First, Build a Shed

[PapuaPilot]

You did make a great decision in getting a Kitfox. Enjoy the build and don't be afraid to ask questions on the forum. There are a lot of people here that can help you when you need some help. It is also possible to find a wealth of data by doing searches.

[Brandon Petersen]

Hi Carl! It was my pleasure to build your wings and help your dream come true. I'm glad you're happy with them!

Brandon

[Cherrybark]

Nice to have you stop by Brandon. While contemplating the upcoming work on the tail feather ribs, it occurred to me that Kitfox needs to have a video of Brandon teaching how to do such beautiful work. If you'll get right to it, I'll put off the work for a couple of days...

[Cherrybark]

I thought it would be convenient to have the fuselage on a rotisserie for the assembly work but it hasn’t been much of a help. Having it elevated does make it a better work height while seated on the almost obligatory red stool. The tail end is supported by an aluminum strap bolted to the tail gear hole. That end of the rotisserie blocks work on the empennage and I’ll resort to a simpler saw horse approach.

With the tail blocked, I started with Flight Control Installation. I was tired of "getting ready" and, with the plane in the shop, wanted to get on with building. There is enough reaming in this stage to practice before getting to the dreaded holes on the stabilizer and elevator. Bolts didn’t always fit the reamed 3/16” holes so I rolled up little tubes of 220 grit sandpaper and sanded for the final fit. There are plenty of 3/16” holes to ream throughout the project and two 3/16” USA made reamers are in the mail as replacements. Bushings were painless using a long bolt, nut and fender washers as a press.

I’ve been keeping a daily work log, mainly as a reminder of the adventure once the plane is complete. Installing the flap handle will be long remembered. When starting a new section I pull all of the required parts and check them off on the diagram. After making three passes through the fuselage related boxes, looking for the single bolt that mounts the flap handle, I finally remembered I had left it in place after reaming the holes. Then I made repeated searches for the tiny roll pin. It was checked off the inventory sheet but was nowhere to be found. My wife, who invariably takes only a few seconds to find things in the pantry or refrigerator after I’ve given up, made a couple of passes through the bags before throwing up her hands. I wasted over an hour before realizing the Ace Hardware ten minutes down the road would have a stock of roll pins. At $0.11, I bought two so I could drop one on the floor when I got back to the garage. Drilling the 1/16” hole through the detent pin went well and I’m still patting myself on the back. Nice to have a drill press.

Other useful tools during this phase were drift pins and a metal dental pick was helpful with the washers in the control column. I also treated myself to sets of Gearwrench 1/4” and 3/8” sockets as well as their combination wrenches with ratchets in the box end. My ancient Craftsman tools were well worn and it is a treat to have new hand tools.

The parts supplied with the kit was very thorough, right down to zip ties and electrical connectors. The manual is well written with clear diagrams. I’ll agree with those who have describe the work as building a very large, very detailed model airplane. It is worthwhile to think through steps before diving in and very satisfying when something new is completed.

I’m 48 hours into the build and having a great time.

[Cherrybark]

I'll soon be starting on the horizontal airfoil ribs and will eventually be installing ribs in the vertical. While I would dearly love to have a good reason to purchase a band saw, I'm not sure the small job of trimming these ribs is sufficient.

I haven't test fitted the ribs yet so no idea how much trimming is required. Can anyone give me an idea how much material might typically be removed and perhaps offer ideas for a hand tool approach to this job?

[rosslr]

Hi Carl,

I just wanted to say how much I am enjoying your posts! I finished last year but your descriptions brought back memories. Fitting the elevator, and I too felt proud of drilling the hole for the pin in the flapperon handle! I reckon I was sure to have broken a drill on that one!

As for the need for a bandsaw - I did use a cheap one and it was useful. But I reckon the trimming could be done using a dremmel tool and fine cutting wheel, and finishing it on a sander.

I am sure others will kick in here with advice shortly, but keep it going and you will be covering and painting in no time!

cheers

[Cherrybark]

Thank you for the kind comment Ross.

Before ordering a Kitfox I spent a few weeks reading through the Discussion section of the forum and bookmarking helpful sections. The build threads offered real insight into just what it takes to complete this project. Documenting my build is a simple way to make a contribution.