Homebuilt Aircraft

2017 Buyer’s Guide Expanded Edition KITPLANES

DECEMBER ...And a

2016 Pedal Plane ®

2017 Buyer’s

• 2017 D irectory Pedal

Plane Over 1000 ListINGS! • Multimeter Musings • AFS Panels • Maintenance • CNC Mold Blanks • Turning Spheres • Resin Infusion • Blind PLUS Rivets

BELVOIR Beyond the Vacuum Bag DECEMBER 2016 Resin Infusion In the Shop

PUBLICATIONS Panels in Days • CNC Mold Blanks AFS Quick Panel • Machining Spheres • Analysis Tools Blind Rivets What You Need to Know www.kitplanes.com SE

No matter what you call it, SE is Dynon’s most affordable and intuitive SkyView experience ever.

Dynon is excited to introduce the newest member of the SkyView family. SkyView SE is made specifically for VFR aircraft and pilots who want the most intuitive flight and engine instruments on the market. They feature simple and clear displays, with almost no menus to navigate in flight. At the same time, SkyView SE retains modern, innovative Dynon EFIS capabilities like SkyView’s revolutionary COM radio interface and 2-axis autopilot with single-touch controls.

Without mapping capabilities, even the 7” SkyView SE display has a large, easy-to- read Primary Flight Display, including pilot-selectable six-pack “steam gauges”. With its simplified feature set and installation, SkyView SE is the successor to Dynon’s legacy D100 series products.

The 7” SV-D600 display is priced at $1850, with the 10” SV-D900 at $3100. A complete 7” SkyView SE system with primary flight instruments starts at $3305 including harnesses. Add the SV-XPNDR-261 Mode S Transponder (with ADS-B Out) and SV-GPS-2020 GPS Receiver/Antenna for a low-cost integrated glass panel system that meets FAA 2020 ADS-B Out requirements. DynonAvionics.com [email protected] (425) 402-0433 December 2016 | Volume 33, Number 12 Annual Buyer’s Guide 24 2017 Homebuilt Aircraft Directory: Pick a plane, any plane—an overview of kit and plansbuilt fixed-wing aircraft and rotorcraft. Introduction by Paul Dye. Directory compiled by Omar Filipovic.

Builder Spotlight 6 Pedal Power: Building a classic biplane for the next generation of aviators. By Tom Brusehaver. 12 Resin Infusion: Taking the next step beyond vacuum bagging. 6 By Dan Horton. 19 P anels in Days, Not Months: Pre-built panels are an easy way to save time and eliminate frustration during avionics installation. By Bruce Eicher. 68 rAP id Prototyping and Experimental Design: CNC mold blank fabrication, part 1. By Eric Stewart. 92 A sk the DAR: Transfering an aircraft’s repairman certificate, replacing a lost airworthiness certificate, converting a certified aircraft to Experimental. By Mel Asberry.

Shop Talk 78 Best Practices: Blind rivet selection and installation. By Dave Prizio. 88 Home Shop Machinist: Sphere turning. By Bob Hadley. 101 Aero ’Lectrics: Multimeter musings. By Jim Weir.

Shop Tip 103 Odd-Size Transfer Punch: By David Paule.

Designer’s Notebook 75 Stressing Structure: Analysis tools. By David Paule. 98 Wind Tunnel: Trikes. By Barnaby Wainfan.

