a post in a topic Oshkosh flight   

    This is very interesting!
    I live in northern Colorado and this would be a great way to fly the KF there. 
     
    about 12 years ago I was able to fly my weight shift trike in to OSH. That was an amazing experience. 
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  10. rdooley79 added a post in a topic Replace leaking wing tank. Adding tank to wing with no tank. Need help.   

    So what do you guys think? 
    Would you go with fabric and wood over the tank like has been done many times or would you use the thin aluminum skin attached with epoxied in rivnuts? 
     
    I like the aluminum skin for so many practical reasons. Also with my wing paint design, I think the panel wouldn't be very visible if I match the pattern well. 
    Should I go that route or fabric? 
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  11. rdooley79 added a topic in Technical tasks   

    Replace leaking wing tank. Adding tank to wing with no tank. Need help.
    I have a KF 4 with a 13 gal fiberglass tank in the right wing and in the left wing is a locker and no tank.
    Question is, My left wing with just the wing locker. Can the internal wing structure be changed to accommodate a 6 or 13 gallon tank? The  cross braces are different for each configuration but once the brackets are riveted in place, that's it, they can't be changed. Is that right or not?
    My fiberglass tank, right wing,  has been sloshed and held for a year but it's coming apart again and it's time to retire it. So it's getting replaced for sure.  It's the older fiberglass and the previous owner let her sit for months with ethanol fuel. 
    Or better yet, does anyone have a set of KF4 speedster wings with 13 gallon tanks? 
     

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  12. rdooley79 added a post in a topic Replace leaking wing tank. Adding tank to wing with no tank. Need help.   

    Has anyone used thin aluminum as a skin over the wing fuel tank? 
    Is there any reason that I couldn't use a thin aluminum skin with a piano hinge and six 1/4 turn fasteners, just like the cargo locker, just bigger. 
    Would it loose any strength?
    That would allow me to open it up and inspect,run wires, or remove the tank without having to paint/cover. 
     
    Haven't run across anyone else with an access panel for their wing tank, seems like a good option.   
    I haven't worked with fabric before but do have the Stits book to reference but am freaked out by cutting in to the wing and especially painting and finishing it nicely as well. That's why I wonder about using aluminum for the skin over the tank, so I don't have to work with the fabric much. Fabric freaks me out, the repair finish is not as good as the original finish and I just hate making another blemish. Thin aluminum shouldn't be much difference in weight than the wood/dope/fabric/paint. Plus it's just the metal painted to match the plane and that I am more comfortable with doing that, seems more straight forward.
    Is the aluminum skin idea just dumb? Should just got with fabric or what do you guys think?
     
    Kitfox is closed until next Monday the 4th, so I want to get all my other supplies lined up in the mean time. 
    Should I order anything else from KF other than the replacement tank?
     
     
    Thanks Guys. I need some guidance here. This is the last thing I wanted to do to the plane.
     
     
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  13. rdooley79 added a post in a topic Over heating on Rotax 670   

    Agreed on both points, check your static rpm/pitch.
    I have a 670 and was having over rich/temp tuning problems until I got my pitch just right. The 670 is sensitive to proper prop pitch and it's only a 1.5 degree window that my engine runs properly. Prop pitch is a very often over looked factor for a good mixture. The static RPM I get is right at 6325, which works nicely for takeoff in summer here in CO. This also has an added benefit of leaning the mix to where the EGT's are running right at 1050-1180 all day long.
     
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  14. rdooley79 added a post in a topic Replace leaking wing tank. Adding tank to wing with no tank. Need help.   

    There was a discussion about replacing a wing tank but making the top wing covering out of thin aluminum rather than wood/fabric and using a piano hinge with 1/4 turn flush fasteners to hold it shut, just like the storage locker. 
    Seems like a good way to go. Allows easy access/inspection and replacement of the tank later on but will there be any structural degradation that way?
     
    She's flying great and most of the time the single 13g tank is more than enough. I've also got two 1.9g header tanks in parallel behind the seats as a reserve. That will get me 45 minutes of flight time at a normal burn rate. So really it's a true 13 gallon usable. Not bad. 
     
    Thoughts guys/ suggestions?
     
     
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  15. rdooley79 added a topic in Avidfoxflyers General Hangar   

    Snowy playground for Christmas
    Yesterday was amazing here in Colorado. The snow was fresh soft. The sky was blue and calm. 
     
    Flying off the "grass" snow runway today was a blast. Takinig off was like being shot out of a cannon. Landing was like touching down on feathers. What a BLAST!!!!! My little brother that went along hadn't flown off of snow before and he was loving it, we were laughing like kids doing touch and go's. 
     
    Love the 22" Desser's and wide Matco wheel. They really work nice in the snow!
     
    Then we went home and had some pork that had been smoking for 18 hours... 
     
    Did anyone else get to go up over the Christmas Holiday?





