KOALA REFURBISHMENT PROJECT

Aircraft Projects Underway or Completed

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Bugwar
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KOALA REFURBISHMENT PROJECT

Postby Bugwar » Tue Mar 10, 2009 2:56 pm

I am in the process of refurbishing my Koala (WRH)

So far I have done some small (and bigger) changes/upgrades:
1) New Windscreen
2) New doors
3) Changed 2.62 gear ratio on the 582 to 3.47
5) Have fitted borrowed (Thank you Manie) 72x50 P Prop. Will also test 4 blade composite. :?: Any comments here will be welcome as I must still decide.
6) Busy changing differential foot brakes to hand brake
7) Fitted new radio and antenna
8) Fitted intercom (Air Magic) - Still have a problem with high pitch noise when the radio is powered externally.
9) Redone wiring
10) New fork for the nose wheel
11) New stick - S bent for easier control
12) Fitted fire extinguisher

The big next step is to redo the covering.
Any advice from the experienced builders out there before I start :lol:

Will post some pictures soon.
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Re: KOALA REFURBISHMENT PROJECT

Postby KFA » Tue Mar 10, 2009 7:22 pm

Good luck, post some pic's. The P prop with the 3,47 is the perfect combo for that plane. You can get all the covering materials from us. Give me a call if you need parts or advice. Enjoy the covering part, it's very rewarding.
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Re: KOALA REFURBISHMENT PROJECT

Postby Greenman » Mon Mar 23, 2009 1:26 am

Paul
I have recently bought ZS VTN and I also own ZS WHH( Further down in the Projects column). Both Super koala's need refurbishment. VTN has been robbed of it's instruments and motor. WHH has had a nose-over. The idea is to rob Peter to pay Paul. ( No pun intended) I only found out now that I will have to redo the 532 as well. Was thinking of fitting another motor and using the 532 for an airboat as it is an old motor and is discontinued. I would need to recover VTN though, so I would like to perhaps visit you sometime while you are busy if you don't mind. Do you have any plans for this type of aircraft ? I will have to do some minor repairs as I had some fabric and rib damage on my trip up from Cape Town and will need some plans. I would also like to find out what your cost was for the windscreen etc.
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Greenman
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Chris
Koala is not a bear but a marsupial. http://www.giftlog.com/pictures/koala_fact.htm
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Re: KOALA REFURBISHMENT PROJECT

Postby Bugwar » Mon Mar 23, 2009 9:15 am

Greenman,

Give me a buzz and we can get together (OH ATE 2 FOUR six seven 5511). Maybe we can go and have a look at some other Koala`s

The windscreen was R1000.00 excl plus R245.00 to cut from Rainbow Aircraft. The windscreen that was on the plane was 2mm of unknown material. It is now a 1.5mm polycarb. I had to buy a whole sheet but have enough left to cut for the doors.

No plans. I contacted Fisher and the plans are $350 plus $100 for courier cost. Only reason why I am interested in plans are for flaps. I am considering fitting flaps when I am recovering the plane.

Again some options for covering. Tri3 vs Aero Muti.

Will be nice to bounce ideas of someboddy.

Paul
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ZS WHH2.JPG
ZU-WHH
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Re: KOALA REFURBISHMENT PROJECT

Postby Bugwar » Mon Mar 23, 2009 11:13 am

Some before Pics
Attachments
WRH-MEDIUM.JPG
Before any changes
WRH-MEDIUM.JPG (47.82 KiB) Viewed 5449 times
STICK_M.JPG
Old and new
STICK_M.JPG (35.65 KiB) Viewed 5427 times
windsc_old.JPG
Why I had to replace the windscreen
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Re: KOALA REFURBISHMENT PROJECT

Postby Bugwar » Mon Mar 23, 2009 11:23 am

Some pics of the old equipment.
Toe brakes.
I prefer a hand brake because there is not enough space not to brake when I do not want to.

Wiring after removing the radio.Will have to do the wiring AGAIN when I change the instruments to digital.

Old radio.

