Gear Leg Alternative Covering

[FFTravism]

I wanted to share an idea I had and I been able to implement and I think it looks good. I am doing Kydex for a lot of the interior and figured it would make a good gear leg covering. A Kydex covered gear leg will take any rough backcountry landing you could toss at it.

I made a paper template and then cut it out in Kydex. I bent it with a heat gun from Harbor Freight. I used Nut Plates to seal the Kydex wrap up. At the top of the gear leg and on the backside.

I learned a few things about Kydex. First if you heated a area and put a clamp on it to keep it from moving it will leave indents. A bit of a "Duh" moment. Work the Kydex slow and don't force it. Kydex cuts easy with sheet metal tools.

I purchased 4'x8' .060 black Kydex sheets.
For some data the gear leg Kydex wrap weights 2lbs 2oz. More then fabric but way tougher.

[Nev]

Nice work. The edges sand pretty easily with sandpaper too.

[TJ_Slice]

While we are talking about Kydex, how have the interior panels you did holding up Nev?

[Battson]

Very nice handiwork with the kydex, I can appreciate that wouldn't have been easy to do.

For one datapoint, after more than a dozen years of robust backcountry and off-airport treatment - rougher than most - the fabric on my landing gear legs is completely unscathed. The paint has come off in a few places, but the fabric is more than strong enough.

[FFTravism]

The strength of fabric really surprises me .

[Nev]

While we are talking about Kydex, how have the interior panels you did holding up Nev?

The Kydex interior panels have held up very well. No maintenance required on those so far. They are hard wearing and stand up to plenty of boot scuff marks. Would definitely use Kydex again. The one area that I would reconsider is the wing root panels. Mine are in direct sunlight and can get quite hot. Initially this resulted in some slight warping. Although it hasn't changed since new and is barely noticeable.

[TJ_Slice]

Thanks for the update. I am planning on trying it out as well.

[interstate al]

I also used Kydex for interior panels. I didn't think about using it for my gear legs. I actually wrapped mine in aluminum and rivited on. The brake lines aren't accessible without drilling rivets, so I used braided brake hoses.

[FFTravism]

Do you have an pictures of your interior Kydex panels? I am just starting to work on them.
Travis

[Nev]

Here's a few photos of the Kydex during my build. My aft cargo bulkhead is also made from Kydex, with a velcroed removable inspection panel.

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[Pbruce]

Boy that looks clean! I’m trying to get some Kydex to do the “kick panels” forward of the front door frame, the wing roots, and the aft bulkhead cover. It’s very rare near me. I can get .028 cheaply and .040 expensively. Since it has to be shipped, by itself from far away. What thickness do you recommend, Nev? Are there published instructions or techniques telling how to work it, or did you just figure it out on your own? Thanks.

[FFTravism]

I used 0.060 for kydex. Doing the front kick panels now.
Travis

[svyolo]

Various types of fabric are extremely tough for landing gear/exterior/interior. If you never have to take it off traditional fabric or Oratex is great. If you have to take it off. something stiffer like composite or kydex might be better. I used composite. Kydex works and looks great. Might be less work than composite. But heavier than thin composite. Your choice.

[Nev]

What thickness do you recommend, Nev? Are there published instructions or techniques telling how to work it, or did you just figure it out on your own?

I used .028 for many of mine - it stiffens up once it's had a crease or bend put in it too. To learn how to mold it, look on YouTube. There were some great videos (very good instruction) from psgflier doing a cub in Kydex here.

• Where possible use a heat gun on the back (rather than the front) so you preserve the texture. You won't always be able to though.
• Try not to get it too hot.
• Be patient with cooling - a wet rag helped me with that. Wear welding gloves - it gets hot!
• For many bends I was able to clamp it in the vice between two pieces of wood, and gradually work my way along with the heat gun and slowly and incrementally bend it over using a block of wood.
• I found it more difficult doing some of the panels in situ, much easier to make a mock up on the workbench.
• You can get a nice clamping action with the kydex clicking into place around tubing.
• It cuts well with scissors or a Stanley knife, and the edges sand well, yet it's tough and holds up well to knocks and abrasion.
• It glues very well to itself using a plastic pipe adhesive and primer. Most other glues won't work.
• Overall I found it to be excellent to work with and would definitely use it again.

[Pbruce]

Thanks. I’ll order up the .028.

[FFTravism]

Those videos really helped me.
Thanks for all your tips and tricks. Didn't know about gluing them together.
Travis