Rotax 583 powered KR2

[AndreJ]

Jong..... Ek was maar 'n lekker brood!!!

Ek kon nie uitwerk wat jy met die driehoekke wou maak!!!

DU!!

Baie nice IDEE!!!!


Groete

Andre'

[Henni]

Hi Andre,

Ja, dit spaar my om brackets te maak en sodoende hoef ek ook nie gate in longerons te boor nie. Verbasend hoe lig alles is. Ek is seker dat brackets meer sou weeg. Boonop word die las nou oor 'n groot oppervlakte verplaas, so dit behoort nogal redelik sterk te wees. En dit moet wees, want ek wil die skouer harnasse daaraan heg.

Lekker nagrus vir jou my vriend,

Henni

[Henni]

Hi all,

This is where I stand after today. I can only do the one side for the day as I want to make sure the glue is set completely before I tamper with the other end of the tube. Late this afternoon it was still tacky, so I'll rather leave it till morn.

I had my hands full between the clamps & the clamping blocks - I needed more hands to hold everything before I clamp it, but managed in the end. When done, I'll stand on the tube to verify the strength of the installation. As always, the caption below the pics says it all.

Man, it's so frustrating that such simple tasks take so long. I don't want to build, I want to fly! The only reason I'm building is because for the moment it's the only way towards flying...

Keep well all,

Henni

[Henni]

Hi all,

Amazing how quick this side took compared to yesterday. Was finished by early morning. Seeing that this is a critical bond and also that it is a public holiday, I'll leave it at that for today. I am not only going to support the seats to the rear with this tube, but also downwards. I'm going to attach a bracket behind each seat that will allow it to also hang from the tube. The only other support to the seats will be the strong hinges I'm going to make to the forward spar attaching to the forward section of each seat. On top of this, it will also be the support for the shoulder harnesses. So this tube has it's job cut out for it in a serious way! I had a real shock when one triangle block did not fit after I've applied the glue - had to sand it to fit in a mad rush!

I'm changing my mind as I go along. Because the wings are built completely out of wood, I have no easy way to create a walkway without opening the wings. If I have to open it, I might as well build fuel tanks into the stub wings. I have some idea in mind how to do this neatly and easily. Will explain more when I get there. If I do this, I can use the space below the seats for luggage. It will easily accommodate a rather big suitcase on either side, if the engine can lift it from the ground. Keep in mind that this KR2 will be at least 150-250lbs lighter than most others and still has the full 64hp available that it was designed for.

I'm also doubting whether the added weight of a nosewheel will make a big difference to the landing gear weight in the current configuration...maybe I'll even leave as is. The current landing gear is built and attached like a tank. Will absorb bad landings with ease! In any case, will finally make up my mind when I get around to that section.

Anyway, have a blessed holiday all,

Henni

[Henni]

Hi all,

Today, my task for the day was chosen for me & I had no say in it. Last night, when we travelled back from visiting, the lower ball-joint failed on our vehicle. It happened as we pulled away from a robot. The result was that the wishbone stuck into the ground with the wheel stuck to the top inside of the fender. Had it happened on the open road, she would have been a write-off & we in the hospital.

Two weeks ago we were running late for an open air outreach. I always drive at the speed limit, but then we did 160 km/hr for 70 km. Had it broke then, we would have been dead for sure!

So, finally my seat tube is in. I must still clean off all excess glue, but the pics tell the story for now. Next is to make the seats fit next to each other and then to make the strong front hinges from 6mm thick angled aircraft aluminium and attach these to the main spar and to the seats.

Just see how much space is left below the seats! Ideal for a luggage or fuel compartment. All in all it worked out as planned and I am more than happy with my idea. Hope the others work out equally as well. I'm anxious to start with the canopy widening part as after all this is REALLY what this is all about.

Cheers everyone,

Henni

[Henni]

Hi everyone,

First seat is in permanently. Decided not to hinge them. Instead they clip into position. I can just lift out if it should be required.

As always, the caption below each pic says it all.

Cheers all,

Henni

[AndreJ]

Jy vorder goed Henni!! Ek is baie nuuskierig!!

Hoeveel beenspasie het jy daar, verseker help die feit

dat jy nie 'n "Header Tank" het nie!!!

Myne het slegs die voorste brandstof tenk en ek het bitterlik

min beenspasie!!! maar nou ja...... ek is 1.83m lank of ander

gestel die ou 6 foet!!!!


Lekker bou!!!! sal graag vir jou wil kom kuier en in lewende lywe

wil sien!!!


Blessings vriend!!!!

[Rudix]

Hi Henni!

