KRSuper2 Aircraft Construction Log
Empennage
detailed progress report
Saturday, July 04, 2009 - 3 Hours
Summary: Empennage
Details: Elevator bellcrank
 |  |  |  |
 |  |
Friday, July 03, 2009 - 2 Hours
Summary: Vertical
Details: Nut plates for vertical
 |  |  |  |
 |  |  |
Thursday, June 18, 2009 - 2 Hours
Summary: Vertical Stab
Details: Elevator pulley assembly
 |
Wednesday, May 13, 2009 - 1.5 Hours
Summary: Empennage
Details: Sanded V-stab and cut out rear fuselage to fit it in. Used the laser to align everything and drilled holes for the dowel rod to position the V-Stab.
 |  |  |  |
 |  |  |  |
 |
Monday, May 11, 2009 - 2 Hours
Summary: Empennage
Details: Rerouted the com antenna cable for the V-stab to come out the front, then micro’d the holes.
Wednesday, April 08, 2009 - 1.5 Hours
Summary: Empennage
Details: Worked on empennage
Tuesday, April 07, 2009 - 2 Hours
Summary: Empennage
Details: Worked on empennage
Monday, April 06, 2009 - 2 Hours
Summary: Vertical Stabilizer
Details: Shaped and micro’d the V-stab
Sunday, April 05, 2009 - 3 Hours
Summary: Empennage
Details: Sanded the V-Stab for a groove to install the antenna. Had Paul solder the antenna connections. Epoxied and micro’d the antenna.
 |  |  |  |
 |
Thursday, March 26, 2009 - 0.5 Hours
Summary: Empennage
Details: Glued on the leading edge of the vertical stab
Thursday, March 19, 2009 - 3 Hours
Summary: Empennage
Details: Sanded out the tail and glassed it up
Wednesday, March 18, 2009 - 2 Hours
Summary: Empennage
Details: Reworked the tail with micro and micro’d the V-stab
Sunday, February 01, 2009 - 7.5 Hours
Summary: Fuselage
Details: Microed and laid up BID on the inner radius of the fuselage
Thursday, December 11, 2008 - 1 Hours
Summary: Horizontal leading edge
Details: Filled imperfections on leading edge
Wednesday, December 10, 2008 - 1.5 Hours
Summary: Horizontal
Details: Micro’d the rib edges on the H-Stab and did some filling (body work) to even up the leading edge before covering.
 |  |
Tuesday, December 09, 2008 - 1 Hours
Summary: Horizontal
Details: Finish sanded the backside of the H-Stab to prep for cover.
Saturday, December 06, 2008 - 4 Hours
Summary:
Details: Floxed panels into place and covereds Fuselage sides.
 |  |  |  |
Friday, December 05, 2008 - 1 Hours
Summary: Closing out Horizontal
Details: Heated each panel with the heat gun to warp them and make them fit better. Left them weighted in the center for the night to cure.
Thursday, December 04, 2008 - 1 Hours
Summary: Closing out Horizontal
Details: Sanded panels to fit for the backside of the H-Stab.
Wednesday, December 03, 2008 - 1 Hours
Summary: EAA tech inspection!
Details: Put our H-Stabs in the truck and took them to have Bill See (EAA Tech Advisor) inspect and sign off on our work. – YEAH! We passed!
 |  |  |
Saturday, November 29, 2008 - 6 Hours
Summary: Horizontal Stabilizer
Details: Finish sanded the H-Stab to prep for covering, then vacuumed it off and put down a layer of micro. Covered one side of the H-Stab with one sheet of UNI then wet it out. Added one sheet of BID over the UNI and then wet it out. Once it was all wetted out, I blotted up any excess resin with paper towels and then smoothed it all out with peel-ply.
 |  |  |  |
 |  |
Friday, November 28, 2008 - 2 Hours
Summary: Sanded V-stab.
