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WhiskeyVictor36(at)AOL.co
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 Posted: Fri Nov 03, 2006 10:41 am Post subject: Ten Rib FireStar |
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To All Kolbers
You might recall that last spring (03/30/06), my buddy, Alan Mancus, had his original model Kolb FireStar upset by a sneaky wind, while visiting Massey Airfield in Maryland. The damage was substantial and at first Alan thought he would just quit flying. But, apparently, once you taste the joy of flying in a Kolb, you just can't stop. And so it is with Alan. I volunteered to help him rebuild it and I'm happy to say it is finally flying again.
It was a lot of work and here is a list of what we did:
One aileron rebuilt. One aileron built new. Rudder rebuilt. One elevator rebuilt. Vertical stabilator rebuilt. New aluminum angle muffler mounts. New Fuselage boom tube/and H piece. Both wings got new leading and trailing spars and a couple of ribs repaired, plus the addition of 5 more ribs making it a 10 rib wing. Polyfiber process covering and painting on all of those components.
I had previously built my own Kolb from a kit, so had that experience. But I must say, in a way, rebuilding is more difficult. Three items of special note:
1. Drilling out the old rivets. We had the most success by just drilling off the head, then using a snap (automatic) punch to knock out the mandrel. On some occasions the rivet wanted to spin and enlarge the hole. On those we resorted to many different ways to hold it from spinning. The best was to hold it with pliers if you can reach it from the back side. If that wasn't possible, then forcing a knife blade under one edge of the head usually stopped the spinning. Still, we had a few holes go oversize.
2. Match drilling hidden holes. On sheet metal I've used a special rivet hole finder tool made for that purpose, but on tubing it doesn't work. So, a lot of time was consumed in measuring once, twice and three times to get the holes in the right place. Someone on the list had mentioned cutting out the existing hole layout from the old tube and use it as a pattern for the holes in the new tube. And this worked well, especially at the tail end of the boom tube for the rudder/elevator weldment. Might have worked for the H piece at the fuselage attach point too, but the original H was so really bent and twisted, he went with new on that.
3.As for the wings, Alan wanted to upgrade from the 5, to the 7 rib style. But after thinking things through, we opted to go for a 10 rib design. The reason was twofold. First, if we simply redistributed the existing ribs, it would leave empty holes in the main spar. Also, I had heard horror stories about trying to slide the previously riveted ribs off the main spar, causing scratches. Especially since the rib flanges on Alan's Kolb seemed to fit very tight. So, instead, we simply removed the 5 false ribs, top and bottom, then installed 5 new full ribs in their place. In most cases we were able to utilize the same holes in the main spar as the false ribs did. We cut the rib flanges, that go onto the main spar, in half, then clam shelled them over the spar and used some reinforcing plates to hold them together. We had built our own ribs and did not rivet the top stringer until it was mounted in place on the spar. This reminds me of another problem that cropped up. Alan had purchased one factory built rib and made up a jig, then built up the other 9 ribs to match. Unfortunately, the old ribs on his wing were shorter, which we didn't realize until after mounting the new ones onto the spar, so off they came for reworking.
I told Alan that we had better get some tie downs. I don't want to go through that again.
Bill Varnes
Original Kolb FireStar
Audubon NJ
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John Hauck
Joined: 09 Jan 2006
Posts: 4639
Location: Titus, Alabama (hauck's holler)
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| Posted: Fri Nov 03, 2006 11:13 am Post subject: Ten Rib FireStar |
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| To All Kolbers
The damage was substantial and at first Alan thought he
| would just quit flying. But, apparently, once you taste the joy of
flying
| in a Kolb, you just can't stop. |
| Bill Varnes
Hi Bill:
Thanks for a very complete report.
Quite an undertaking.
I like the idea you all used for increasing number of wing ribs.
