by b1x4nqb » Tue May 22, 2007 5:40 am
Here is a copy of his first hand information.
Howdy, Y'all.
I've had N1010Z back in my shop for a couple of weeks to install the interior and do a few updates and fix some nits. Along the way I discovered a couple of problems everyone should be aware of.
Corrosion.
Along the leading edges of the wing struts, jury strut attach fittings, and a couple places around the back of the cockpit structure the powder coating is showing rust. It buffs off, with paint compound, fairly easily, but it ain't supposed to rust at all. My kit is less than 1-1/2 years old and has only been flying for a little less than 6 months with about 100 hours of flight time. The powder coating was thin is several out of the way places. I fixed those during construction. What I didn't expect was the stuff to be so thin all over that rust would rear it's ugly head through what appeared to be a good solid coat. It's a good thing I don't have floats and will get it wet every time I fly.
Corrosion part II.
The flying wires on the empenage are apparently galvanized, not stainless. They seem to be OK, just turning grey, but the thimbles are also plated and the plating is all gone. Completely. The thimbles are coated thinly with rust. The thin powder coat is, so far, just an annoyance, but the rusting hardware is a serious safety hazard. I ordered, from Wicks (don't get me started on Aircraft Spruce), stainless cable and thimbles and remade all the flying wire assemblies. (Thank you very much DaveU for your tips on making up the flying wires. My first attempt was less than satisfactory and I was going to replace them even without the rust.) While I was doing it, I also wanted to incorporate some nifty tangs an aquaintence of mine, Ed with a Kolb Ultrastar, has on his airplane. He got them from Leading Edge Airfoils. The are also stainless (the catalog discription doesn't mention the material) and have four staggered attachment holes on one end so that you can adjust the wire tightness on each end of the wire by about 1/8" four times per end. Even with DaveU's tips I needed that to get the horizontal stabilizer perfectly level and straight.
The control wire assemblies are also corroding, but have less exposure to the dirty air around Houston, so are only partially covered with rust. I will have to replace all of them in the next couple of years. I realize that any kit company must make money, and this is the first time I have not been satisfied with what I have recieved from Just Aircraft, BUT.....I recommend all you guys (any gals out there?) buying stainless wire and fittings and doing that part out of your own pocket rather than having to replace it soon after first flight.
I'll take some pictures of the interior and old/new wires when I'm finished and post them here.
Happy building and flying.
Alan
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If I had known I would live this long I would have taken better care of myself.