Re: KR> Instrument Panel KR2S

2018-02-13 Thread Stef den Boer via KRnet

We used 2024t3 aluminium thickness is 1.6   . If you make an angle at the
lowerside you can use it as a stiffner and you can at the lower flange also
connect your min connections. The whole instrument pannel is that stif, that we
made good connection at the longaron side so we will remove one wooden member (
from longaron to longaron) 

Stef



> Op 13 februari 2018 om 7:18 schreef Luis Claudio via KRnet
> :
> 
> 
>  Thank you guys, great ideas all. I like the idea of the aluminum panel and I
> didn't think about the hassle of the foam being more of a detriment than
> helping for all the now obvious reasons. Aluminum it is... I like the
> grounding and stiffening suggestions and the fact that I already had the
> double knockout (can't remember why I bought it but its been sitting in my
> garage for years).
> I looked at your panels from the links that you provided and I am super
> impressed with the work. Lots of great ideas and believe me I will be visiting
> your links as I build to make sure that I pick up on some of these great
> ideas. I think I can put this to bed and start cutting the aluminum sheet that
> I had purchased and was using as a shelf in the work shop...let the cutting
> begin...
> While I am at it let me share my progress on the building of my KR2:
> Dismantled Revmaster 2100D and in the process of re-assembly with the new
> heads that Joe (from Revmaster) provided. Final stages of elevator assembly
> (complete rebuild) since the PO had cut the elevator with a saw. Converting
> from two control sticks to single stick in the center, Installing T-style
> throttle assembly and mixture control. completed brakes and rudder peddle
> installation. Completed fuel lines, electric fuel pump and selector valve
> installation. Mounted electrical flaps controls with actuator. 
> work left to do: Complete firewall installation, controls to the elevator
> (rudder controls completed). mount tail wheel, fabricate control panel and
> mount instrumentation, electrical controls, complete engine assembly and
> install. 
> Thanks everyone.
> Luis R Claudio, KR2S, Dallas, Texas On ‎Monday‎, ‎February‎ ‎12‎, ‎2018‎
> ‎11‎:‎17‎:‎27‎ ‎PM‎ ‎CST, Global Solutions via KRnet 
> wrote:  
>  
>  Hi Mark.
> 
> How thick was the aluminum you used on the panel?
> 
> I am now thinking of making mine from AL as well.
> 
> Thanks
> 
> Stan
> 
> 
> 
> On 2/12/2018 1:41 PM, Mark Langford via KRnet wrote:
> > Luis Claudio wrote:
> >
> >> I am torturing myself with the decision to build the instrument panel out
> >> of aluminum or do a layup of glass and foam.
> > I think you'll find 1/4" plywood will be very heavy by comparison to
> > aluminum. It all adds up.  N891JF has a seat back made of 1/4" plywood,
> > and I figure I could save 4.5 pounds by redoing it out of foam and glass
> > like N56ML's seatback.  A leftover piece of 3/32"  aircraft plywood with
> > fiberglass on both sides would be much lighter, although could lack the
> > "structure" to even remain flat, unless you fold the glass over at the
> > bottom 2"-2" to give the thing something to keep it straight.  This
> > lower lip also helps to eliminate the cut hazard of the bottom of the
> > panel, as well as provides a very handy shelf on the forward side to
> > mount a bunch of stuff that you don't even know you need yet, like a
> > terminal strip for power and a ground bar for all the ground points to
> > connect to one place.  And there may be relays, timers, etc. added on
> > later.
> >
> > Aluminum is a better choice though, although it is more difficult to
> > modify later, often requiring a redo.  I had my first panel waterjet
> > cut, but on N891JF I started with one that I'd previously bent up, cut
> > it down to shape, and put a layer of carbon fiber on it to make it look
> > nice.  I doubt that it weighs anywhere near 4 poundsprobably more
> > like 2 pounds. Adding a lip at the bottom is more problematic with
> > aluminum, as it requires a bending brake (a sharp corner may simply
> > break off), but a local sheet metal shop can do that in about 5 minutes,
> > most of which is setting up the machine with the appropriate radius
> > dies.  Really, the more radius the better, from a crash protection
> > standpoint.
> >
> > See http://www.n56ml.com/n891jf/panel/ for how I made the N891JF panel
> > with carbon fiber covering.  All holes in the aluminum were drilled or
> > cut with a jig saw, except the round instrument holes, which were cheap
> > hole saws from Home Depot (they cut aluminum just fine).  If you ever
> > want to redo it,  you can make new cutouts and recover with carbon fiber
> > for a new façade. Another simpler option is to just cut big square
> > pieces out and install new ones with a different configuration, like the
> > panel Herbert Furle did on his KR panel, flat panels in aluminum (see
> > www.krnet.org for that site). See
> > http://www.krnet.org/krs/hfurle/instruments.jpg. Steve Anderson did a
> > similar one.  See http://www.k