Details: Finish sanded the H-Stab and added more micro to the rib caps to make a smoother finish. Tech Note -I added a joggle of about 1/16” to the leading edge on both sides to compensate for the overlap of fiberglass. Hopefully this will keep me from having to do more sanding and body work on the finish. Scott didn’t mention this in the manual, but it makes since so I confirmed with him that this is what he did.
 |
Thursday, November 27, 2008 - 1 Hours
Summary: Sanded V stab
Details: Sanded V stab
Wednesday, November 26, 2008 - 5.5 Hours
Summary: Horizontal, vertical
Details: Sanded panel inserts for H-stab. Filled in rib edges with micro. Grinded out excess glass on the V-Stab and inserted foam and Great Stuff. Paul did the same stuff today but also decided to glass out one side of his H-Stab. Tech note – we used low density Great Stuff and we felt that something else should be used since this is very hard to work with after it cures. We chose to use the low density to keep the Great Stuff from deforming the V-stab as it expands. My suggestion is that we should cut the foam as close to fit as possible and then Micro the foam into place.
 |  |  |  |
 |  |  |  |
 |  |  |  |
 |  |
Tuesday, November 25, 2008 - 6.5 Hours
Summary: Assemble vertical, flange horizontal
Details: Glassed joints on the V-Stab Laid up trailing edge flange on the H-Stab Cut out panels for backside of H-Stab Worked on Fuselage layout.
 |  |  |  |
 |  |  |  |
 |  |  |  |
Monday, November 24, 2008 - 4 Hours
Summary: Sanded H-Stab and assembled V-Stab
Details: Sanded H-Stab and assembled V-Stab
 |  |  |  |
 |  |  |
Saturday, November 22, 2008 - 1 Hours
Summary: Post cure complete
Details: Put Paul’s H-Stab in the post-cure box and let it cook at 160 degrees for about 6 hours.
 |
Monday, November 17, 2008 - 7 Hours
Summary: Post cure
Details: Built post-cure box out of ½ inch insulation foam for Lowes. Used Kerosene space heater to cook the H-Stab at 160 degrees for 6 hours. Note- H-Stab was lined up, leveled and clamped into position to keep it from warping.
 |  |  |  |
 |
Sunday, November 16, 2008 - 4.5 Hours
Summary: Horizontal Stabilizer Sheeting
Details:
 |  |  |  |
 |  |  |  |
 |  |  |
Friday, November 14, 2008 - 2.5 Hours
Summary: Horizontal Stabilizer flanges
Details: Created flanges
 |  |  |  |
 |  |  |
Thursday, November 13, 2008 - 3 Hours
Summary: Horizontal Stabilizer Sheeting
Details: Cut out templates for sheeting, fit to size. Cut last-a-foam sheeting
 |  |  |  |
 |  |
Wednesday, November 12, 2008 - 2 Hours
Summary: Horizontal Stabilizer
Details: Finished basic asssembly of H stab
 |  |  |  |
Saturday, November 08, 2008 - 3 Hours
Summary: Horizontal Stabilizer
Details: Attached leading edge
 |  |  |
Thursday, November 06, 2008 - 4 Hours
Summary: Horizontal Stabilizer Assembly
Details: Aligned and fixed ribs, formed leading edge
 |  |  |  |
 |  |  |  |
Tuesday, November 04, 2008 - 3 Hours
Summary: Horizontal Stabilizer Preassembly
Details: Installed aluminum plates with nutplates to the spar. Mounted spar to aluminum angle and check for straightness. Attempted to install ribs but had issues with alignment.
 |  |  |  |
 |  |  |  |
 |  |  |  |
Monday, November 03, 2008 - 2.5 Hours
Summary: Horizontal stabilizer
Details: Drilled out holes for installing eyebolts with nutplates.
 |  |  |
Sunday, November 02, 2008 - 4 Hours
Summary: Finished nutplates. Mocked up Horz Stab
Details: Finished nutplates. Mocked up Horz Stab, and checked initial alignment for pop riveting nutplate plates. Starting to look like parts for two airplanes!
 |  |
Saturday, November 01, 2008 - 1.5 Hours
Summary: Template for nutplates
Details: Created template for nutpate mounts from 1 1/2" wide aluminum, 2 inches in length. Setup drill press jig for production. Riveted nutplates to aluminum plates
 |  |  |  |
Friday, October 31, 2008 - 2.5 Hours
Summary: Holloween- We had candy, but no goblins showed up.
Details: Cut out hardpoints from 1/4" Birch plywood. Used hole saw to create cutouts for hardpoints in horizontal and vertical spars.
 |  |  |  |
 |  |  |
Thursday, October 30, 2008 - 3 Hours
Summary: Joined the elevator spar halves. Sized up the vertical.