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  16. rdooley79 added a post in a topic Bad 582 Mikuni fuel pump   

    I have had a pump start to go south. They don't all up and fail, they just get weak. 
    This is one of those things that does wear more quickly with ethanol fuel. Rebuilding the pump is super simple. it's some diaphragmms and gaskets that take 5 minutes to swap out. 
    It's so easy that now I rebuild mine every year along with the other yearly maintenance stuff. 
     
    Buy two:
    http://www.cps-parts.com/catalog/eppages/dualpump.php?clickkey=10931
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  17. rdooley79 added a post in a topic Silver and pink cleaning from frame   

    You're right, powder coat is tough. Needed a reason to buy some  MEK. 
    I just stripped the powder coat from my rudder pedal assembly. That was a real pain and only a wire wheel really got it all the way off.
    What happened is that the rudder pedal tube weld where it connects to the cross linkage cracked on the right pedal. I took the pedals out and had them all re-welded and braced with strap material. In the process the powder coat was burnt off.
     
     
     
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  18. rdooley79 added a topic in Avidfoxflyers General Hangar   

    Silver and pink cleaning from frame
    Any tips out there for cleaning the excess silver and pink from my kitfox cockpit exposed frame cross members?
    What I want to do is remove the top paint coats, leaving the powder coat intact.  
    Whoever recently covered my bird used a lot of silver and pink. seems like they went with the dip method. Dip the entire plane in a giant vat and then let it drip off. Might explain some of the weight I can't account for. 
    As a result in the cockpit the white powder coat frame looks really dirty from all of the silver and pink. Then to top it off another previous owner thought it would be a good idea to take a paint brush with another white paint and paint over the silver and pink. It's not even close to the white of the frame and looks awful. I have thought of MEK but I'm concerned it'll go through everything and I'll have bare metal showing which is definitely not good. Rather have the bad paint than disturb the powder coat integrity.
     
    Any ideas of how to proceed?
     
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  19. rdooley79 added a topic in Avidfoxflyers General Hangar   

    Barefoot Flying
    Am I the only one?
     
    When I was learning to fly my kitfox I was having a lot of trouble getting used to the rudder. I kept nicking the toe brakes and over correcting. I tried with only my socks on and found that I was MUCH better. The tendency to accidentally hit the brakes went away. I also was much better on the pedals with more finesse because I could hook my toes on the bottom of the pedal. It was so noticeable that my CFI commented that he might use that technique with another student that is having similar problems in a Citabria. 
     
    The best part, when it's super hot, I'm very comfortable. When it's cold, wool socks seem to work great and are nice and soft.
    The only bad thing I've noticed is that I tend to have to hold a bit of right rudder which over time makes my foot tingle from the constant pressure. With a shoe there is enough padding.
    Between the two negatives, I'll go bare foot with a slight tingle rather than nicking brakes with a clunky shoe. 
     
     
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  20. rdooley79 added a post in a topic rotax rick   

    I've got two of his engines, 670 and a 618. Both are running great.
     
    Rick has been great with any questions. Fantastic support after the fact. He stands behind his engines.
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  21. rdooley79 added a post in a topic Tailwheel Swap   

    I agree the solid Maule is a piece of junk. 
     
    My kitfox has the Matco 8" wide pneumatic wheel now. Drives like a Cadillac. 
     
    The tailwheel spring on my plane has flattened out a little as a result of the previous owner removing the smaller 3rd spring. The shimmy was wicked with the Maule and with a Matco it's much less but still present. Hope to install the new spring this weekend and have a nice shimmy free tail with a super smooth Matco to steer with.
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  22. rdooley79 added a post in a topic Close Call groundloop   

    Hey I agree with you and had the same feelings but wasn't sure if it was just my nerves taking that perspective. I am still getting used to the rudder in a split second moment scenario. When things are all "normal" I'm o.k. but still at 8 hours from solo am still very green. I totally admit that. I'd like to think that If I were further along I wouldn't have had to unexpectedly depart the runway. All in all everything is o.k. No damage to anything other than my nerves. It was a good wake up for me to keep on top of my little taildragger. As sweet as she is she can bite back when not treated right. 
     
    My wife is in much more verbal agreement with you and is yelling "That's Right" in the kitchen as I read your reply to her. She even went on to say that when I have taken her up in the weight shift trike, she doesn't like going to Longmont because of the jump planes always up our butt. Come to think of it now, it's a fairly common scenario. No wonder they have so many complaints from the neighbors. 
     
    I'll be calling the airport manager and the FBO both.
     
    I still need to go do a ton more takeoffs and landings to get my feet more firmly beneath me so when the $#!t hits the fan, I'll make better snap decisions controlling my plane better. I am that way with my trike now, with over 1200 hours and 14 years at the controls. It's an odd thing being experienced and yet a noobie at the same time. 
     