Re: KR> Instrument Panel KR2S

2018-02-12 Thread Luis Claudio via KRnet
 Thank you guys, great ideas all. I like the idea of the aluminum panel and I 
didn't think about the hassle of the foam being more of a detriment than 
helping for all the now obvious reasons. Aluminum it is... I like the grounding 
and stiffening suggestions and the fact that I already had the double knockout 
(can't remember why I bought it but its been sitting in my garage for years).
I looked at your panels from the links that you provided and I am super 
impressed with the work. Lots of great ideas and believe me I will be visiting 
your links as I build to make sure that I pick up on some of these great ideas. 
I think I can put this to bed and start cutting the aluminum sheet that I had 
purchased and was using as a shelf in the work shop...let the cutting begin...
While I am at it let me share my progress on the building of my KR2: Dismantled 
Revmaster 2100D and in the process of re-assembly with the new heads that Joe 
(from Revmaster) provided. Final stages of elevator assembly (complete rebuild) 
since the PO had cut the elevator with a saw. Converting from two control 
sticks to single stick in the center, Installing T-style throttle assembly and 
mixture control. completed brakes and rudder peddle installation. Completed 
fuel lines, electric fuel pump and selector valve installation. Mounted 
electrical flaps controls with actuator. 
work left to do: Complete firewall installation, controls to the elevator 
(rudder controls completed). mount tail wheel, fabricate control panel and 
mount instrumentation, electrical controls, complete engine assembly and 
install. 
Thanks everyone.
Luis R Claudio, KR2S, Dallas, Texas On ‎Monday‎, ‎February‎ ‎12‎, ‎2018‎ 
‎11‎:‎17‎:‎27‎ ‎PM‎ ‎CST, Global Solutions via KRnet  
wrote:  
 
 Hi Mark.

How thick was the aluminum you used on the panel?

I am now thinking of making mine from AL as well.

Thanks

Stan



On 2/12/2018 1:41 PM, Mark Langford via KRnet wrote:
> Luis Claudio wrote:
>
>> I am torturing myself with the decision to build the instrument panel out of 
>> aluminum or do a layup of glass and foam.
> I think you'll find 1/4" plywood will be very heavy by comparison to
> aluminum. It all adds up.  N891JF has a seat back made of 1/4" plywood,
> and I figure I could save 4.5 pounds by redoing it out of foam and glass
> like N56ML's seatback.  A leftover piece of 3/32"  aircraft plywood with
> fiberglass on both sides would be much lighter, although could lack the
> "structure" to even remain flat, unless you fold the glass over at the
> bottom 2"-2" to give the thing something to keep it straight.  This
> lower lip also helps to eliminate the cut hazard of the bottom of the
> panel, as well as provides a very handy shelf on the forward side to
> mount a bunch of stuff that you don't even know you need yet, like a
> terminal strip for power and a ground bar for all the ground points to
> connect to one place.  And there may be relays, timers, etc. added on
> later.
>
> Aluminum is a better choice though, although it is more difficult to
> modify later, often requiring a redo.  I had my first panel waterjet
> cut, but on N891JF I started with one that I'd previously bent up, cut
> it down to shape, and put a layer of carbon fiber on it to make it look
> nice.  I doubt that it weighs anywhere near 4 poundsprobably more
> like 2 pounds. Adding a lip at the bottom is more problematic with
> aluminum, as it requires a bending brake (a sharp corner may simply
> break off), but a local sheet metal shop can do that in about 5 minutes,
> most of which is setting up the machine with the appropriate radius
> dies.  Really, the more radius the better, from a crash protection
> standpoint.
>
> See http://www.n56ml.com/n891jf/panel/ for how I made the N891JF panel
> with carbon fiber covering.  All holes in the aluminum were drilled or
> cut with a jig saw, except the round instrument holes, which were cheap
> hole saws from Home Depot (they cut aluminum just fine).  If you ever
> want to redo it,  you can make new cutouts and recover with carbon fiber
> for a new façade. Another simpler option is to just cut big square
> pieces out and install new ones with a different configuration, like the
> panel Herbert Furle did on his KR panel, flat panels in aluminum (see
> www.krnet.org for that site). See
> http://www.krnet.org/krs/hfurle/instruments.jpg. Steve Anderson did a
> similar one.  See http://www.krnet.org/krs/sandersen/120604_060.jpg for
> that one.  There's a lot of flexibility in this method, especially if
> you're not going to have access to the back of the panel!
>
> Mark Langford, Harvest, AL
> ML "at" N56ML.com
> www.N56ML.com
>
>
>
> ___
> Search the KRnet Archives at 
> https://www.mail-archive.com/krnet@list.krnet.org/.
> Please see LIST RULES and KRnet info at http://www.krnet.org/info.html.
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Re: KR> Instrument Panel KR2S

2018-02-12 Thread Global Solutions via KRnet

Hi Mark.

