Documenting the construction of a KR2S

Making slow but steady progress, which is ok. I’m just happy the build is moving along. I’ve been able to install the bottom crossmembers along the length of the fuselage. They still need their gussets though, that’ll be the next step.

I’ve also installed the top crossmembers from Fuse Station (F.S.) J and aft. I figured since my fuselage is upside down, why not use the wonderful support of my table to make things easier.

The Lower Forward Firewall support has been installed, and the mating firewall compression brace has been cut to fit. I’ll also install that in the next couple of steps.

Upper crossmembers installed while the fuselage is still inverted on the workbench

Finally got to cut wood again! Moving and starting a new job has taken most of my time over the last 3 months, so it feels great to finally do something on the KR again.

Tonight I built a simple jig system to square the fuselage sides.

Total Time: 1.0 Hrs

I have a question for those who have built their fuselages with the strait 90 degree sides.

I am about to join my two fuselage sides and I plan on just building them vertical rather than going the banna boat route. But, before I start, I foresee an issue with the tail that needs clarification.

Because the tail post is set at a 7 degree angle, the width of the fuselage at the tailpost will not be uniform like it is on the original. See the picture of what I am describing below.
My thoughts are to build the fuselage strait and then just bend in the bottom longeron after that last fuse station. I’m curious what others have done or would do in this area?

Fueslage Boat, View of tail, looking forward.

Finished the truss structure of the new fuselage sides. Finally making progress!

This will be my stopping point until I get moved into my new house in Savannah (Found a new job at Gulfstream )

Fuselage Sides Complete

One fuselage side down, one to go. This one took about 15 hours.

On a different note, Piper canceled the PiperJet Altaire program. So, I will be out of a job on December 16th. It appears that airframe designers are not needed when there is no airplane to design, lol.

The job loss isn’t too bad, what frustrates me is that I will have to move again. Arg! just when I got the new shop setup and things rolling again. So now my goal is to finish the fuselage trusses before moving.

http://www.tcpalm.com/news/2011/oct/24/205-lose-jobs-after-piper-decides-mothball-altaire/

Finished restoring my new table saw.

New Belt: $10.00

T-9 Rust Remover: $10.00

Boesheild Wax stuff: $10.00

New Blade: $40.00

Look at that glossy table top!!!!!!! just like new...

I finished a good portion of work on the RH truss this afternoon. Got everything glued up to the front spar bay. I found that it  is a little tricky fitting everything on the contoured table top. My solution was to clamp down the affected joints with spruce jig blocks wrapped in duct-tape.

Truss work comming along quickly with my new set of gusset shop aids.

Glue drying...

I added a new table saw to my arsenal of tools. Its a 1960′s craftsman saw that I found on Craigslist for $150. It needs some work but nothing that about $50.00 cant fix.

I also cut a set of gusset shop aids ( A gem that I found on the KRnet archives). These things are great when doing the truss work. Just find the one that works and I know the angle.

Gusset Shop Aids

More truss work on the RH fuselage.

The RH Longerons are now dry and I started to cut the vertical members.

Cutting the vertical members for the RH fuselage side.

Building has commenced again! Today I was able to bend the pre-soaked longerons to shape and start laminating the center spar caps.

Soaking the longerons is definitely the way to go. I filled a PVC pipe containing the spruce longerons with hot tap water and left to soak over night. The next day they bent to contour like spaghetti, too easy.

Soaking Longerons for bending.

Bending longerons to shape

First longeron bent and secured for drying.

Both longerons bent and drying.

Laminating center spar cap

Clamped up and drying.