Homebuilding

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img_9602As a first-time aircraft homebuilder, there has been this veil of mystery about the final airworthiness inspection. Thanks to the gracious invitation of a new-found fellow Zodiac builder in Corona, the inspection process has been de-mystified. Yesterday I joined Ted Taylor at his hangar in Corona for the airworthiness inspection on his beautiful Zenith Zodiac 601XL. Ted has been laboring in relative isolation from the larger builder community, which may account for his steady progress and the completeness of his final product.

 

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The DAR (Designated Airworthiness Representative) was thoroughly prepared and did an excellent job of outlining the scope of responsibilities — both his and the builder’s. At the end of the session, Ted passed with “flying colors” (pun intended) and I learned a whole bunch about final inspections. Congratulations, Ted.

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I am at a crossroads.  I learned today that waiting for plans for the new Zenith Zodiac 650 could delay me until late September or early October. 

The purist in me is willing to wait.  I could put together a laundry list of odds and ends jobs to do for the next month plus.  If I’m smart, these are all things I need to do anyway so I’m just time-shifting them to the front of the line.  That way I can keep busy and productive instead of just sitting on my hands and losing time.

The pragmatic part of me says that I should be content with a hybrid that would incorporate all the changes except the changed angle of incidence on the wing.  The day I decide to leave my wing at the 601XL angle (not dropped down by 2% at the back), I free myself to continue building my fuselage and cockpit area.  Then I’m still in a position to incorporate the major changes (new canopy system and re-styled rudder) without slowing down for plans.  That’s what my Park Ranger building buddy in North Carolina has done.  Debo, you’re looking smarter every day.

Either way I must make a decision soon.  I’m quite sure that I’ve expended more calories fretting over this decision than I could possibly spend making metal shavings in the garage.  Stay tuned, but even as I write I believe the pragmatist may have won the arm wrestling match.

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On June 27, 2006 I picked up my Zenith Zodiac 601XL plans from the factory in Mexico, MO and have been happily working toward completion of that aircraft since then.  At AirVenture 2008 in Oshkosh this year, Zenith unveiled the new Zodiac series model — the 650. 

Reading posts on the internet, I quickly learned I was not the only 601XL builder concerned with having an uncompleted aircraft that was already yesterday’s news.  Great relief came as subsequent statements confirmed that Zenith had made every single innovation on the 650 retrofittable to the 601XL.  For completed airplanes, the expense might outweigh the rewards.  For someone like me, the only cost will be some new plan pages and upgraded materials, where that applies.  Count me in.

The 601XL has been built by several manufacturers around the world, to somewhat different standards based upon special regulations, particularly in Europe.  There has also been nearly unanimous disdain for the 601XL canopy design.  The folks at Zenith took this opportunity to pull together the best of all the existing 601XL design mods, in addition to a new canopy system with roll-over protection, to create an internationally certifiable model called the 650.  Good thinking, and I know it has to make life simpler for them.

The biggest single change is the canopy system, which is now split with the back portion fixed to the roll-over protection structure.  This gives a better hand hold for cockpit entry, a lighter portion to lift when entering, and less surface to be caught by wind on the ground.  The latching mechanism is also dramatically improved, with a single shoulder-height lever between pilot and passenger.  The updated canopy system is even roomier, which means I should really have no issues with fitting now, even at 6′6″.

 

Additionally they changed the rudder to be less upright and more swept and streamlined.  For the non-aeronautical types among us, the rudder is the “thingy” at the back of the plane that sticks up and helps turn the plane.  Some minor bracing was added to the rear of the fuselage to comply with European standards, and the trailing edge of the wing was lowered slightly to increase over-the-nose visibility. 

It is good to work with a company (centered around the designer, Chris Heintz, and his four sons) that continues to value their existing customers by providing them with new innovations and a clear path to incorporating them.  I invite you to visit their website to see all of their airplanes, as well as more detail on the 601XL/650 I am building.  You can visit http://mykitlog.com/lwinger to follow my progress as I make my Zodiac 1251 (601+650) or Zodiac 649 (not quite a 650).