Glad you did not have an accident with the lower ball-joint failure!

I see your landing gear mounting is the same as VYZ, it is really solid, I can attest to that......

The seat is looking good, at this rate it won't take long to get the mod done, then you can get stuck into the engine and panel installation.

Well done my friend, can see how determined you are!
Rudi

[AndreJ]

Moet by se.....jou drastiese benadering be indruk my!!!!

Meeste ouens sou weg geskram het van so 'n projek!!!!



Maar soos jy se..... Grassroots!!!

Uitstekend!!!!


Andre'

[AndreJ]

Hi Henni

I would recommend that you use your stub wings for the fuel tank instead of the cabin area.

If it would not have been such an big job, I would have removed VYX's header tank and build new

stub wheel tanks for her!!!!

Greetings


Andre'

[Henni]

Hi Rudi and Andre,

Tx for the comments gents. Andre, I am even longer than you at 1.85. My legs fit rather nicely, but I think I will make the mod to move the rudder pedals forward. Really not that difficult to do. For sure, no ways I would have fit with the header tank. Right now my knees are just under the front deck.

However, I'm going to cut most, if not all of it away. My canopy might start sloping from right behind the firewall. I want everything inside the canopy completely open, so there might be nothing but canopy above my legs. Thinking about a small centre console instrument cluster ala Robinson R22.

As for the fuel, have not as yet made up my mind. The Bensen Gyros have their fuel tank built behind and under the seat. I'm considering something similar. But first I'll finish the canopy and then I'll tackle the fuel. Next after that will be the engine.

Rudi, my progress feels rather slow to me. But then I have to scheme and make plans as I go along. Would have loved to be able to also fly in the interimn.

Keep well all my friends,

Henni

[AndreJ]

Hi Henni

The reason for me saying to have your fuel tank not inside the cockpit area is only for

safety issues!!! NO OTHRER REASON!! not that we plan to have fuel leaks within the

cabin area or even worse, to have fuel tank raptures due to crashes!!

Keep it up my friend!!!


Andre'

[Henni]

Hi all,

Wasn't happy with my seat attach brackets. There was no ways that it could withstand 7g's! So today I made a complete new set. Now they'll withstand those g's along with the rest of the aircraft.

Yeah, I know, waisted as whole day. But at least now my seats won't give in from under me during high g turns. All in all I'm glad I re-made these.

As always the caption below the pics says it all.

Keep well all,

Henni

[Henni]

Hallelujah!!!

The other seat is 90% done! I am elated - soon I can tackle something else.

Cheers all,

Henni

[Henni]

Hi all,

Just for fun: Some before & after pics.

The centre flap handle clearly shows how far forward the seating position has been moved. Next is to finish off the 2nd seat, make holes for the control sticks. Then I can cut away the forward turtle deck, cut open the firewall, move the rudder pedals forward and then start with widening the canopy.

When done I'll add the fuel tanks below the seats (hopefully standard off the shelve plastic fuel containers). Then I can start to concentrate on the engine installation. Slowly but surely my idea is coming together.

I just had an excellent weight saving idea to replace the wing walk area: I can mount a foldable aluminium step to the side of the fuselage just forward of the wing. Should be easy to make, have very little drag & be very light. With my seats being so far forward, this would be the ideal position to step onto to get inside the cockpit.

This is my modest attempt at trying to achieve the following:

1. a KR2 that weighs less or same than the first one built by Kend Rand himself.
2. a KR2 that is roomier inside than any other built to date that I know of.
3. a KR2 that will stall below 40mph.
4. a KR2 that will be a full two seater & always be flown as such.
5. a KR2 that will have no cg issues.
6. a KR2 that will still fly at 120 to 130mph despite all of the above.
7. a KR2 that will easily operate from the same grass strips as most ultralights do.

To achieve the above from scratch might not be all that difficult. However, starting off with a pre-built stretched KR2 built mostly to plans requires just a tad more head scratching. Maybe this might be of value to some of you. Most opt for heavy with more power. I’m opting for the very extreme opposite

Henni's goals with a 480 pound aircraft? Maybe the drug reference was correct.

A 480 pound aircraft with a minimum 490 pound payload (two 200 pound people and 15 gallon of fuel) that stalls at less than 40 mph and cruises at 120 to 130 mph? Seems like a real engineering challenge to me. If Henni can pull this off he's a better engineer than those that have come before him...

There are some laws of physics you will have to sneak around or crawl over. More passenger room means more airplane which means more weight. Small field operation means more power or more wing which means more weight. Stall below 40 mph = more wing = more weight. Two up with no CG problems on such a small aircraft will be tricky. High cruise speed with more wing and low horsepower (to accomplish the above) will be a challenge.