Details: Joined the elevator spar halves. Sized up the vertical. Put excess epoxy and glass to use
 |  |  |  |
 |  |
Monday, October 20, 2008 - 2.25 Hours
Summary: Empennage continues
Details: Finished up the rib flanges and sized up the H-Stab
 |  |  |  |
 |  |
Thursday, October 16, 2008 - 2 Hours
Summary: Flanges continued
Details: Laid up with Uni for flanges. Edges of ribs HRIB1, HRIB2 and HRIB3 as well as the inboard side of HRIB4
 |
Wednesday, October 15, 2008 - 1 Hours
Summary: Separated ribs from flange jig
Details: Separated ribs from flange jig. Cut flanges to size. Prepped second set of ribs for flanging. Cut Uni for flange material.
Monday, October 13, 2008 - 2.5 Hours
Summary: Flange Ribs
Details: Laid up flanges on the ribs with 2 layers of BID about 2 inches wide – one inch for each surface.
 |  |  |  |
 |
Sunday, October 12, 2008 - 2 Hours
Summary: Create flanges
Details: Flanges were created by using a custom made flanging tool. We added flanges to both sides and both edges of HRIB1, HRIB2 and HRIB3 as well as both edges on the inboard side of HRIB4. Tech Note: We found that ¼” last-a-foam is too expensive to waste on SFTs so we used thick poster board purchased from Staples. Cut board to 1” wide and about 12” long. Glue two of these to another scrap 2.25” wide and 12” long. Use ribs to gap ¼” to create the space between the smaller strips. Gorilla glue is the best glue for board to board. Apply gorilla glue to one side and spray the other side with water. We want our flanges about 5/16” from the edge, so we need to build up the SFT (special flanging tool) with several strips of duct tape. The reason for this is that we will be sheeting with 3/8” foam sheets shooting for a nominal foam thickness of 5/16”, not more than 3/8” and not less than ¼”. Side note: These would probably come out a lot smoother and uniform if you built a jig out of plywood but it would take a lot more time to manufacture one. Might shave off a few grams and make the final panels more uniform to the H-stab= less sanding.
 |
Saturday, October 11, 2008 - 3.5 Hours
Summary: Started basic horizontal assemblies
Details: Built special flanging tools (SFTs) for horizontal stabilizer ribs. Sanded H-stab and elevator leading edges.
 |  |
Tuesday, October 07, 2008 - 2 Hours
Summary: Cutout and cleaned up parts
Details: Sanded all previously cut ribs to size. Worked with Chris to keep progress in lockstep. Started cutting out vertical stabilizer parts
 |  |  |  |
 |  |  |
Saturday, October 04, 2008 - 1.25 Hours
Summary: Prepped sheet for parts cutout
Details: Marked the 1/4" sandwich for empennage parts. Rough cut into manageable sections, and bandsawed ribs and edges.
Sunday, September 28, 2008 - 3.5 Hours
Summary: Familiarity with fiberglass
Details: Laid up 1/4" fiberglass/core for horizontal stabilizer ribs, and 3/8 sandwich for horizontal stabilizer sheeting. Laid up another 3/8" sandwich for the empennage.
 |  |  |
.............................................................
SITE WAS UPDATED ON
Tuesday, October 20, 2009
contact
.............................................................
SEND AN EMAIL
paulskrsuper2 @ gmail.com
construction
detailed progress
.............................................................
| Empennage | 131 Hours | |
| Fuselage | 267 Hours | |
| Wing | 54 Hours | |
| Shop Supplies | 2 Hours | |
| Miscellaneous | 11.6 Hours |
.............................................................
CURRENTLY WORKING ON
Fuselage
TOTAL AIRCRAFT BUILD TIME
465.6 Hours
PROGRESS CHARTS
specs
.............................................................
| Length |
19' |
| Wing Span |
24' |
| Total Wing Area |
93 ft^2 |
| Empty Weight |
750 |
| Gross Weight |
1200 |
| Useful Load |
450 |
| Fuel Cap |
26 gal |
| Stall Speed |
48 mph |
| Maximum Speed |
170 mph |
| Cruise Speed |
140 mph |
| Range |
600 miles |
| Engine |
Corvair 2700 |
| Power Loading |
100 hp |
| Wing loading |
12 lbs/hp |
| Power Loading |
12.5 lbs/ft^2 |
| Fuel consumption | 5.5 gph |
| Seating | 2 across |
| Gear | Tri-Gear |
| Cabin Width | 43" |
disclaimer
.............................................................
THE LEGALESE
This website was built to document my work on my KRSuper2 in compliance with the FAA requirements needed to certify my aircraft. My experiences and comments are by no means to be considered as instructions on how to build a KRSuper2 or any other aircraft.