    As always, I want to be safe and be one of those "Old Pilots" with many stories to tell. Just got another one unfortunately. 
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  23. rdooley79 added a topic in Close Call's and dumb stunts   

    Close Call groundloop
    Hey guys,
     
    I was out flying this morning, no wind, very nice morning. Came in to Longmont Colorado (Vance Brand airport) which is the next airport north (10 min flight time) of my home field at Boulder. I've flown in there a lot in my weight shift trike over the past 14 years. It's notoriously busy on weekend mornings especially when the sky diving operation is in full swing. But this morning I'm in my Kitfox and just solo'd 8 hours ago. Noobie green taildragger pilot.
     
    As I entered on a 45 to the downwind for 29 at pattern altitude. I heard the jump plane give a warning of skydivers and to please not overfly mid field. I'm in good position, right where I should be and called my midfield left downwind for 29. Get to the beam of the 29 numbers and pull flaps to 3/4 where I like them and settle the plane in to a 60mph decent as make a nice turn on base and shortly thereafter final. As I turn final I hear the jump plane call base circle to final. This is a twin Otter that's now right up my butt. These guys are impatient and want to get another load of divers in. It hasn't been 3 minutes since they dropped a load out at 10k and now they are on base hauling butt right at me. My brain is concerned that they don't see me in my little Kitfox and are going to be on top of me. So I call on the radio "kitfox is 50 feet above the 29 numbers landing". Of course this is where I should be focusing on keeping the plane straight and my feet nimble on the rudder. Well, I admit, I was very distracted and only 8 hours past solo and am not as good with my feet as I want to be. So when I flared out I had the nose pointed to the left about 10 degrees. Tires squawking and screeching but I pulled back on the stick and planted the tail and wasn't as fast jabbing right rudder as I needed to. Fortunately there is a wide grass skirt  between the runway and taxiway. So when I got her under "control" the loop stopped, I didn't want to over control to keep it on the concrete so I just ran off in to the grass. I taxi forward to the taxiway and call that I was clear of the runway just as the Otter touched down right there where I went off the runway not 20 seconds earlier.
     
    Now, I know, fly the plane and always fly the plane but I was scared of being crushed by that Otter and also being a green taildragger pilot I wasn't as fast on the controls. Not sure what to do here. I can't be mad at the Otter driver that I almost ground looped but I've had this same thing happen before in my weight shift trike that's much slower. They are always up my butt. They fly aggressively and act like they own the airport and have priority. So after I checked the plane over and taxied over to the FBO for some non ethanol mogas I taxied back out with calmer nerves. The Otter was on the opposite side of the runway on the hold short, three planes on my side of the runway, I was last #4 waiting in line. The Otter jumps out in front of this plane that had just turned a fairly short final and screamed off. The Cessna 182 on my side of the runway said something like "ok you have the runway Otter but it was my turn" The plane on final I could tell was effected by wake turbulence because there wasn't even 30 seconds between the Otter taking off and them landing. They should have gone around considering how much they waffled up and down. I'm sitting there watching this and was getting kindof pissed because they had caused two pilots to be placed in to a situation that wasn't necessary.
     
    Telling my wife about this she said I should call the airport manager and tell him what had happened. I don't want to be one of those people that complains but I'm thinking about it because this has happened to me flying my weight shift trike and my trike buddies at Longmont before. Even my CFI that trained me in the Kitfox didn't like to fly to Longmont because of the Otter jump plane reputation as being a pattern "hog".
     
    Tomorrow morning I'm going out to a buddies big grass freshly mowed air field and doing about 40 takeoff's and landings to get the sight picture burned even more in to my brain and get better with the pedals. That's what I'm supposed to be doing in this solo - pre checkride period. Get to the point where I put the plane on like a pair of pants. Definitely not quite there yet.
     
    I would say that I won't go back to Longmont when the jump planes are running, except Longmont is the only airport with non-ethanol mogas and I want to run that much more than 100LL. The time I need to fill up is typically on my way back from flying in the morning and by then the jump planes are running. 
     
    What do you guys think? Should I call the airport manager or the dive operation or just let it go. I'm still kinda shook up from the almost ground looping of my bird.
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  24. rdooley79 added a post in a topic 582 charging   

    Good info Joey, I need to put a fuse on my Key west. I've ran a key west for about 14 years on my weight shift trike and never had a problem, still going strong. My Kitfox has one as well and has always worked. Everyone on my field runs the blue key west rectifier and not a single one has had a problem. They're bullet proof in my opinion. Still It won't hurt to put a max charge fuse on the DC supply. Hot batteries have a tendency to go pop. 
     
    On a side note the Rotax OEM rectifier I have seen fail on at least two aircraft. They promptly swapped out to the Key West. $65 Nuf said. 
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  25. rdooley79 added a post in a topic NEW 670 ON EBAY   

    Bump just because it's a 670. I am a fan.
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