Kyle Communications

Hey its been a while since I have been able to get back to work on Mabel. I really have to finsih some stuff on her so I can get her down to the hamgar. I need the build shed for storage for a big redevelopment project here at Burpengary then the build shed will also be pulled down and the new shed to be put up will be the new build shed. The straps for the parachute are different to what are supplied by ICP and their parachutes so had to make some mods. The rear straps go around the undercarriage then come up the back but this version they come out of the upper fuselage skin using the rear overhead bar as the backstop if deployed. The kevlar straps are then exposed to the outside so I wanted to have them covered. I got on my Fusion 360 and designed up a cover then 3D printed a couple of versions and settled on this one that fits really nicely and should work well. I have a new Bambu Labs P1Ps printer..what a cracker..just a incredibly accurate and super fast printer. Once finished I can get the polycarb roof down to get film applied. I just need to fit the tray for the straps in the roof area and also sort out a cover for the main strap from the parachute that goes from the alu cover and under the polycarb in the middle at the back then onto the tray.

04/10/23 Drilled pilot holes for fuel tank retainer bracket in lower wing skin. Trial fitted fuel tank and root rib, mark filler cap opening. Cut filler cap and sight gauge holes, vacuumed and flushed swarf from fuel tank. Drilled and countersunk fuel cap flange holes. Fabricated fuel flange retainer. Installed fuel tank take-off fittings, reinstalled fuel tank with internal fuel tank support and installed filler flange and cap. 5.1h

Yes the LE is a extruded section basically a LE spar and so is the trailing edge or rear spar and the lot is held together with a truss in the centre

25/09/23 Matched drilled skin to rear spar. Removed all clecoes, deburred skin and spar, vacuumed wing cavity to remove swarf. Clecoed skin back in position, re-squared and levelled wing and completed riveting bottom RH wing skin. 4.4h

23/09/23 Riveted RH wing bottom wing skin to forward spar, stringer and ribs from leading edge to 5 rows forward of rear spar. 3.6h

My parachute came on a Emirates flight from Europe

My parachute is a GRS The dangerous goods thing is pretty over the top. The rockets are anchored and you have to remove that anchor when it is installed. I imported mine directly from the factory but I piggybacked the freight with the BRS agent here. I also found out a few things about how this dangerous goods" thing is done and who does it. I found out by accident and now know who to approach directly for the dangerous good import details . These devices all come to Qld because it is who does the dangerous good import and paperwork and internal freight here in OZ. I have to get another parachute for my RANS S-21 but its a bigger one than the 600kg and is a lot more expensive but I will be chasing the freight for it directly with my now updated knowledge of how to do it. The 6 years repack and rocket changeout I was not going to worry about as I have done a bit of research into previous tests with older rockets and chutes and I have seen videos of rockets and chutes that are up to 15 and 20 years old and they were deployed to see if it was still viable and they all still worked. OH&S is a rippoff in most cases it redtape crap gone mad and not sensible as usual govt bullsh*t is. This makes things overcomplicated and of course expense comes with that when realistically it doesnt ahve to be.

I have to confess its not all me doing this work on the RANS wings. I am not superhuman 😅 . I have great guy helping me get this done because I do have too many things happening at once here . I am very lucky to have him helping me get the wings done. Rodger wanted to have another project to do as he is retired and offered to give me a hand...of course I jumped at the offer. He has previously made a set of these same series wings for his aircraft, He is a master builder too. The previous aircraft a Waiex and RANS S-20 with the metal wing he has built are beautifully made. There is still a lot to do of course. The tail feathers and the fuselage will be delayed until I can get the new shed built here as all the other sheds have to be removed for the development of this block here at Burpengary. Mabel is almost ready to go to the hangar as soon as I can get the parachute install finished and that has to be done in the next week or three so the build shed can be cleared out to store all the stuff out of the first 2 of 6x9 sheds to be sorted and packed into boxes and stored in the 7x15 shed while the new 9 x 18 shed gets put up. Mabel will be moved to the hangar and the build table dismantled. Then all the gear will be stored in the 7x15 shed until the new one is up then the 7x15 will be taken away and the RANS will then be under way again in the new 9x18 shed...The house build at the farm should have its final inspection in about 2 weeks and the new shed up there hopefully will be erected in November, the concrete for the floor went down 2 weeks ago. That way all the farm gear will come out of the current hangar there and the hangar will be available for Mabel and the Mistress when she is finished.