24 Exploring 2 Editor’s Log: The flying bug. By Paul Dye. 84 cHeckpoints: Maintenance. By Vic Syracuse.

Kit Bits 4 Letters 93 list of Advertisers 94 builders’ Marketplace 104 kit StufF: Drawing on experience. By cartoonist Robrucha. 12 On the cover: A few examples of the aircraft in this year’s directory. Any similarity to a busy AirVenture arrival is purely coincidental. Photo composite by Dan Maher. For subscription information, contact KITPLANES® at 800/622-1065 or visit www.kitplanes.com/cs. KITPLANES December 2016 1 Editor’s log The flying bug. Have you ever seriously considered what it was that got you started in aviation? I am sure that many pilots know the exact moment, the exact impetus— the very place, time, and event that got them fascinated by flight. But my experience has shown that many others simply don’t know why they are enraptured with the thought of flying and flying machines. They simply are and feel like they always have been. I am afraid I fall into that second category, which makes it very difficult for me to get involved in a meaningful way with figuring out how to get the next generation hooked on playing with aeroplanes. I can’t understand why they aren’t already. It’s sort of like a Building a pedal plane (see page 6) is a great way to get youngsters interested in aviation. sighted person trying to describe color (Photo: Tom Brusehaver) to one who has never had the use of their how they could have done that; weather motorcycles. It’s all good, and airplanes eyes—the vocabulary simply isn’t there. always seemed to be an issue in the real are just another step. I get that—it is For those who know why they love world. Later, after moving to the west- understandable how flying can hook aviation, the reasons vary. For some it is ern regions of the U.S., I understood. For one looking for excitement. pure transportation. The classic case is much of the country west of the Rockies, But then we have the category of folks the man or woman who has business at weather just really isn’t an issue most like me who simply have what seems like many locations within an hour or two of of the time—you get in and go! So for an inbred need for flight. It’s not true of flying time from their home. Getting in those who look at flying as basic trans- course; I really don’t think that flight is in the plane to visit multiple locations saves portation and can make it work, air- our DNA. I think that somewhere, some- so much time that their business booms; planes are just a part of life. how, we get hooked, be it from a parent, it is as if they have multiplied themselves Others are clearly bitten by the bug from a TV show, from a movie, or the call to get more done. As an aside, I remem- because of the excitement and adven- of a book. I suspect that in my case, being ber watching Sky King as a lad, enrap- ture of aviation. Seeing the earth from surrounded by people who had recently tured at how they treated the airplane above, the speed and freedom—it fought a world war—many of whom like my parents used a car—or I used a is yet another of the various thrills to talked and wrote about their experi- bicycle. They hopped in and went where be experienced in the modern world. ences—there was a romantic excitement they needed to go, regardless of time of Many in this category have tried a lot of that surrounded aviation. It was some- day. Later, when I became a pilot in the different things to get their adrenaline thing that not just anyone could do. And middle of the United States, I wondered rush: skydiving, rock climbing, boats, for a scrawny kid not very good at sports,

Paul Dye, Kitplanes® Editor in Chief, retired as a Lead Flight Director for NASA’s Human Space Flight program, with 40 years of aerospace experience on everything from Cubs to the space shuttle. An avid homebuilder, he began flying and working on airplanes as a teen, and has experience with a wide range of construction techniques and materials. He flies an RV-8 that he built in 2005, and an RV-3 that he built with his pilot wife, as well as a Dream Tundra they recently completed. Currently, they are building a Xenos motorglider. A Paul Dye commercially licensed pilot, he has logged over 5000 hours in many different types of aircraft and is an EAA Tech Counselor and Flight Advisor, and a member of the Homebuilder’s Council. He consults and collaborates in aerospace operations and flight-testing projects across the country.

