Cracked Fuselage! - Annual Inspection Time

[@BorkToThe3rd]

Tip/trick from auto racing. Always paint tube structures with cheap paint. When the structure starts to crack the paint will crack and chip. A "high quality" paint has more flex and chip resistance and can help hide small cracks.

[@5xls]

Exactly. That’s why you should never powder coat an aircraft motor mount. Too thick, too flexible, hides cracks.

[@clarkstonguy1065]

@@5xls Huh - Learned something today, thanks!

[@tomcoryell]

Plus, it’s cheap to re coat if you scuff it up.

[@derqatarzan4207]

This 100%! Use the exact same trick on my cage as my daddy taught me! Great advice sir!

[@deeremeyer1749]

@@5xls You know nothing about powder coating.

[@MTNDOG39]

Kyle seems awesome, his quiet confidence and calmness are inspiring. Definitely the kind of person I would want working on my plane.

[@Hunter-ko7lk]

This can’t be real You can’t be real… This must be satire

[@marsdirt]

Ah! The old Square Space in cowling inlet trick. That'll shorten the takeoff role by at least 50ft. :)

[@danielhostetler9493]

One of the best sponsor transitions I’ve seen yet!!

[@glennllewellyn7369]

I use motocross stickers. They’re worth about 5hp each!

[@A7x_Forever]

That trick is old. The new kidz paint their tyres red (+150 hp) and have some sick JDM decals on the body (+200 hp). I've seen these planes race Teslas on the runway, no joke!

[@tropicthndr]

Hey take a look at this, this is where everyone gets the signal to end video.

[@ooklamoc4411]

Stickers make everything faster!

[@HEATRACER24]

Kyle seems like a really straight up guy. Happy Flying!

[@chupacabra1765]

Cracks in the tailwheel mounting area are fairly common, especially if a larger assembly is installed. Just by the nature of its narrow design, it's structural strength is mostly on the Y axis. The longer moment arms of bigger "bush style " tail gear put tremendous torque and twisting forces into the narrow structure on the X axis. It difficult to reinforce in that direction.

[@larz46north18]

I wonder if spring /shock adjustment would help.? '5:25 ' salute . good catch.

[@rexcowan9209]

Landing in the middle of no where wouldn't help. The big tires are good shock absorbers for the front but the small back wheel would get beaten up.

[@chrisbjohannsen]

Kyle is awesome. I took a cracked fuel tank out of a '59 Champ to him and he cleaned it up, pressure tested, welded and retested. Nobody else would even look at it because of its age.

[@bigbudmcl1869]

Kyle is such an awesome guy. He makes aviation and pretty much everything he does ... better. I flew into Albany, OR one day and my Cardinal broke down. After a short while the owner of the FBO said he new a young mechanic that might be able to come by and help. It was a Sunday, Kyle and his girlfriend were out shopping, they dropped everything and came right over. He had my plane running agin in about an hour then gave me details on what to do if I had a problem after take-off because I was to fly straight to his home airport. The most amazing part ... he never accepted any money. This man is just a great person and an amazing ambassador for aviation and everything he gets involved in.

[@Aran2323]

Great to see that sponsors haven't been scared away from your channel! I think that speaks to how self-evident it is that you've done nothing wrong, and that the aviation community supports you

[@sonora108]

I spent 21 years active duty Navy working on different Navy aircraft and another 15 years as a civilian Tech Rep for Navy and the US Marines. Those tiny cracks can grow into a disaster if not found also noticed Kyle mentioned corrosion, that's another thing that can go unseen until it's causing big trouble. Inspections both scheduled and unscheduled can seem like a pain but after they are complete really give you confidence in your aircraft. Keep flying Trent, love your videos.

[@Snailmailtrucker]

Thanks for serving OUR Country Brother/Sister !

