Talkdocs KR2 project

Talkdocs KR2 project

Stub Tank - Aluminum

With the plane flipped upside down I'm going to add an extra fuel tank to the passenger side wing stub. This tank will have an electric pump that transfers fuel to the main header tank.










I've removed the glass and foam where the old retracts used to go and now have plenty of space for a wing tank. ( the tie-downs were used to hold the main spar in place when I removed the glass and replaced the corner blocks which were split).










I replaced the corner blocks on the front and back of the main spar (passenger side) with epoxy and flox. When the plane was ground fliped the wing on this side took the impact. These two blocks were split vertically but I could find no other structural damage.











I used a metal brake to form the wing tank which I held together with a few sheet metal screws. I did install baffles forming a cross front to back and side to side. I have now started tacking with a TIG welder and will TIG all the seams and screw holes.










I'll be welding these bungs to the tank for the (left to right) Fill Cap, low fuel sensor, pick-up line, air vent, and drain valve ( all from Aircraft Spruce). Once I've cleaned the tank out and pressure tested it I'll anchor it in place with tabs, add a 1/4 piece of foam, and then glass in place. I have access holes on the inside and outside of the stubs if I ever need to check things.







The tank fits snug between the wing Spars. According to my calculations it should hold almost 7.8 gallons which will give me 20 gals total including the standard header tank.












A nice snug fit with just enough space for glassing. Not bad for my first tank.


Next up will be Split Flaps on each stub wing.

Repair List

My first order of business has been to list what is apparent in terms of repairs. One wing stub needs the underside re-glassed (everything structurally appears fine)

I figured while I'm in the stub it would be nice to add a wing tank, and flaps. Since I would be doing the other stub as well I have to decide weather to strip off all the glass and start over, or just cut out enough for the modifications. I'm leaning towards removing all the glass on the stubs and then re-covering with CF.










I have this, basically new, canopy from my other plane which would be nice to use to to replace the cracked one. My problem still lies in having more headroom. I'm still wondering if it's possible to attach the new canopy to the old frame after adding a one or two inch strip of glass and foam to raise the canopy. I would then have to add foam to front of the turtle deck to meet the raised canopy and then taper it to conform with the slope of the turtle deck.

KR2 Project Start

I started this blog to share ideas and post pictures of my latest project

(Build one plane that flies -- hopefully, from two that don't)



Here's what I'm starting with:

Two KR2's to make one that flys (hopefully)

One was never finished or flown (on the left) with a Revmaster 2100D Mag engine with only 2 hours of run time.

One has 280 hours in the air but was ground flipped from prop strike with cowling and canopy damage (on the right with orange stripes); Has a 1984 Hapi VW engine with electronic ignition.

This canopy has a hole in it, but the other one is fine.

First Problem: After sitting in the cockpit I discovered that I'm too tall, or the canopy is too short...I need to come up with a solution before I install the other canopy (it's the same size).

I'd like to preserve the canopy frame if I can, since it is strong, has a good seal, and fits the decks perfectly.

Feel free to Email any suggestions to: talkdoc55@sbcglobal.net

Or click on the comments link ........