Just for the record: The MCR4 lifts four fully grown adults from an ordinary sized runway using only 100hp. And the cruise speed is not that shabby either. Talk about an engineering feat!!! And of thinking outside of the box and far above the norm... Some strive on: "It cannot be achieved!"

For whatever it's worth, I've gained close to 100lbs just by my engine choice alone! The rest of the airframe is built very light. The canopy windows will be made from lightweight lexan with a centre piece down the middle front to help with the wind pressure. I'll start weighing everything soon with the engine on the seats and then post the figures over here. It should give a rough indication of where I'm headed.

Herewith some interesting info:
Engine HP Weight(lbs) Comments
Cuynia 460F-35 35 66
Rotax 503 ` 50 85
Great Plains VW 1600CC 55 160
Hirth F23-EP2 60 70
Jabira 60 119
PZL 2A-120 60 129
Rotax 582 63 95 Includes 20 lbs radiator, etc.
Continental A-65 65 173
Limbach L 1800 66 154
Limbach L 1700 66 161
Rotax 618 74 136 Includes 20 lbs radiator, etc.
Great Plains VW 2180CC 75 165
Franklin 225 75 230
Limbach L 2000 80 155
Rotax 912 80 165 Includes 20 lbs radiator, et
Continental C-85 85 207
Limbach L 2400 94 181
Continental C-90 95 207
Great Plains VW 2600CC 96 190
Stratus Subaru EA-81 100 205
Continental O-200 100 220
CAM-100 100 225 Includes 20 lbs radiator, etc
Formula Power C100 104 210
Rotax 914 115 155
Lycoming O-235 115 215
PZL 4A-235 116 226
Hirth F30-FP24 120 101
Continental IO-240 125 250
Continental O-300 145 277
Lycoming O-320-A 150 243
Lycoming O-320-D 160 253
Franklin 335 165 320
Formula Power F170 174 270
Lycoming O-360-A 180 265
Lycoming IO-360-A 200 293
NW Aero Ford V6 200 415
PZL 6A-350 205 330
Continental IO-360 210 350
NW Aero Chevy V6 230 420
Lycoming O-540-B 235 366
Lyoming O-540-E 260 368
Formula Power F260 274 390
Lycoming IO-540-K 300 443
Continental IO-520 300 459
Lycoming IO-720 400 568
Certified Engine
O-200-A 100 190
O-200-B 100 190
O-300-A 145 268
O-300-E 145 268
IO-346 165 297
IO-360-B 210 327
TSIO-360- 210 334
O-470-J 225 381
O-470-R 230 438
O-470-13 235 414
O-470-15 190 405
IO-470-C 250 432
IO-470-D 260 426
IO-470-E 260 461
IO-470-F 260 464
IO-470-V 260 472
TSIO-470-D 260 511
IO-520-L 285 466
O-200-A 100 190
O-200-B 100 220
O-300-A 145 268
O-300-E 145 268
IO-346 165 297
IO-360-B 210 327
TSIO-360-A 210 334
O-470-J 225 381
O-470-R 230 438
O-470-13 225 414
O-470-15 190 405
IO-470-C 250 432
IO-470-D 260 426
IO-470-E 260 461
IO-470-F 260 464
IO-470-V 260 472
TSIO-470-D 260 511
IO-520-L 285 466
O-235-C1B 115 240

I also emphasize again that VG's have proven to reduce the stall speed by 8 to 10mph. Yes, there is a definite penalty to the cruising speed, I know! If I gain only 5mph, I can make her stall below 40mph. I do not think that my goals are unachievable! I say again, if I'm over optimistic, it won't be by too wide a margin.

As for the cruise speed: Well, if I make only 100 to 110mph instead of 120 to 130mph, no big deal. It will still be way faster than most other microlights using the same engine. Most others cruise around 80mph or so.

Ken Rand managed 150mph on 60hp. Something to keep in mind & consider. As far as I know his could carry two occupants. Rudi's managed a recorded & documented 180mph plus over a 500km course on a modified VW engine. Troy manages 230mph straight and level on 100hp. This builder did not specifically build or design for speed, yet see what he achieved on a similar engine that I'm using. Most of the above are all there on the KRNet. After all, the tiny & very light little Rotax can also make 64 horses at sea level, same as many VWs!

In any case, this is one of my dreams for now. At least it occupies my attention and gives me something to strive for. Nice to have some extra ordinary challenges to try & overcome. Keeps my brain young and active. Nothing repetitious or boring about any of it...

Keep well all,

Henni