[@exrobowidow1617]

"Just going through it and saying it's great..." Reminds me of when a plumber re-piped my house. When he was all done, he took me out front and showed me all the copper manifold he had built to join the house main, the irrigation main, shutoff valves, etc. I saw a bunch of neat, shiny copper pipes and said, "That's nice." After all, that's what I was paying him to do. He was proud of his work and wanted to show me everything. Then the city inspector showed up. That guy stood back, admired the glorious manifold thingy on the front of the house, and was ready to sign off right then and there. But the plumber, proud of his work, insisted on having the inspector traipse through my house and look at everything before signing off. A few years later, I had this same plumber replace my kitchen faucet, which was a more complicated job than it should have been. After he finished and left, I noticed the faucet was leaking at the joints! How could an experienced plumber of so many years fail at this?? My point is, a good inspector knows good work when he sees it, but even the masters of their craft can make mistakes. So yes, the inspector needs to actually inspect the whole thing.

[@adamriehl8166]

On the borescope: if you want a borescope for airplane engine look at a Vividia VA400. You can find them for $150. They are rigid and 180° reversible. That is important in Lycomings and Continentals for inspecting valves.

[@davidrobins4025]

Fascinating - thanks for including us in this process. I'm glad you discovered the minor crack. The fix looked great.

[@guyguthrie3236]

I especially enjoyed this video as well as the other videos of engine swap and other upgrades and mods as I am an A&P in addition to pilot. Thanks for all the great videos, I learn something new every video you post.

[@Breeto]

OMG that Squarespace transition! That was soooo good. I literally laughed out loud. 🤣

[@peteschutte8937]

Trent, you are right. It is a CONDITION inspection. Kyle said CONDITIONAL inspection. I see mechanic signoffs with conditional inspection written in the logbooks. That is not what the FAA regs state. It must be a conditon inspection. Thanks for keeping everyone on the right track! And, best of luck with the FAA!!

[@av8ir68]

Way cool!!!!!! You have the best guy for the job on your inspection!!! I live here in Creswell and Kyle flys over my house all the time in his N3N and Navion!!! Thanks for posting this Trent!!!

[@montyantcliff1299]

Always feels good to know that she’s good go. Fantastic inspection guys! ✈️👍

[@Kulis747]

We needed an endoscope when I was in the air force in the mid 80s to inspect some obscure parts on the B-1B. As a young maintenance guy, I mentioned that buying two $40,000 dollar "borescopes" ($100,000 in today's dollars) seemed excessive. My mx commander explained, that was about the cost of one day of the airplane not be ing utilized. So I ran the conversion backwards of a what $60 endoscope In today's dollars would have cost in 1985..... $24 is the 1985 cost....compared to $40,000. My how technology has advanced and become affordable.

[@stanceworks]

Hopefully this comment doesn't get lost, but I want to make sure someone points out: Aluminum anneals when you weld it, and it will be weaker. I'm not sure what the answer here is, and chances are it will be okay, but that aluminum mount is certainly softer and less strong than it was prior, by a considerable amount. Because its a part of the plane that will see a lot of shock loads, if that segment of the plane is removable, I'd remove it and send it out to have it re-hardened. Hopefully I'm worrying over nothing, but in the automotive/motorsports world, this would be a very big fear of mine. Just wanted to say something in case you find it helpful. Awesome video as always.

[@UncleKennysPlace]

I would assume that the mount is steel, not aluminum, as the fuselage is steel.

[@KD5XB]

@@UncleKennysPlace That plus the fact that aluminum doesn't rust as shown in the video. Aluminum might corrode, but it sure doesn't rust.

[@Project2Aero]

More than likely that tailwheel mount is 4130 chromoly. Good on you man for lookin out for the man though! Much respect for what you do sir. Now go finish the Ferrari so we can see it on the road!

[@NoPressurex]

That's not aluminum, but you are correct and this comment might help others regardless of application. Love the builds as well, one of the reasons I got into e36s years ago.

[@stanceworks]

If it's steel, then ignore me entirely. I assumed the whole plane was aluminum! My mistake. Here's me, knowing nothing about planes at all.

[@SmittySmithsonite]

What a great segue into the Squarespace ad! Well done! I LOL'ed! I was expecting a big crack! 😂 Nice find by Kyle there! That's a tough spot to see, looks like. Even in the automotive world, knowing about pattern failures of certain models is a HUGE help at inspection time. The longer a model has been in service, the better. And that goes for ANYTHING with wings or wheels. Great vid man! 👍😎

[@PDZ1122]

I don't weld anywhere near fabric without a ton of wet towels covering everything, buckets of water and extinguisher standing by.

