Another kydex thread..

Im in the process of fabricating another kydex interior.
Thought I’d share some thoughts and numbers.

certified PA 18, univair fuselage w inverted dogleg and full baggage compartment.
Trying to keep it lite but also utilitarian.

I’m using “Calcutta black” and a combination of .060 and .040.
larger panels, baggage area are .060
lower door and kick panels .040

Total weight of kydex cabin interior (dogleg to firewall) - 8.4 lbs
Total weight of previous interrior (.020 alum primed and painted) - 5.92 lbs
2.48 lb penalty, Kydex approx 30% heavier.

I’ll get some photos as re assemble the interior.
Benefits I can report:
flexible, won’t dent
resistant to scratching
shears and brakes like aluminum
Eliminate paint process.

Disadvantages:
weight
will distort over time in areas exposed to direct sunlight: (throttle quadrant tunnel)

Couple photos:
Ran all the edges as well as overlaps thru a bead roller.
As well as nut plated all of the overlaps for 8/32 machine screws.
Also nut plated trim and fuel covers as well as throttle tunnel.
Univair fuselage has ample mounting tabs to support panels.

Looks very nice Oliver. I like working with Kydex too. The weight disadvantage with Kydex only happens if you use material thicker than .040”. I tried to copy the chart I put in this thread: https://www.supercub.org/forum/showthread.php?60501-Building-a-4-Seat-(4S)-Javron-Cub (post 40) showing weights but my iPad was not willing.

The bottom line is .020” aluminum and .040” Kydex weigh the same. Where did you feel you needed .060” Kydex? I’d think .040” would be stiff enough anywhere in a Cub, especially with bead rolling.

Looks very nice Oliver. I like working with Kydex too. The weight disadvantage with Kydex only happens if you use material thicker than .040”. I tried to copy the chart I put in this thread: https://www.supercub.org/forum/showthread.php?60501-Building-a-4-Seat-(4S)-Javron-Cub (post 40) showing weights but my iPad was not willing.

The bottom line is .020” aluminum and .040” Kydex weigh the same. Where did you feel you needed .060” Kydex? I’d think .040” would be stiff enough anywhere in a Cub, especially with bead rolling.

Floor panels back from powdercoater.
.050 diamond plate front two panels,
.040under the px seat and extended floor.

For comparison,
varnished 1/4” birch:
front floor-3 lb 2 oz
back floor- 4lb 2 oz

diamond plate .050 non skid powdercoated
front -3 lb 4 oz
rear - 4 lb 5 oz

gave up a couple oz but accounting for the extra material in turned up edges, probably dead even.
the turned edges are handy for attaching lower interior panels, help contain debris.

rear extended floor - .040 with stiffeners was same weight as removed birch floor.
Also 1” edges bent up 3 sides.
both 5 lb 4 oz.

upper baggage floor and lined 3 sides .040 kydex including door and door frame
4 lbs 5 oz

As mentioned: mix of .040 and .060 kydex interior panels.
gave up a couple lbs when I opted for .060 in high traffic areas - not prone to warping, does not require as much support. I’ll get a total weight on interior panels for comparison.

couple photos:
floor:


rear baggage floor:


upper baggage:

spinner2 said:

Looks very nice Oliver. I like working with Kydex too. The weight disadvantage with Kydex only happens if you use material thicker than .040”. I tried to copy the chart I put in this thread: https://www.supercub.org/forum/showthread.php?60501-Building-a-4-Seat-(4S)-Javron-Cub (post 40) showing weights but my iPad was not willing.

The bottom line is .020” aluminum and .040” Kydex weigh the same. Where did you feel you needed .060” Kydex? I’d think .040” would be stiff enough anywhere in a Cub, especially with bead rolling.

Click to expand...

you are probably correct, .040 would be adequate though I have seen .040 distort a bit over time.
msybe the southern calif. environment (heat) a little tougher.

Looks very nice Oliver. Where are you sourcing the Kydex from? What type of Kydex is it? Kydex T?
I have a customer now that is looking for a carbon fiber Kydex look but I'm not seeing that in any size.

Bearhawk Builder said:

Looks very nice Oliver. Where are you sourcing the Kydex from? What type of Kydex is it? Kydex T?
I have a customer now that is looking for a carbon fiber Kydex look but I'm not seeing that in any size.

Click to expand...

yes, kydex T “Calcutta black” is what’s pictured.
Interstate plastics is a good source, check their website for colors

Very nice job, looks great and solid. But very heavy.

I’ve got .016” alu in extended baggage floor, .020” for baggage floor, carbon fiber passenger and pilot floors.

I put a plywood sheet on baggage floor when I need to haul heavy or sharp stuff.

.040” Kydex is a nice product to work with. Did my side panels with it.


Envoyé de mon iPhone en utilisant SuperCub.Org

Oli,
Ive been very impressed with your workmanship and performance of your build.
I agree with you, I could have shaved weight in several areas going with lighter material. Theres always a compromise and ensuing struggle. It easy to get caught up in the “it’s only a couple lbs” thing as weight ads up quickly. I was pretty content with the weight of the upper baggage, then hefted the ELT to install, WTF,
it weighs more than the entire upper baggage mod. And so it goes..

Mission with this build:
The fuselage I’m working with is a univair, 3rd seat option, flat floor, tailored to be a “working airplane” I’m trying to incorporate some creature comforts and durability into this build.
IE: floor not oil canning and denting if one had to sleep in it, antlers not denting, poking holes in interior panels etc..
Everything is a compromise.
last build came in at 1095 on 31”s, same interior, Certified, Piper wings, tanks, fuselage, Atlee baggage. Not crazy light but still a performer, utilitarian and durable, interior looks as good as it did 800 hrs ago.

This build, also certified.
Im already looking at a 15lb penalty with bare fuselage mods, Dakota 24 gal tanks, ribs, 2k gross.
I’m shooting for 1150 (w/sen ga prop - I hope)

Always open to ideas on shedding weight though.
thanks
doug

Rear baggage panels are finally installed and attached,



Anchor side and top panels mid span

Nice work. How are you going to rethread that trim indicator cable through they little guide when it breaks? My interior was pop riveted in like yours and I had to drill them all out to get the wire rethreaded. Might want to cub a small access hole now and cover it. DENNY