Hopefully I can do the doors this weekend

Will post some pics of the new brakes, radio and intercom, fork and prop soon...
Attachments
wiring_old.JPG
Busy with wiring
wiring_old.JPG (84.37 KiB) Viewed 5414 times
toebrakes.JPG
Toe brakes
toebrakes.JPG (28.53 KiB) Viewed 5413 times
INT_RAD_M.JPG
INT_RAD_M.JPG (48.31 KiB) Viewed 5428 times
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Re: KOALA REFURBISHMENT PROJECT

Postby Greenman » Mon Mar 23, 2009 10:34 pm

Paul
Thanx for the photo of WHH. vhpy I wish it looked like that again. :cry: I will be in contact soon. Where are you rebuilding.? I stay in Witbank. I was hoping that we could revive the Koala club again and have some sort of kuier together. I believe that there are two Koala's in Middelburg. It would be nice to know where are all the koala's and to exchange some ideas especially on motors, props and modifications done. If my memory serves me right Gunter Rostek sometime ago said something about covering material that could be obtained from the factory at Standerton. I do have the info somewhere otherwise if Gunter can readvise if he reads this.
Regards
Chris
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Re: KOALA REFURBISHMENT PROJECT

Postby Bugwar » Tue Mar 24, 2009 8:50 am

I am at Springs.

I know of 2 Koala`s at Baragwanath/Syferfontein. Used to be 4 (see pic below). I bought one and another one was involved in an accident. If I look at the pic of WHH it looks like it was also there at some point in time. The 2 on the right has been refurbished after the pic was taken. Looks really GREAT.

Deon Pretorius phoned me with an almost finished Koala he wanted to sell a while ago. Do not have his detail. Who ever bought that one must also be rebuilding.

Some more koala`s at http://www.koala4.netfirms.com/ - do not know how old the info is.
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Re: KOALA REFURBISHMENT PROJECT

Postby grostek » Tue Mar 24, 2009 10:40 am

Greenman wrote:if Gunter can readvise if he reads this.
Regards
Chris
Hi Chris,

Phone Kobus on Oh ate two 872 7610 he may be able to help you with fabric.

Kind regards,

Gunter Rostek
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Re: KOALA REFURBISHMENT PROJECT

Postby Greenman » Tue Mar 24, 2009 8:23 pm

Thanx Gunter I will call him. Are you still in Dubai? You know that you still owe me 'n kuier when you are here for a visit again.

Paul I see that there is 35 Koalas registered in SA with 29 supposedly to be airworty. I only know now of about ten or so my two included. :cry: I did make a post and looks like no one is interested in forming a koala club so I withdrew the message. Looks like we are on our own here. :cry:
Regards
Chris
Last edited by Greenman on Sun Mar 29, 2009 6:20 pm, edited 1 time in total.
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Re: KOALA REFURBISHMENT PROJECT

Postby grostek » Tue Mar 24, 2009 8:28 pm

Greenman wrote:Thanx Gunter I will call him. Are you still in Dubai? You know that you still owe me 'n kuier when you are here for a visit again.
Hi Chris,
I am still in Dubai but will definetly visit when I return. vhpy vhpy

Kind regards,

Gunter Rostek
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Re: KOALA REFURBISHMENT PROJECT

Postby Bugwar » Wed Mar 25, 2009 3:58 pm

Some pics of the replacement parts
Attachments
radio_new.JPG
New Radio and intercom.
radio_new.JPG (73.58 KiB) Viewed 5177 times
windscreen_new.JPG
Ne windscreen
windscreen_new.JPG (48.14 KiB) Viewed 5167 times
brake_new.JPG
Hand Brake
brake_new.JPG (18.13 KiB) Viewed 5172 times
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Re: KOALA REFURBISHMENT PROJECT

Postby Bugwar » Wed Mar 25, 2009 4:01 pm

Old mild steel fork and new stainless steel fork.

Note the tear in the metal on the old fork...
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fork_old.JPG
OLD FORK
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fork_new.JPG
New Fork
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Re: KOALA REFURBISHMENT PROJECT

Postby Bugwar » Wed Mar 25, 2009 4:05 pm

Wiring after the new radio and intercom was installed.
I will have to do this again when putting in the digital instruments.

Now it is the doors and then..............re-covering.
Attachments
wiring_new.JPG
Version 1
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Re: KOALA REFURBISHMENT PROJECT

Postby Massimo » Mon Mar 30, 2009 4:43 pm

Hi Paul nice meeting you the other day. Wow you not playing games here, you moving along fast. So Rainbow managed to cut and bend the windscreen to your required curves etc with no problems? Im asking this because i may also need a new windscreen and i dont want to import it from the states.

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