Project completed 7/1/2002>>> but your never done
Having the manual and parts list is mandatory
Frame parts replaced
New landing gear struts....................... You can make these yourself with simple hand tools & 6061-T6 TUBE
New upper frame half............................. important to replace if wing bolt hole is enlarged or if tubes are worn or bent
New lower rear frame tubes.................... high wear item
New cross brace stabilizers ................... Make these yourself with simple hand tools!!
New dacron sail ....................................... Looking for sources for kasperwing sail makers
Make you own parts>>>>
Zenoah Engine service
clean and gap points << gap was pretty darn close
Replace ignition coil
new fuel lines and filter
new fuel tank
new pull start rope
strip and paint exhaust port
New reduction drive belts......................... 7m710 from Gates NOTE: You must replace all 4 belts at the same time
New tachometer and hour counter
Clean carbon
.... Zenoah cylinder
head. I had this one dipped in a parts bath to remove carbon
...... Piston having carbon removed
Step by Step Progress
Old sail comes off!!
1/15/02
4/9/02
Wing spars ready for all new landing-wires to be attached.
5/9/02.... New sail arrives from the sail loft!!
>>>> Sail Makers <<< Click
for info
7/1/2002
Update... The new sail fits correctly. When the sail is brand new it is an extremely tight fit and may require you to stretch the fabric a bit at a time. You cannot get the sail to fit if your working in mid day sun or a warm/hot work area as the sail will be tighter under these conditions. Its best to wet the fabric down with a garden hose and work early in the morning or late evening for the first few times you stretch the sail in place.
Rudders being covered in dacron. I used liquid nails as the contact cement. Note: if you stretch the dacron to tight you will not be able to re-mount the rudder panel onto its mount. Glue the rudder dacron in place just tight enough to pick up the slack without bowing the tubes
<<Before .................After>> 
While I wated on the new sail I made Repairs to the Power Pod
I added this Aluminum plate to the cross bars so I could mount my Gauges
........ New upper frame half installed
The wing gets mounted with new sail installed. Now the rigging begins >>>>
Kasperwing being rigged at spadardo airport hanger>>> Long Island NY.
wind damage from storm end of may>>> kasperwing was tied down but wing was not yet rigged. when the wind kicked up to 33mph the cable clamps slipped and the wing tore loose causing a great deal of damage to wing and frame. Picture above in hanger was after I recovered the craft from tiedown location
site down wing while rigging>>> the guy asleep in this image was waiting on a friend but slept there all day. He's from Jamaica :)
Here the kasperwing is about 95% done. all thats left to do is rig flight controls and mount the fuel system