[@terrancestodolka4829]

Wow, the little it is all about the details and the great work done by Kyle the mechanic making sure that it is airworthy.

[@chrisevil7012]

Nice selection of welding process. reliable all position tig for a smaller than normal heat affected zone. perfect for not setting other components on fire. Great video Trent, thanks for posting it.

[@stephenp1717]

On big vehicles, we would wipe the area clean. If you wipe away the rust, then spray with wd40 in the suspected crack and you move it like the mechanic did or bang on it with a large dead blow hammer. You will see the rust run out and it’s definitely cracked. Sometimes we don’t have the leverage to move the suspected piece so the hammer must move and create a vibration to help identify. I don’t know if it would work here. I worked on airplanes for awhile but don’t have an a and p.

[@DIGGER19860]

industrial finishes by the airport will color match and automotive paint and put it in a spray paint can for like 35$. by one can and use it for years for little touchups.

[@tedc6694]

What a good attitude to have going into an annual! So much better than, "I sure hope they don't find anything" like many owners

[@burtvincent1278]

Following a clean annual on an old cub I shook the horizontal stabilizer like you are taught to do on the wing to check the integrity. The leading edge tube snapped. It had fatigue cracked most of the way around and my preflight variation caught it. I decided old tube and fabric aircraft weren't for me.

[@barek257]

Yep, the good, old SquareSpace intake manifold stickers, providing additional 500 ft/min of climb rate and +10 mana 😉 Keep on the great work! Cheers 👍

[@dmc2554]

@ 5:41 CLEARLY there is a vertical bolt interfering with the head of a screw above it......you praise the guy but what kind of mechanic sees that and says nothing?? All bolts should have a maximum of 1.5 threads showing and that one has five, on top of the fact that you have a very thick washer under it....THAT BOLT NEEDS TO BE SHORTER! Its the most likely cause of your crack....honestly I saw that a mile away....In Canada we're called Aircraft Maintenance Engineers. TELL that guy what I showed you, see what he says because this is a SAFETY issue, not an issue of my ego...................with all respect, Fly Safe!

[@stoldrag85]

Educational and with one of the very best IA's I know. Kyle is the real deal. Thanks Trent

[@markhottman2652]

When you see a crack in a wood spar, go find the Baking Soda. Dash baking soda in the crack, use “c-glue” , “Super Glue” and let it harden like CONCRETE! Just my Engineering 2 cents.

[@lookronjon]

No. That’s not right. You fix it not patch it.

[@2002ktm453]

LOL

[@SoloRenegade]

the aviation community can Definitely benefit from more content like this. The FAA needs to be better about allowing and Encouraging maintenance of privately owned noncommercial use aircraft. We'd all be better off if they did. More aircraft would get much needed maintenance and upgrades at lower cost.

[@hotrodray6802]

CP/AP 50+ yrs here There are so many incompetent and unethical aircraft mechanics out there you would not believe it. Really. And I have seen the FAA ignore and blow off so much stuff in more than one FISDO. Buy them a steak and a beer and they look the other way. Really.

[@SoloRenegade]

@@hotrodray6802 but if the FAA was more permissive of people doing their own maintenance and buying more affordable parts that are 100% as good as "certified" (they could even publish lists of equivalent parts to help people know what is acceptable), then less under the table work would need to be done, and people wouldn't be afraid to ask for help and learn how to do it properly. but to ask for help now is to admit they are breaking the rules. Aviation would be more affordable, more accessible, and we'd be safer overall and not stuff scrounging for old/used parts that cost an arm and a leg. Just look at trying to swap old position lights with LEDs. it's as easy as changing lightbulbs in your car, maybe easier than some cars. But the price of those "certified" LEDs is legalized extortion. And claiming it's somehow unsafe for anyone but an A&P mechanic to swap them is 1000% bullshit.