It is easy to slack off on appropriate tie downs until you see and
experience what the wind can do to your own aircraft. Fortunately, or
unfortunately, John W, Gary Haley, Jim Hefner, and I, experienced a
freak wind at Moab, Utah, a couple years ago. We were extremely lucky
that time. Could have been a total disaster for all of us.
john h
mkIII
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_________________
John Hauck
MKIII/912ULS
hauck's holler
Titus, Alabama |
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tkrolfe(at)usadatanet.net
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| Posted: Fri Nov 03, 2006 3:02 pm Post subject: Ten Rib FireStar |
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WhiskeyVictor36(at)aol.com (WhiskeyVictor36(at)aol.com) wrote: | Quote: | To All Kolbers
You might recall that last spring (03/30/06), my buddy, Alan Mancus, had his original model Kolb FireStar upset by a sneaky wind, while visiting Massey Airfield in Maryland. The damage was substantial and at first Alan thought he would just quit flying. But, apparently, once you taste the joy of flying in a Kolb, you just can't stop. And so it is with Alan. I volunteered to help him rebuild it and I'm happy to say it is finally flying again.
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Bill,
I'm glad you were able to convince Alan to rebuild. Sounds like you two did a super job and I look forward to seeing his plane again. I wasn't aware before this that it happened at Massey Airfield, Willie my friend who you met at Homer's along with Earl Zimmerman who you also met there, led me down there to their fly-in this year.
Weather prevented our trip down your way earlier this year. Missed getting to see you again.
Terry - FireFly #95
DO NOT ARCHIVE
[quote][b]
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WhiskeyVictor36(at)aol.co
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| Posted: Fri Nov 03, 2006 6:58 pm Post subject: Ten Rib FireStar |
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In a message dated 11/3/2006 6:02:51 P.M. Eastern Standard Time, tkrolfe(at)usadatanet.net writes:
| Quote: | Willie my friend who you met at Homer's along with Earl Zimmerman who you also met there, led me down there to their fly-in this year.
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Hi Terry,
Good to hear from you. Is Willie the Candy Man? If so, then I know who he is. And I know who Earl is.
Massey Airfield has an 'Open Hangar Day' scheduled for Sunday, December 3, 2006. From 1:00 to 5:00 PM.
If the weather is good, maybe I'll go. But I cannot stand the cold anymore. Too soon oldt, too late smart.
Bill Varnes
Original Kolb FireStar
Audubon NJ
Do Not Archive
[quote][b]
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tkrolfe(at)usadatanet.net
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| Posted: Sat Nov 04, 2006 10:13 am Post subject: Ten Rib FireStar |
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WhiskeyVictor36(at)aol.com (WhiskeyVictor36(at)aol.com) wrote: | Quote: | In a message dated 11/3/2006 6:02:51 P.M. Eastern Standard Time, tkrolfe(at)usadatanet.net (tkrolfe(at)usadatanet.net) writes:
| Quote: | Willie my friend who you met at Homer's along with Earl Zimmerman who you also met there, led me down there to their fly-in this year.
|
Hi Terry,
Good to hear from you. Is Willie the Candy Man? If so, then I know who he is. And I know who Earl is.
Massey Airfield has an 'Open Hangar Day' scheduled for Sunday, December 3, 2006. From 1:00 to 5:00 PM.
If the weather is good, maybe I'll go. But I cannot stand the cold anymore. Too soon oldt, too late smart.
Bill Varnes
Original Kolb FireStar
Audubon NJ
Do Not Archive
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Roger on that, Willie is the "Candy Man". Where did you learn the Pennsylvania Dutch?
Terry - FireFly #95
[quote][b]
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WhiskeyVictor36(at)aol.co
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| Posted: Sat Nov 04, 2006 6:11 pm Post subject: Ten Rib FireStar |
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In a message dated 11/4/2006 1:14:13 P.M. Eastern Standard Time, tkrolfe(at)usadatanet.net writes:
| Quote: | Where did you learn the Pennsylvania Dutch?
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Hi Terry,
Well, I used to live in Cochranville, PA. Born and raised on a farm. Had relatives living in the heart of Amish country around the Bartville/Nine Points area. I moved to NJ when the company I worked for moved there. Been here 42 years now. Wow! Doesn't seem that long. Now retired and I guess I'll stay put. Have a 6 year old grandson close by.
Bill Varnes
Original Kolb FireStar
Audubon NJ
Do Not Archive
[quote][b]
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