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Building the Kiss 400 Microlight

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Building G-TRYK - a Kiss 400 Microlight

IMPORTANT NOTE: This site documents how I built my plane. In no way does it endorse any of the methods or techniques described as 'officially correct' - for that, please refer to your own build manual. Remember, the TOTAL responsibility for an aircraft build lies with the builder and inspector, NOT with any 3rd party who offers advice, such as is contained within these pages. If you crash and burn after reading this site, it's your fault, not mine!

Introduction

Tools required

Loctite adhesives and threadlocks required

Stuff all this Steve, just show me the pictures!

Click here to read about the build in story form, or use the links below to access the photo-documentary pages.

Build Status

Total build time to date: 101 hours
Sorting the bits out: 8 hours
RTFM'ing 10 hours
Rolling chassis: 15 hours
Engine and electrics: 25 hours
Wing: 16 hours
Pod: 22 hours
Rechecking build against manual: 5 hours

The Build

Please note each of the following pages has a next and back button at the top left, which you can use to page through the build without returning to this page. Also remember all pictures are clickable for a larger version, then use your browser's 'back' button.

Days 1 & 2 - Saturday and Sunday 21st/22nd October 2001

Unboxing and checking parts

Day 3 - Tuesday 23rd October 

Assembling Trike keel, front forks, pylon, engine mount and seat frame.

Day 4 - Wednesday 24th October 

Wheels, front forks, regulator/rectifier and radiator

Day 5 - Friday 26th October

Gear struts, fuel tank and seats

Day 6 - Saturday 27th October

First shot of complete rolling chassis, plus engine mounts and  wing assembly

Day 7 - Sunday 28th October

Throttles, brakes and seat belts

Day 8 - Monday 29th October

Fuel system and engine

Day 9 - Tuesday 30th October

More on the engine, and carb assembly too

Day 10 - Wednesday 31st October

Cabling (No pictures!)

Day 11 - Friday 2nd November

The main wiring loom

Day 12 - Saturday 3rd November

Fitting the sail to the wing

Day 13 - Sunday 4th November

Finishing fitting the sail to the wing (big job!). Nice picture of the assembled, rigged wing.

Day 14 - Monday 5th November

Fitting the pod

Day 15 - Tuesday 6th November

Choke cables, hand throttle and windscreen.

Submission to BMAA Chief Technical Officer (Guy Gratton) for approval of modification to instrumentation and fuel system

Day 16 - Wednesday 7th November

Instrument panel

Friday 9th November 

no work done today on the build, but received approval from BMAA CTO for mods - a 3-day turnaround! 

There are 3 additional inspections required for the mods:

  1. Instrument Panel - confirm range limits correctly set up and working properly (Temperatures and Revs), with audio warning on comms interface.

  2. Radio/intercom - TIL101 Page 3 to be completed and attached to stage inspections

  3. GPS Mount - to be load tested as per TIL 027 para 14.2

Day 17 - Saturday 10th November

Radiator, radio aerial and propellor

Day 18 - Sunday 11th November

Underslung radiator housing, fuel system and instrument panel wiring

Friday 16th November

Small build update with no pictures.

Day 19 - Saturday 17th November

Exhaust manifold, electric start and the finished cockpit with a great picture of the digital instrument panel.

Day 20 - Sunday 18th November

On the trailer for the first time, plus the wheel spats are fitted.

Day 21 - Sunday 25th November

Excellent Flycom integrated helmets and headsets, plus finishing the exhaust system

Day 22 - Saturday, 5th January, 2002

Finishing touches

Day 23 - Sunday, 24th February, 2002

Fitting a rear-seat steering kit and a new trike cover, plus an early look at the engine intended to replace the Rotax 582.

Day 24 - Friday 22nd March, 2002

Final inspection at Rochester Airport.

Day 25 - Tuesday, 2nd April, 2002

Engine run-in at Frieze Farm

Day 26 - Sunday, 7th April, 2002

Fuel flow test at Frieze Farm, and application for Permit to Test all ready to go in the post to the BMAA - hurrah! (and there was much rejoicing)

Test Flight - Saturday, 1st June 2002

Paul Dewhurst puts my Baby through her paces at Sywell aerodrome.

Hints and tips for future Kiss builders  

Things that made me go 'Hmmmm'

Some points on Build quality and time

The kit had shortcomings, but few and far between!

Build manual errata

One day, I'll get around to transcribing all my notes from the build manual - I promise!

Inspections

Inspector: John Whelan

Work area: 21st October 2001 - passed
Rolling chassis: 28th October - passed
Wing frame:  28th October - passed
Finished trike and wing 22nd March 2002 - passed
Fuel flow test 7th April - passed

Flight Test

Test Pilot: Paul Dewhurst - 1st June, 2002 - passed!

5 hours test flying are required: 2 by Paul and the remainder by me. Before this can happen, a 'Permit to Test' must be issued. This cannot happen until the stage inspections are all signed off, and is likely to take a few weeks.

Once the test flying is complete, application can be made for a 'Permit to Fly'. Until that is issued, only 'endurance test' flights can be conducted.

 

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What is a Microlight | Costs | Learning | Rules of the air | Fly-In Database
What's in a Kiss | Pics of a finished Kiss | Building a Kiss | Stories | The Tryk
Flying Links | Technical Tips | GalleriesNews | Owners' Pages
BMAA Microlight Recovery Database | Feedback and Discussion Forums

This site is owned by Steve Elsbury - all content is copyrighted unless otherwise stated.

This site is a member of The Microlight Webring owned by Steve Brown.
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Last Revised: 28 September, 2004