2 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes it provided a way to excel in something a great many pilots are now grand- Yes, take kids on Young Eagles flights that few others chose to try. It wasn’t the parents. And if your children weren’t if you have the opportunity, and take the influence of a parent who flew—mine so interested in your tales of joy in the time to look at kids that you can influ- didn’t, although they were supportive— air, weren’t excited by the adventure ence for more than just one flight. If you but there were people I met who were of flight, empirical evidence suggests have no grandkids, adopt them (unof- influential. Quiet, but supportive. that your grandkids might very well be ficially) from the neighbors. Invite them It has been my observation that avia- primed to be infatuated. to participate, and spend some money tion tends to skip a generation for some Are you currently building an airplane? to get them on board. Burn the gas, reason. Yes, there are boys and girls Get the grandkids involved! Teach them buy the parts, invest in the future. I was who grow up in an aviation family, with how to rivet, how to sew, and dope fabric. fortunate to have adults who invested opportunity and resources to fly when- Order a few extra parts so they can ruin in mine, and it took me years to under- ever they want. They solo 15 airplanes a few, and you’re still covered to finish stand that it wasn’t just their time—it on their 16th birthday and inherit their your plane. Take them flying, of course, was their money—that effectively sub- parent’s FBO or airplane company. But but make sure that they understand the sidized my way into aviation by giving many more simply don’t get the bug romance of aviation. Teach them about me cut-rate flying time in exchange for from their flying parents. I have no idea Lindbergh, about Doolittle, about Saint- the sweat equity of working on airplanes why this is so. But—and this should put Exupéry. Show them two sunsets in five and sweeping the hangar. And you know a twinkle in all of our eyes—the gen- minutes from the air. Introduce them what? I would have done all that for free! eration after that seems to once again softly to the world of flight, and if the As the holidays approach, think about become infatuated. I hate to say it bug bites, spend the time and money giving the gift of flight—if not literally, folks, but the pilot population is aging. to take them places—just for fun. Build then figuratively—by exciting the spark That’s just a fact, and we all know that them a pedal plane (see page 6) so that of aviation in your grandkids, your own without new blood, the field is in dan- when their friends are scooting around kids, or the kids next door. The future ger of becoming nothing but a bunch on plastic wheeled devices from the is going to come no matter what. The of remote-operated flying machines. big-box store, they are sitting proudly in question is, will aviation as we know it Ahh…but since we’re aging, that means their own Eagle or P-51. still exist? J

KITPLANES December 2016 3 EDITORIAL Editor in Chief paul Dye [email protected] Trim Tabs the most current version of the limita- Managing Editor mark Schrimmer Barnaby Wainfan’s recent article about tions, but he may also simply request a Art Direction Dan Maher trim tabs [“Wind Tunnel,” September replacement special airworthiness cer- Editorial Director paul Bertorelli 2016] advised having enough stiffness in tificate and operating limitations, both Contributing Editors larry Anglisano, Marc Ausman, the trim tab system to preclude tab flut- of which would replicate those that were roy Beisswenger, Chuck Berthe, David Boeshaar, LeRoy Cook, ter. What about mass balancing the tab originally issued. robert Hadley, Dan Horton, like a control surface is balanced? Brian Ingraham louise Hose, Amy Laboda, Dave martin, Sid Mayeux, David Paule, Steve Grossman Dave Prizio, Dean Sigler, Dick Mel Asberry responds: Thanks for your starks, Eric Stewart, Vic Syracuse, barnaby Wainfan, Jim Weir, Barnaby Wainfan responds: Mass bal- comments, Brian. What I should have tom Wilson. ancing of tabs has been used to alleviate said is that the new owner should request Web Editor Omar Filipovic tab-induced flutter in the past. Several amended operating limitations. Unless Cartoonist Robrucha airplanes, including the Avro Lancaster, the aircraft was bought locally, the Phase I ADVERTISING ARV Super 2, Short SD3-60, and flight test area would need to be changed, in Sr. Advertising Manager Chuck Preston DeHavilland Sea Venom used mass bal- case he ever wanted to do a major change. 805/382-3363 [email protected] anced tabs. For more technical detail see: Otherwise he would have to request a new “The Effect of Tab Mass-Balance on Flut- flight test area at that time. BUSINESS OFFICE Belvoir Media Group, LLC ter,” Reports and Memoranda No. 2418 535 Connecticut Avenue (http://tinyurl.com/gw26yf3). Grass Strips Norwalk, CT 06854-1713 I enjoyed the article [“Getting High EDITORIAL OFFICE Replacing Lost Documents Off Grass,” October 2016], but think 535 Connecticut Avenue I just read Mel Asberry’s column in the one item should be clarified. The author Norwalk, CT 06854-1713 August 2016 issue, and as a Designated states that “You can’t just mow off a [email protected] Airworthiness Representative, I have to piece of pasture and start landing there,” CIRCULATION disagree with one point. claiming that FAR Part 157 mandates Circulation Manager Laura McMann The question was whether an Ama- notification 90 days prior to starting SUBSCRIPTION DEPARTMENT teur-Built aircraft would need to be work. However, if operations are VFR 800/622-1065 placed back into Phase I flight testing only, and the intent is for use no more www.kitplanes.com/cs in the event of a lost airworthiness cer- than three days per week with no more P.O. Box 8535, Big Sandy, TX 75755-8535 For Canada: PO Box 328, Norwich, Ontario N0J 1P0 tificate. Mel’s answer was “No,” and than 10 operations per day, you are that a replacement certificate could be exempt from reporting. I would think REPRINTS FOR PUBLICATION AND WEB POSTING AVAILABLE issued with no other requirements. I this applies to most pastures. We have Minimum Order: 500 agree. However, Mel went on to say that many like this in my neighborhood. Contact Jennifer Jimolka, 203/857-3144 if the operating limitations were also Mark Varvayanis lost, the owner would be required to request amended operating limitations Reader Varvayanis is correct. However, Change of address? and will be issued the most current ver- FAR (157.1c) also specifies that the site is Missing issue? sion of the limitations. Subscription Question? to be “used or intended to be used for less I disagree that issuance of amended than one year.” Proving intent, of course, is Visit www.kitplanes.com/cs. operating limitations is required. The always tricky. It is also important to check Or call 800/622-1065 from the U.S. and Canada. owner may request that an amended spe- your local laws and regulations to see if they cial airworthiness certificate and oper- have additional requirements before start- Foreign 903/636-1112 or fax ating limitations be issued to introduce 203/857-3100. ing operations.—Ed. J