How thick was the aluminum you used on the panel?

I am now thinking of making mine from AL as well.

Thanks

Stan



On 2/12/2018 1:41 PM, Mark Langford via KRnet wrote:

Luis Claudio wrote:


I am torturing myself with the decision to build the instrument panel out of 
aluminum or do a layup of glass and foam.

I think you'll find 1/4" plywood will be very heavy by comparison to
aluminum. It all adds up.  N891JF has a seat back made of 1/4" plywood,
and I figure I could save 4.5 pounds by redoing it out of foam and glass
like N56ML's seatback.  A leftover piece of 3/32"  aircraft plywood with
fiberglass on both sides would be much lighter, although could lack the
"structure" to even remain flat, unless you fold the glass over at the
bottom 2"-2" to give the thing something to keep it straight.  This
lower lip also helps to eliminate the cut hazard of the bottom of the
panel, as well as provides a very handy shelf on the forward side to
mount a bunch of stuff that you don't even know you need yet, like a
terminal strip for power and a ground bar for all the ground points to
connect to one place.  And there may be relays, timers, etc. added on
later.

Aluminum is a better choice though, although it is more difficult to
modify later, often requiring a redo.  I had my first panel waterjet
cut, but on N891JF I started with one that I'd previously bent up, cut
it down to shape, and put a layer of carbon fiber on it to make it look
nice.  I doubt that it weighs anywhere near 4 poundsprobably more
like 2 pounds. Adding a lip at the bottom is more problematic with
aluminum, as it requires a bending brake (a sharp corner may simply
break off), but a local sheet metal shop can do that in about 5 minutes,
most of which is setting up the machine with the appropriate radius
dies.  Really, the more radius the better, from a crash protection
standpoint.

See http://www.n56ml.com/n891jf/panel/ for how I made the N891JF panel
with carbon fiber covering.  All holes in the aluminum were drilled or
cut with a jig saw, except the round instrument holes, which were cheap
hole saws from Home Depot (they cut aluminum just fine).  If you ever
want to redo it,  you can make new cutouts and recover with carbon fiber
for a new façade. Another simpler option is to just cut big square
pieces out and install new ones with a different configuration, like the
panel Herbert Furle did on his KR panel, flat panels in aluminum (see
www.krnet.org for that site). See
http://www.krnet.org/krs/hfurle/instruments.jpg. Steve Anderson did a
similar one.  See http://www.krnet.org/krs/sandersen/120604_060.jpg for
that one.  There's a lot of flexibility in this method, especially if
you're not going to have access to the back of the panel!

Mark Langford, Harvest, AL
ML "at" N56ML.com
www.N56ML.com



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Re: KR> Instrument Panel KR2S

2018-02-12 Thread Flesner via KRnet

On 2/12/2018 10:22 AM, Luis Claudio via KRnet wrote:

I am torturing myself with the decision to build the instrument panel out of 
aluminum or do a layup of glass and foam
Luis R Claudio

++

I built my first panel with 1/4" ply and didn't like the way it turned 
out.  The instruments were recessed, difficult to drill holes for 
instruments accurately, and things like that.


I made my second panel ( 
https://www.dropbox.com/s/1vajeb0u48h0aio/IMG_8717.JPG?dl=0 ) using left 
over KR cloth, 12 layers, mostly scrap left from wing, with one good 
layer on the front for appearance.  Carbon fiber might look nice or just 
lay it up on a smooth surface and paint it black.  I used a piece of 1/2 
round trim from the lumber yard to stiffen the bottom back side with two 
1/4" aluminum tubes from the hobby store from the bottom back to the 
firewall box to stiffen.  Just smash the end of the tube flat and bend 
90 degrees to mount.  I made 5 shock mount locations using approximately 
1 1/4" square blocks epoxied to the bottom side of the glare shield.  I 
drilled a hole in the block, then enlarged the hole from each side using 
a cheap tapered rasp type bit.  I installed rubber corks from each side 
and cut them down so only about 3/16" extended beyond the hole, front 
and back.  I removed the corks and drilled a center hole to accept the 
mounting bolt.  The panel mounts against the rubber cork on the front 
and I used a "wood washer" against the cork on the back side.  Presto 
!!! I have a shock mounted instrument panel.