22-09-23 Removed bottom RH wing skin and vacuumed swarf from cavity. Roller applied two coats of anti corrosion paint to ribs, stringers, spars and fuel tank supports. Deburred access cover ring tabs and clecoed in position on skin. Squared and leveled wing structure and refitted skin. 2.1h

EXC-3-185-C4-T (X-AIR Rotax 582 gear ratio 2.62) This is what you would require for your Xair

19/09/23 Match drilled leading edge of RH bottom wing skin to main spar. Removed clecoes and deburred bottom skin. Microstop countersunk main spar. Dimpled lead edge skin and re-clecoed skin to spar and ribs. 2.7h

Read the instructions for Eprop..they are the designers and manufacturers..they say pitch for 5500 WOT in level flight. This is where the prop is most efficient Setting it anywhere else you will obviously compromise the original design critieria. That drop off seems to be pretty large from my experience here with over 50 Eprop propellors fitted you must have a very high AOA on takeoff. most will climb at around 5200 to 5300 rpm when set to 5500 at WOT

Marty I doubt that very much...still have a lot of work still to get done on Mabel and the S-21. The problem is there isnt enough hours in a day now I am retired..its worse than when I had a real job. Between trying to get the house at the farm to a final inspection and the concrete went down for a new tractor shed up there last week also subdividing this block we are on here at Burpengary not to mention trying to get CDI modules and throttle kits made, things here at Burps will come to a grinding halt soon as I have 4 sheds to pull down and a new 9 x 18 mtr workshop shed to go up which will be the new build shed as well. The sheds have to go for the develoment of the block and a new shed put on a totally new alignment. I hope I live long enough to get it all done. 😩

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18/09/23 Inverted wing, leveled and squared structure on supports. Installed draw string for wing lights. Notched stringer around wing truss. Clecoed bottom skin to ribs to check aileron/flaps/tie down attachment penetration clearance. Removed skin and rolled edge break on leading and trailing edges. Trimmed skin around binding penetrations. Reinstalled and clecoed skin to ribs. 2.7h

15/9/23 Match drilled rear spar to upper RH wing skin. Removed skin clecoes and deburred rear spar. Trimmed and deburred aileron and flap wing gap seals. Aligned gap seals with upper wing skin profile and clecoed into position. Match drilled gap seals to spar and removed to debur. Refitted gap seals and riveted remaining rows to wing ribs. Riveted gap seals to rear spar. 4.8h

Oh yes she has many commands I must get done..she is still working so I am the gopher

Well I understand what you mean...been retired as such fr about 3 weeks and I need to go back to work for a rest

Savannah have a similar system on the firewall but use bowden cables one long and one short which of course creates issues with travel over each cable. Some have modified that to use 2 straight cables including myself. The rotating rod wears out over time. Most aircraft firewalls have other crap mounted on them. It was easier and more consistant to mount the whole assembly onto the carbs to tie them together and just use one throttle attachment. A couple of uys with savannah used my carb mount and use their bar on the firewall and use 2 rods with turnbuckles to operate my system. That seems to work fine as well so long as on a ring mount not a bed mount as the bed mount allows too much engine movement

I havent made any for a while as I have been so busy with other projects. I have another 10 almost ready except for the tig welding of the bars.Maybe in a couple of weeks I will have another batch done. I have just retired and am finding I still dont have enough hours in a day at the moent. But hopefully soon I can get a routine going building all this add on gear.

The 3.5mm and 2.5mm plugs are used for handheld hadios

I bought a set of Lightspeed Zulus. and have used them for about 10 years then Lightspeed offered a $450 upgrade to the the next version with the sexy kevlar cables and updated controller. Pacific Avionics did it and returned in less than a week. I have a set of DC,,,may as well be in the bin the Lightspeeds are light years ahead in comfort and performance

Helicopters have a "Nato" plug ...seems to be a hold over from the military copters and never changed

09/09/23 Riveted RH upper wing skin to ribs and stringers from leading edge back to five rows forward of rear spar. 3.7h

06/09/23 Checked adhesion of scupper plate to inner surface of RH upper wing skin. Safety wired aileron and flap bellcrank bolts to rib lightening hole flanges. Match drilled upper leading edge to forward spar and deburred. Microstop countersunk leading edge rivet holes. Dimpled RH upper wing skin leading edge rivet holes. Removed wing skin and roller applied two coats of anti-corrosion coating to ribs, forward and aft spars, stringers and fuel tank support contact surfaces. Reinstalled upper wing skin and levelled wing on supports. Riveted lead edge of upper RH wing skin to forward spar. 5.9h