Web site Information: General homebuilt aircraft information, back issue availability, online directories ordering info, plus a Kitplanes® article index and selected articles can be found at www.kitplanes.com. Unsolicited manuscripts: are welcome on an exclusive basis, but none can be acknowledged or returned unless accompanied by a stamped, self-addressed envelope. No responsibility is assumed for loss or damage to unsolicited material. Kitplanes® (ISSN 0891-1851) is published monthly by Aviation Publishing Group, LLC, an affiliate of Belvoir Publications, 535 Connecticut Avenue, Norwalk, CT 06854-1713, Robert Englander, Chairman and CEO; Timothy H. Cole, Exec. Vice Pres./ Editorial Director; Philip L. Penny, COO; Greg King, Exec. Vice Pres./Marketing Dir.; Ron Goldberg, CFO; Tom Canfield, Vice Pres., Circulation. Periodicals postage paid at Norwalk, CT, and at additional mailing offices. Copyright ©2016 Aviation Publishing Group, LLC. All rights reserved. Reproduction in whole or in part is strictly prohibited. Printed in USA. Revenue Canada GST Account #128044658. Canada Publishing Agreement #40016479. Subscriptions: One year (12 issues) is $29.95 U.S. $41.95 in U.S. funds in Canada, includes GST. $41.95 in U.S. funds for Foreign Surface Mail or $57.95 in U.S. funds for Foreign Air Mail. Single copy price $4.99 U.S., $5.99 Canadian. POSTMASTER: Please send address changes and subscription inquiries to: Kitplanes®, P.O. Box 8535, Big Sandy, TX 75755-8535, or Canada Post: Return undeliverables to P.O. Box 2601, 6915 Dixie Rd, Mississauga, ON L4T 0A9 or call 800/622-1065. Kitplanes® is a registered trademark of Aviation Publishing Group, LLC.

4 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes You love to fly. Not spend money. Have we got an ADS-B solution for you.