[@billbinnings4347]

I've owned several airplanes and was a Commercial Pilot/CFI-I as well. Flying on a good A&P/IA's work is a HUGE part of Aviation safety for sure. Reputation and testimonials from other Pilots you trust will tell you who to deal with and who to AVOID!!! I have heard the stories......

[@mannythehunter]

Yep own the same little camera... it's handy when working on your house too!

[@TrentonPalmer]

That was half of why I bought it, figured it’s just good to have around

[@btmike01]

smooth transition into the squarespace ad lol. priceless.

[@kinghy]

Trent, do you ever crack test the through tube between the struts'... also double check the Junker aileron hangers

[@mustanggun]

Tig welding is an art.

[@musoseven8218]

Really interesting video, I like learning about this sort of stuff 👍✌️😊 My dad had an early Kitfox, no end of issues with the fuel tanks etc - long story, but some pioneering work had to be done on those early machines to get 'em safe and in the air.

[@chrisgibbs6176]

Hey Trent, how about a video showing the capabilities of the crosswind capabilities of the Kitfox? I would love to see you showing us in your opinion the max crosswind that you would be comfortable landing in. That’s my only concern before buying one. Love the videos, keep my hope’s up, CHEERS

[@jeffreytlynch]

The air races are coming up. Any videos planned for that week? I saw the NOTAM. Do they ground all other traffic or can you still fly during races? Looks like your property is inside the air space.

[@Mike-01234]

Those borescopes off amazon are okay for areas where don't have to push much of it in, but if you want to look down a pipe I wanted to look inside a sewer line found it was way to flexible to push it into anything it would just bunch up. If were to get one again I would buy the shortest one.

[@timthomson7178]

Wrap a spiral of safty wire down the lead. Stiffens up but flexable, can be preformed to follow curves.

[@TobyLong]

I like that cowl so much more than the original. Good looking plane my man

[@TECAdventures]

Tennis elbow from holding the camera? I had a severe case from working on my aircraft engine of all things, tried literally everything to fix it and ended up having 5 PRP blood injections, super painful but it fixed it up and it’s been near 10 years of pain free elbow.

[@andrewellis4991]

Damn not only is Nikk up and walking and flying and stuff, but Hulk-Smash style lifting up airplanes as well! sweet

[@2airwolv]

Watched this again as I am finally am working on finishing my pilots license. I do not own a cell phone so can not do the telegram. But do live in Spanish Springs area here in Reno, Nevada. One of these days I will see you flying. As every time I hear an aircraft fly over I look up.

[@jameshicks4663]

And you learned more about the plane...and things to watch out for. Keep it up ..we love this stuff

[@douglasknutsen]

Trent, What a great couple of guys to know !

[@heregoesmike]

That’s a hell of a good mechanic you’ve got there. That Rustoleum 2x stuff is fantastic!

[@JMOUC265]

👍👍 to Kyle. Would that all A&P/IAs be as knowledgeable and yet as humble.

[@keithsears9333]

My dad worked for Tim Talon for awhile up on Jasper ridge where Ragwood refactory started. Glad someone is caring on the tourch. Are you doing Interstate Cadets still?

[@heartsky]

Bought one of those cameras and have now thoroughly checked my ears and nose, all good.

[@nbrowser]

I see Nikk I like the video...glad to see him recovering so well!

[@pasp6868]

A common weak area for Kitfoxes, it has been known for decades not sure why it has not been redesigned. I built a simple bolt on solution for a friends KF 3 and we did a weld on solution for another friends KF 4 like the original Avid design.

[@CharlieVictor102]

Kyle is a keeper. I have the Repairman’s Certificate for my 87% plus plans built Zenith CH701. It takes me at least 32 hours to do the Conditional Inspection. I see a lot of places signing these off after a couple of hours of inspection and I think WTF?

[@michaelollom9964]

Saw Nick there. Any updates on his build?

[@jameschristian643]

Looking for an update on f.a.a. we are with you . Trent , God is with you !

[@flutetubamorg]

I think that bracket could use a gusset. Just a little triangle would really firm it up.

[@asoldierofrome]

Love your videos! Plus connection to Mike Patey and Heavy D Sparks! Keep aloft!

