Updates coming this spring  

We can rebuild it.  We have the technology!

    The Kasperwing 1-80 Ultralite was Designed to be easy for the end user to make replacement parts and repairs using simple hand tools. In fact it was Steve Grossruck's (owner of Cascade Ultralites) intention to make detailed plans and specs available so that kasperwing owners could make their own replacement parts.  This was documented in the 1987 April 10th news letter From Steve detailing the close of Cascade Ultralites inc.  Though these techniques and tips are not factory spec items and are created and used "at your own risk", if you follow the tips on this page closely you should get very good results with your own replacement parts.

basic working rules

Know your materials-   The kasperwing is made up of mostly 6061-t6 aluminum tubing.  6061-t6 has unique characteristics that you need to be familiar with before you start working with it. First of all you need to understand the chemical reaction that takes place when 6061-t6 comes in contact with steel.  Steel and 6061-t6 aluminum do not mix.  When the two metals are in direct contact a chemical reaction takes place that corrodes the aluminum tube.  Dacron is the sail material the kasperwing is made with.  Dacron is destroyed by UV light rays.  Faded Dacron color indicates that the sail has suffered from UV damage and may need to be pressure tested or replaced.  Over all you just need to become familiar with the materials that make up your Kasperwing.

Use the correct tools-  Sounds like a simple thing but you really need to pay attention on this one.  On all aluminum parts avoid using any type of steel wire brush or steel bolts not treated for contact with 6061-t6.  Electrical conduit pipe benders do not bend this tubing.  You will need a machine shop with the proper pipe bender equipment to get a clean bend without taking the tube out of round.  Never drive a bolt through a hole with a steel bit driver.  Never use vise-grips on bolts when tightening as you know it will strip the bolt/nut. Two open end wrenches for each size required is the best means to assemble the entire plane

Click on the Part Name to link to an image or diagram of the part

Power Pod Parts- 180A

Power Pod Parts- 1-80 A cont.

Wing Parts-1-80A