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Two years ago I entered the world of blogging through the back door.  A weblog to chronicle my airplane building project was the easiest way to track my progress, and a side benefit was that it connected me to a whole world of builders — quite literally around the world — who regularly connect with me to offer suggestions, to seek advice or just to say  “hi.” 

After my recent two-month hiatus from building (due to my bad back), I was surprised to hear from a good building buddy who told me he checks my kitlog daily.  That’s hardcore!  Talk about the power of intermittent positive reinforcement.  Sorry to leave you hanging for so long, Dave.  I’m back.

That was just a reminder to me to keep up both blogs for those who are tracking with me.  With the help of the “delayed posting” feature,  I hope to send out something — if nothing more than an interesting fact or observation — each and every day.  More later.

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Today I’m writing about the first significant anniversary to be celebrated this week.  On June 27, 2006 I was in Louisville, KY for the North American Christian Convention which was to begin the next day.  Taking advantage of my proximity (all things are relative) to Mexico, MO I drove nearly 6 hours each way to visit the Zenith Aircraft factory where I took my very first demo flight in the Zenith Zodiac 601XL. 

This was the culmination of decades of dreaming and months of comparing various homebuilt aircraft, and I left that day with plan set #6493, a metric tape measure and a smile.  Now, two years later, I have wings and all control surfaces in the hangar, my engine is  a few months from completion, and I’m starting to tie together the bottom half of the fuselage.  In retrospect, I feel quite good about my progress, notwithstanding a couple of unplanned delays (for parts and recuperation from a sore back).  Based on my rate of progress and level of determination, I predict that N601VP should be ready for an FAA inspection by this time next year.  This is the view I’m most anxious to have some time in 2009. 

Three years to scratch build an airplane seems downright respectable when I hear sad tales of full kits just collecting dust…sometimes for decades.  For the record, I wouldn’t pick a different course, even if I had it to do all over again.  The amount of learning and satisfaction I have gained from scratchbuilding has been well worth the extra work and increased time to fabricate parts.  Above all, I’ve enjoyed joining the community of airplane builders from around the world.  What could be better than broadening your circle of friends while doing something you love?  I’m hooked.

If you’d like to track my building progress toward the plane you see below, jump on over to my weblog anytime at www.mykitlog.com/lwinger.

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When you set out to build an airplane in your garage, you can’t just measure its cost in sheet aluminum, rivets, an engine and gauges.  If you are wise, you’ll factor in something for the inevitable ”how-could-you-possibly-say-no-when-you-are-building-an-airplane-in-our-garage” projects that will come your way.  And you know, it’s hard to knock holes in that logic.

For our family, it has meant the replacement of everything we walk on — both inside and out.  First the lawn got ripped out and new sod put down. 

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Then it was pulling out the carpet in our guest bath (yes, the previous owners had carpet in the bathrooms) and putting in limestone tile by hand.  By that point, the camel’s nose was in the tent, and the final, world-class “honey do” was revealed last month.  “Since you’re building a plane in the garage, can’t we get rid of that old carpet, tile and sheet vinyl in the rest of the house?”  How could I say no?  Even if I wanted to.

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By the time you unhook every electronic doodad, unload every bookshelf, move every piece of furniture in the house…only to reverse the process several days later, some would argue you might as well move.   Not me.  At least my airplane project is resting comfortably surrounded by all my tools that never got touched once during the process.  That’s one thing I don’t plan to move until the day it takes a trip to the local airport.

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No one builds an airplane alone.  At least no one whose plane I would ever want to fly in!  The remarkable thing I quickly learned about homebuilding airplanes in the internet age is that the seeming isolation of long hours in the garage is not reality for most builders.  For every hour spent in the shop, making metal shavings and plenty of noise, I probably spend at least one hour connecting with my “building buddies” around the world.

My circle of friends took a major jump up when I signed up for the Zenith list on Matronics.com.  Every day dozens of messages fly back and forth between builders who are scratching their heads and those who are now sipping lemonade, having recently completed the daunting tasks that others still face.  Oh, and then there are the soap-box preachers, Monday-morning quarterbacks and armchair engineers who drive everyone a little crazy.  But what would you expect.  Like family, you can’t pick ‘em so you learn to love ‘em. 

Someday I’ll introduce you to some of my flying family.  The really good ones who have saved my sanity…and maybe my life.

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