One advantage I found with glass is that before painting I could back 
light the panel with instrument in place and precisely drill the mount 
holes.   12 layers works for me with stiffeners but to do again I might 
go 14 or so layers.  If properly rigged the panel could be hinged on the 
bottom and fold down with the removal of just a few bolts.  I didn't 
take it that far but it would be nice.


Larry Flesner

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Re: KR> Instrument Panel KR2S

2018-02-12 Thread n357cj via KRnet
Sorry Guys, That last one was to go private- Joe Horton

- Original Message -
From: "n357cj" 
To: "KRnet" 



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Re: KR> Instrument Panel KR2S

2018-02-12 Thread n357cj via KRnet
Wow, you must have time on your hands today...writing a short novel. How did 
you make out with the swift firewall?
I ordered a new needle today. They are not made from brass anymore and a few 
more things I learned from their web page. They also don't offer the 38mm carb 
anymore.
J

- Original Message -
From: "KRnet" 
To: "KRnet" 
Cc: "Mark Langford" 
Sent: Monday, February 12, 2018 2:16:17 PM
Subject: Re: KR> Instrument Panel KR2S

I should've included a link to my first N56ML panel, which is at
http://www.n56ml.com/kpanel.html .  I didn't emphasize the utility of
the bottom shelf, but my next panel will probably have a 6" shelf on the
bottom for all that extra stuff.  Really, 062" aluminum is thicker than
it needs to beI'll go for .040" on the next one

Mark Langford, Harvest, AL
ML "at" N56ML.com
www.N56ML.com



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Re: KR> Instrument Panel KR2S

2018-02-12 Thread Mark Langford via KRnet
I should've included a link to my first N56ML panel, which is at
http://www.n56ml.com/kpanel.html .  I didn't emphasize the utility of
the bottom shelf, but my next panel will probably have a 6" shelf on the
bottom for all that extra stuff.  Really, 062" aluminum is thicker than
it needs to beI'll go for .040" on the next one

Mark Langford, Harvest, AL
ML "at" N56ML.com
www.N56ML.com



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Re: KR> Instrument Panel KR2S

2018-02-12 Thread Christopher Pryce via KRnet
I followed Marks panel and made it out of aluminum. I paid some hvac shop
20 bucks to put a two inch bend in the bottom. All of my wiring and ground
bus is installed on the shelf for an easy install. Two bolts on the side
through some wood blocks and two screws on the top hold it in. The two top
screws go into a small 4130 rod from the panel to the firewall which makes
a nice point to run wires to the firewall. You can see how I did it on my
website at mykitlog.com/vr6chris or my Facebook album which is public.

Chris Pryce
Vacaville, CA
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Re: KR> Instrument Panel KR2S

2018-02-12 Thread Mark Langford via KRnet
Luis Claudio wrote:

> I am torturing myself with the decision to build the instrument panel out of 
> aluminum or do a layup of glass and foam.

I think you'll find 1/4" plywood will be very heavy by comparison to
aluminum. It all adds up.  N891JF has a seat back made of 1/4" plywood,
and I figure I could save 4.5 pounds by redoing it out of foam and glass
like N56ML's seatback.  A leftover piece of 3/32"  aircraft plywood with
fiberglass on both sides would be much lighter, although could lack the
"structure" to even remain flat, unless you fold the glass over at the
bottom 2"-2" to give the thing something to keep it straight.  This
lower lip also helps to eliminate the cut hazard of the bottom of the
panel, as well as provides a very handy shelf on the forward side to
mount a bunch of stuff that you don't even know you need yet, like a
terminal strip for power and a ground bar for all the ground points to
connect to one place.  And there may be relays, timers, etc. added on
later.  

Aluminum is a better choice though, although it is more difficult to
modify later, often requiring a redo.  I had my first panel waterjet
cut, but on N891JF I started with one that I'd previously bent up, cut
it down to shape, and put a layer of carbon fiber on it to make it look
nice.  I doubt that it weighs anywhere near 4 poundsprobably more
like 2 pounds. Adding a lip at the bottom is more problematic with
aluminum, as it requires a bending brake (a sharp corner may simply
break off), but a local sheet metal shop can do that in about 5 minutes,
most of which is setting up the machine with the appropriate radius
dies.  Really, the more radius the better, from a crash protection
standpoint. 