[@al-lal]

It's good to see you could weld that tail wheel mount without stripping everything off the tail! Is that an air Nautique in the back? Do you have any wakeboarding video? Cheers from the land under the southern cross

[@grantgarlington7ACDriver]

Exact same issue on my Champ last annual… Thank goodness you caught that… That could’ve been a real pain in the drain

[@slyrss3]

I bought that borescope too! Nice tip! Thanx!

[@Jon_Flys_RC]

Nice to see an old trailing arm RMK in the background!

[@ashton403]

Smooth squarespace plug.

[@steveshoemaker6347]

Glad you guy's found the crack....Fly safe young man Trent....Shoe🇺🇸

[@stephenfabiszak6039]

The big difference between a Condition Inspection and an Annual Inspection is the person who holds the Repairman Rating, usually the airplane builder, issued by the FSDO and FAA, can perform and sign off the Condition Inspection. That's one of the cost saving benefits of Experimental aviation. The Repairman writes in the airframe and engine logbooks that he "finds this airplane/engine in a condition for safe operation." Only an IA can declare the airplane to be "airworthy", in an experimental or certificated airplane's logbook.

[@johnreed5253]

Hey Stephen!...you beat me to it, I was just getting ready to point out all of the benefits of building your own and obtaining the Repairmans Certificate keeping in mind that Trent bought the Kitfox already made. I most definitely could be wrong but I think there are avenues to obtaining the Certificate through training specific to each type.

[@tristanismyboy]

Only the original builder can do this without an A&P rating, experimental does not require an IA at all only certified aircraft.

[@3dogman311]

Love Kyle's attention to detail. Thanks for the referral..!

[@paulg.yarger8797]

Great Job!!! Pretty Sure you got a Great inspection!!! Yee Haa too the Maintainers!!!

[@skydive1424]

No shit that cracks, the way it’s designed. Side loads creat very high material stresses on that fitting. Good welder! He piled up a good amount of material!

[@NC700_68]

that 90 degree angle on the tail wheel mount could be made a lot stronger. with a 45 degree for example.

[@cD-vg5go]

Nice TIG weld Gary ! tight little spot, you could see the original weld was too light

[@montreysmitherman7466]

I am so ordering the 60$ bore scope, I have a matco bore scope that hooks to my diagnostic tool but its so difficult to manage in this tight spot's

[@chrisaerts6489]

The bore scope is a must have. use them for looking inside of walls before I remodel homes.

[@davidmeek8017]

Aloha; cute roll into the commercial. Also I think the welder (not introduced?) did an EXCELLENT job! Mahalo

[@capnpete1154]

I worked in aviation for a while. I was in charge of taking engine parts through overhaul and making sure they were done to spec and under budget. I also did boroscope inspection of engines on and off wing.; I loved the work. Unfortunate the guy worked for was crooked as a dog's hind leg, so I got out of it. Nothing got done without a little mordida. The guy that balanced my disks for me had to have a bottle of Absolute or it wouldn't get done on time. Loved the work, hated the corruption. Certain alphabet agencies weren't immune either.

[@Zt3v3]

I had to look up mordida. I thought had had it from the context, but I've never heard or read that word before. Thanks for the morsel of knowledge today.

[@alexmikhael5061]

did that WELD actually strengthen that connection point??? I doin't mean like armored it but, unless it's a strengthened part adn the welding took away actuall hardening of the whole piece.... seems like it may be stronger around there now:) do you have an autopilot?? you gunna do one of those 1.5 lb autopilot things that use REMOTE CONTROL SERVOS to do trim tabs ?????? hehehe still waitin to see how long they last...

[@tomjoseph1444]

Doesn't matter which ticket you have, in our shops you always have a second pair of eyes go over work before closing it up.

[@campkohler9131]

Are LED replacements allowed for incandescent lamps in GA aircraft?

[@davidparker2627]

When I first saw the title I thought wow, what kind of nondestructive inspection (NDI) technique did they used to discover the crack. Turns out it just needed some sharp eyeballs. Looking forward to seeing you back burning holes in the sky.. 👍🏼😄

[@LeviShaffer]

Good to see another video from you!