The best is within your reach. Because there’s a Garmin ADS-B solution to fit any budget or aircraft. Your solution can be seamlessly integrated to your G3X™ Touch with remote-mounted options. Or if you’re not flying with G3X, simply add a GTX series ADS-B transponder to your aircraft, starting at $2,199*. You’ll get the full benefit of ADS-B with subscription-free weather and our TargetTrend™ and TerminalTraffic™ technology. It’s the most advanced, all-in-one ADS-B technology you can find at the most cost-effective price. So you sacrifice nothing to get the safety you want when you fly.

Discover the advantages of safety now. See which ADS-B solution is right for you at garmin.com/ADS-B.

Building a classic biplane for the next generation of aviators. By Tom Brusehaver

I really enjoy passing on the love of just because. When my granddaughter The first thing I needed was a sheet of aviation to young people. I fly Young showed some interest, I decided it would ⅜-inch AC plywood. None of the build- Eagles every chance I get and recently be worth pursuing. I hoped she would ing centers in my area stocked it, so I decided to immerse my granddaugh- appreciate the gift. special ordered it. I knew I needed AC ter in aviation. For her first birthday, The plans from Aviation Products are to get a smooth surface for the pilots to I bought her a plush Dusty Crophop- amazing—very detailed and complete. touch. A lower quality board would be per from the Disney movie Planes. They outline everything that needs to be too rough. I also bought the metal and a This year was her third birthday, and I done. Aviation Products also offers kits 1x10 board for the wheelpants and nose. thought she might be old enough for a for things that some builders may not pedal plane. feel comfortable fabricating. I thought I Control System, Landing Gear I bought the plans for a Christen would be able to fabricate the whole air- and Crankshaft Eagle from Aviation Products (www. craft myself. I have moderate woodwork- I started working on the gear legs and pedalplanekits.com) when my youngest ing skills, OK metal fabricating skills, the controls. The controls are made from son was about 3. I was still building my and adequate welding skills. I thought I thin-wall conduit, which is very easy to Cozy, so I didn’t have time to build both. could build the plane in about four to six fabricate. Cut the tubing to length and The Cozy took priority, and I never built weeks, so I backed up six weeks from her squash the ends where the bolts will the pedal plane. I hung on to the plans, birthday and got started. connect the parts together. There is a

6 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes Pedal Power

Landing gear and wheelpant parts with bearings. Fuselage after initial sawing with bulkheads in place. bellcrank that needs to be welded, so this Fabricating the crankshaft for the cloth to steam the area. I thought bend- was my first chance to try some welding pedals was a fun challenge. I had never ing the plywood fuselage sides would on this project. I did an adequate job, and tried to bend solid half-inch bar stock take hours. Using the method suggested, it came out quite strong, but I had things like that. Building a jig was the key, and it took about 15 minutes per side. I left out of phase, so it had to be redone. After using lots of heat at the bend locations each side under pressure overnight. getting all the controls done, I made the made it come out pretty accurate. After- With all the parts cut and fabricated, two cabane struts, again out of conduit. wards, cutting to length was done with I could start assembly. There was a fuse- Some bends around a squashed section in an angle grinder. One end is threaded lage assembly jig in the plans that was the middle where the wing attaches came for attaching to the drive wheel. ideal for getting everything square and out very nice. tight. That assembly was critical for Next, I started on the landing gear Fuselage, Tail Feathers and Wings later steps. A little gluing and clamp- struts. I followed the plans, and because The plywood showed up about this ing ensured the fuselage and bulkheads I hadn’t purchased the wheels, I didn’t time. The plans come with full-size tem- were assembled square in all directions. know how big the bearing was going to plates, so laying out the parts is easy. I The joint used for the rudder and hor- be. Once I found the right sized wheels, taped the templates to the plywood izontal stabilizer was perfect if cut cor- I found the plans were correct, and I was and traced them. Where the plans had rectly. I was shocked how tight, square, able to put the wheel bearings in place straight lines, I used a straightedge to be and well locked it was when I first dry without any modifications. The drive sure everything was as straight as pos- assembled it. I considered not gluing the wheel has both bearings removed and a sible. I did most of the rough cutting joint because it was so hard to get apart. nut welded to a washer for the replace- with a sabre saw, and then finish cutting I did finally get it apart and glued prop- ment. The nut screws to the pedal on a band saw. Some parts wouldn’t fit erly. The slot in the back of the fuselage crankshaft, and another nut has the in the band saw, so I put a finer blade in needed no additional trimming when I threads drilled out. Welding the wheel the sabre saw and cut closer to the edges. slid the tail assembly in place. was tougher than the conduit. The sheet The fuselage sides have dados for the Removing the fuselage from the jig metal used for fabricating the hub of the bulkheads and a bend just behind the only took a couple screws. I was able to lawnmower wheel is very thin, and the cockpit. I cut the dados on a table saw. work on the bottom of the fuselage at washer is about four times thicker. Man- The plans have you build a jig for the this point. There was a block that needed aging the heat was much harder. bend, then suggest using an iron and wet to be fabricated out of two pieces of