See http://www.n56ml.com/n891jf/panel/ for how I made the N891JF panel
with carbon fiber covering.  All holes in the aluminum were drilled or
cut with a jig saw, except the round instrument holes, which were cheap
hole saws from Home Depot (they cut aluminum just fine).  If you ever
want to redo it,  you can make new cutouts and recover with carbon fiber
for a new façade. Another simpler option is to just cut big square
pieces out and install new ones with a different configuration, like the
panel Herbert Furle did on his KR panel, flat panels in aluminum (see
www.krnet.org for that site). See
http://www.krnet.org/krs/hfurle/instruments.jpg. Steve Anderson did a
similar one.  See http://www.krnet.org/krs/sandersen/120604_060.jpg for
that one.  There's a lot of flexibility in this method, especially if
you're not going to have access to the back of the panel!

Mark Langford, Harvest, AL
ML "at" N56ML.com
www.N56ML.com



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Re: KR> Instrument Panel KR2S

2018-02-12 Thread Jeff Scott via KRnet
I built my first panel with aircraft grade plywood and the second with 6061-T6 
Aluminum sheet when I replaced the original a few years ago.  Photos of both 
are at <http://jeffsplanes.com/KR/2013_Panel.html>.  If I had to do another, I 
would use Aluminum again.  Aluminum made for a pretty simple and clean 
installation.  Aircraft Spruce sells a double ended punch that has the two 
primary instrument hole sizes on each end for $160, but somebody in your local 
EAA Chapter should have the punches available to use.  Everything else can be 
done with a die grinder (or Dremel) and a unibit.

Building a panel using foam core is a problem in that the screws will want to 
pull into the panel unless you clean around every screw hole and fill with 
milled fibers or flox.  If I wanted a composite panel (which I have 
considered), I would do a single layup of carbon fiber for the face, then 
laminate the rest with glass, probably 8 - 10 lay ups to make a reasonably 
solid panel.  I need to build a new panel for my SuperCub clone sometime in the 
near future.  Maybe I'll try that method.  Thanks for planting the seed to make 
me think about it. :o)

-Jeff Scott
Cherokee Village, AR

 

Sent: Monday, February 12, 2018 at 9:22 AM
Cc: "Luis Claudio" 

Subject: KR> Instrument Panel KR2S
I am torturing myself with the decision to build the instrument panel out of 
aluminum or do a layup of glass and foam. Can I have your input on what you 
did? I value greatly the inputs and discussions on this forum and its great to 
be able to be knocked back into reality by your comments and suggestion... 
working like the dickens to get this bird flying...
Luis R Claudio, KR2S Dallas, Texas
_

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Re: KR> Instrument Panel KR2S

2018-02-12 Thread Teate, Stephen via KRnet
"aluminum or do a layup of glass and foam"

Luis,

That sounds kind of familiar. Because of my lack of experience and tools for 
working aluminum I decided to make mine out of 1/4" aircraft plywood. I then 
put a layer of glass on both sides with a silk weave on the front. You could 
probably do the same thing with 1/8" plywood but I would probably up the glass 
layers. Using the plywood allowed me to bolt through it where ever I needed to 
without having to scrape away foam and add flox for reinforcement. I just use 
normal wood tools to make the shape I needed. But its biggest advantage is that 
it is very easily modified. Many changes since I started my build. Still the 
original panel.

Stephen Teate
Paradise, Texas

 
 
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Re: KR> Instrument Panel KR2S

2018-02-12 Thread Craig Williams via KRnet
I used 1/4" plywood and put a brown laminate on it. I have a small shock 
mounted Aluminum panel in the middle. The entire panel is removed with 8 
screws. The panel with instruments shown weighs about 8 lbs. Not sure how that 
compares to the other materials.

http://kr2seafury.com/7.html

Craig

> On February 12, 2018 at 11:22 AM Luis Claudio via KRnet 
>  wrote:
>
>
> I am torturing myself with the decision to build the instrument panel out of 
> aluminum or do a layup of glass and foam. Can I have your input on what you 
> did? I value greatly the inputs and discussions on this forum and its great 
> to be able to be knocked back into reality by your comments and suggestion... 
> working like the dickens to get this bird flying...
> Luis R Claudio, KR2S Dallas, Texas
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KR> Instrument Panel KR2S

2018-02-12 Thread Luis Claudio via KRnet
I am torturing myself with the decision to build the instrument panel out of 
aluminum or do a layup of glass and foam. Can I have your input on what you 
did? I value greatly the inputs and discussions on this forum and its great to 
be able to be knocked back into reality by your comments and suggestion... 
working like the dickens to get this bird flying...
Luis R Claudio, KR2S Dallas, Texas
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