[@attackofthesquishys7489]

When are you going to get more hats and T-shirts in stock on your website?

[@evfarry]

Really cool Trent! Kyle is based at my home airport, 77S! I’m a big fan of your’s and Kyle Bushman as well. Keep up the awesome videos!

[@justplanefred]

Do many planes use Dutz fasteners or just experimental aircraft?

[@Journeyman1642]

Have a safe flight today,!,

[@afterwork101]

Hello, assuming no repairs are needed, how much would cost a condition inspection like this one?

[@mattmansell3486]

Kyle B. is such a cool dude. He should be the poster child for modern day aviation.

[@timchilders3535]

Hey Trent/Kyle. Say where can I get that borescope? I can really use one of those, and yes the ones from the big 3 tool trucks, are fairly high pricey. Thank you!

[@2airwolv]

Still Love Haley's scream. Makes your videos exciting. Plus if you need the Sheriffs I am sure they would hear her. Man looks like I have watched this video three times. LOL

[@JustCallMeChad]

Square Space should give you a bonus for that awesome advertiser transition!

[@boogerwood]

Okay, I do have to admit I laughed at the SquareSpace sticker gag. That was well done.

[@DIGGER19860]

maverick on north mcaren by home depot has ethanol free its the best

[@realulli]

"You guys know the drill" - "Yes! Back to work!" ... Oh. ;-)

[@frizzlefry5904]

Trent, is there a check flight too ? cheers bud from the uk.

[@AeroworksProductions]

Nice video Trent, you probably sold 1000 borescopes, hopefully that was an affiliate link.?

[@larrylegg8245]

Good job Trent. Keep it up.

[@budowens6478]

Nice. Are you going to Oshkosh in July.

[@cptzoom]

I was a design engineer for SkyStar Aircraft Corporation from early 1993 until early 2004. I did design work on the Series 5 through 7. Let me know if you ever have any technical questions I might be able to answer about your plane. I’m an aeronautical engineer with a degree from Embry-Riddle, an EAA Technical Counselor, and an FAA Designated Airworthiness Representative.

[@PhilBender612]

Wow, that tail wheel mount plate looks to be a week design on Kit fox's part. Are they still manufactured like this if I were to purchase a kit today?

[@TrentonPalmer]

They have reinforced that part, my kit wasn’t even built by Kitfox Aircraft, mine was built by Skystar way back in the 90s so I still have some of the woes of the older planes

[@chemistrykrang8065]

It seemed like you just welded up the crack - was there nothing that could be done to beef things up a bit and stop it happening again? My philosophy with this sort of thing is to always try to do what I can to prevent it happening again... but it isn't always easy.

[@BackRoadsOutlawsRC]

Keep safe Brother!!! Kyle is the man!!!

[@cposer47]

Trent just wondering what your aircraft empty weight with the 915 is?

[@j.walker3498]

Don't be a hunter, say no to crack!

[@trbeme1346]

I wonder how I can get my annual paid for hehe. Nice video. Running ethanol gas that is causing issues with your tanks? My first solo flight. I landed and all of a sudden I had no rudder control. Turns out tailwheel spring bolt broke (most likely due to age being 47 years old). Spring came down, wheel assembly went up into rudder and at end of day about 2k fix. I now inspect the it more closely though I am not sure if that really will help out any as I am not able to see the threads of bolt and nut but at least if I see it is backed off I can investigate further. I will say I am not looking forward to what will be done this year. Constant speed prop needs to be taken off and inspected if I don't reach the hours prior to annual. Then plus whatever else comes up. Recently had fuel draining out of my header tank or so my IA and I thought so. Had him take it out and run leak down test along with pressure test. No leaks but the 400 I spent was well worth I think. Prior to that on another issue, he had found that a line to the header tank was leaking a bit and he tightened up. We are wondering if on the unknown chance, the fuel accumulated into the carpet and then somehow came out during preflight?????? No clue on it as I've not had issue since he did leak down and pressure tests. Stay safe and have fun

[@LordMeepalot]

Look at what ethanol does to some motorcycle tanks. starts warping them - mounts stress and eventually crack.