Any tips on forming Kydex interior panels?

[John Bickham]

Starting on my first attempt forming Kydex interior panels. My thinking is I would abuse whatever is on the walls and at least I could replace the kydex down the road. Also can access and inspect my work behind the panels easier and more frequently. My plan is to use .028" material (0.197 lbs/sq ft) as much as possible for weight considerations.

Just looking for suggestions from those that have experience with beading and forming flanges with the .028" kydex material? Tape on the the bead rollers to minimize defects? When is cold forming ok vs adding a little heat?

Mark Moyle - I never could get to that Facebook video link you posted previously. Not sure if that operator error on my part?

Any and all help and suggestions appreciated.

[Mark Moyle]

John,
There is a thread on the supercub.org site and my thread on the shortwingpiper.org site. Do a search there for Kydex panel fight.


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[John Bickham]

thanks Mark

[Bdflies]

"Kydex panel fight"?
Are we to surmise that it wasn't much fun?

[John Bickham]

Well, since I ask so many (dumb?) questions, I thought I would make a novice attempt at making a slight contribution. Just a little update on this weeks adventures and attempts at making interior panels out of .028" Kydex T. Besides the skylight that I have been working on, this is the only other thing that will be a weight debit over the Bob recommended construction technique of covering the interior with fabric. The accepted weight of fabric is 0.10 lbs/ sq ft. Kydex T 0.028" weight is stated as 0.197 lbs/ sq ft. Gotta add the required extra tabs and fasteners to that weight. Just to restate - .016 2024T3 is 0.230 lbs/ sq ft. I'm gonna see if I can make 0.028" work even though some have wisely recommended .040" in the cargo area. I'm doing that for basically two reasons: 1) save weight and 2) can't get .040"!

I just like having access and looky, looky to places behind what would be covered by a fabric interior. Besides if weight ever gets so critical that 15 feet of ground roll becomes critical, 15 minutes with a philips screwdriver and all this, except welded tabs, can be laid in a pile on the ground. Would that be cheating at a STOL competition? I can also replace pretty easily the pieces that get cargo abused down the road.

The little bit I've learned about Kydex leaves me grinning. Besides being flame resistant, this stuff is super easy to work with. It can be cut with heavy scissors, bends easily, easy to "adjust" notches and cutouts with a sanding wheel in a dremel tool, etc.

So a few pics to illustrate progress so far. I've still got some work to do in a few places on the left side. You will see some wavy gaps at the post aft of the left side passenger window. I have an idea to address that with results to be determined. My second attempt at the front seat channel on the right side should have a better result now I've learned a little on heating techniques.

DSCF1904.JPG

DSCF1912.JPG
Practice pieces for clearance spacing at rudder arms and rudder return springs. These looked good but didn't feel comfortable with the clearance in the forward rudder position.


Thanks Mark Moyle for guiding me through this adventure.

[N3UW]

Well, since I ask so many (dumb?) questions, I thought I would make a novice attempt at making a slight contribution. Just a little update on this weeks adventures and attempts at making interior panels out of .028" Kydex T. Besides the skylight that I have been working on, this is the only other thing that will be a weight debit over the Bob recommended construction technique of covering the interior with fabric. The accepted weight of fabric is 0.10 lbs/ sq ft. Kydex T 0.028" weight is stated as 0.197 lbs/ sq ft. Gotta add the required extra tabs and fasteners to that weight. Just to restate - .016 2024T3 is 0.230 lbs/ sq ft. I'm gonna see if I can make 0.028" work even though some have wisely recommended .040" in the cargo area. I'm doing that for basically two reasons: 1) save weight and 2) can't get .040"!

I just like having access and looky, looky to places behind what would be covered by a fabric interior. Besides if weight ever gets so critical that 15 feet of ground roll becomes critical, 15 minutes with a philips screwdriver and all this, except welded tabs, can be laid in a pile on the ground. Would that be cheating at a STOL competition? I can also replace pretty easily the pieces that get cargo abused down the road.

The little bit I've learned about Kydex leaves me grinning. Besides being flame resistant, this stuff is super easy to work with. It can be cut with heavy scissors, bends easily, easy to "adjust" notches and cutouts with a sanding wheel in a dremel tool, etc.

So a few pics to illustrate progress so far. I've still got some work to do in a few places on the left side. You will see some wavy gaps at the post aft of the left side passenger window. I have an idea to address that with results to be determined. My second attempt at the front seat channel on the right side should have a better result now I've learned a little on heating techniques.

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Practice pieces for clearance spacing at rudder arms and rudder return springs. These looked good but didn't feel comfortable with the clearance in the forward rudder position.


Thanks Mark Moyle for guiding me through this adventure.

John....Very nice. Thanks for sharing. Where did you buy the Kydex? What was the cost? I am very impressed on how you got it to stretch so uniformly with just two wooden blocks and a heat gun.

[John Bickham]

I tried to purchase locally from a couple of vendors with no luck.
I bought from Interstate Plastics:

Jessica Paxiao
Interstate Plastics
Phone: (888) 768-5759 Ext. 2737

https://www.interstateplastics.com

The biggest expense of Kydex can be the shipping if you go the whole sheet, shipped flat, via freight.

As Mark stated, the best deal is whole sheet, shipped rolled.
They did not have whole sheets in stock at the time. I bought 7 ea, 24&quot; x 48&quot; Kydex T (.028) for <$215.00 shipping included.

[Mark Moyle]

John,
You can order .040" from CAC plastics up here (AK.) and have it mailed to you....rolled up. I really like those formed panels!
Mark


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