Sides are bent using an iron and wet cloth. Fuselage in jig for alignment. Initial assembly is square and tight.

Photos: Tom Brusehaver KITPLANES December 2016 7 plywood and four dowels for the bellcrank. Clamping and gluing allowed that part to come out strong, then it was screwed to the seatback bulkhead. Many parts are assembled with hardwood dowels, as the places where screws will penetrate the plywood from the side may cause the plys to split. The locations in the plans are exactly where they need to be to prevent the split and give a strong joint. I wanted to be flexible and wait until assembly before com- mitting to the dowel location, but the location worked out to be in the correct place every time. The wings and parts of the fuselage need the edges rounded. Using 80-grit Test fitting the control system. sandpaper and a good sanding block made all of the edges round. Most of the want to fiddle with things, there was might be shorter than others, so the plywood shaping was done by hand with nothing that should hurt them. gear legs have two sets of holes. The top the block. It wasn’t hard and gave me The gear legs went into the holes in holes allow the pedals to be closer to the control to not sand where I shouldn’t. the sides of the fuselage exactly where pilot, and the bottom holes allow taller The plans insisted on making every- they were drawn in the template. I pilots to have comfort. As the pilot thing soft for the pilots of this airplane. didn’t always get the holes in two parts grows, the position can be adjusted. Most of the screws were flush, with some exactly where the plans drew them, round head. The sharp pointy end never but the holes had enough tolerance to Wheelpants, Cowl and Tail Fairing protrudes where the pilot can come in allow assembly to be completed. The Fabricating the wheelpants and nose contact with it. The threaded bolts in gear leg has a wheelpant bracket as took some real woodworking skills. the landing gear struts were almost flush part of the design. This bracket is also Both the wheelpants and forward sec- when coming through the steel. Even where the crankshaft bearings attach. tion of the cowl are laminated 3/4-inch in places where little mechanics might The designer thought that some pilots pine boards that need to be shaped. I tried spokeshaves, chisels, and various planes, but settled on a power belt sander with 40-grit sandpaper for most of the shaping. The belt sander worked, but I am sure there would be better ways to do it. When I was done, I had a couple inches of dust on everything in the garage.

Wheelpants before and after rough shaping. Shaping with a sander leaves a mess.

8 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes By following the plans, the rear cover and mid cover fit well. Rough shape of nose bowl with cowling fitted and riveted. When all the wood was shaped and edges exposed for little pilots or mechan- The airplane was partially disassem- assembled, the sheet metal work began. ics to get cut on. Something didn’t quite bled before painting. The plans recom- The top and bottom of the cowl are cov- work out with my top cowl, and I needed mended using an aircraft paint, but I ered with an aluminum skin. The plans to split it and splice a section of scrap chose to use a common hardware store have patterns for all the aluminum parts aluminum to make half of the cowl fit. lacquer paint (Rust-Oleum). I sprayed as well. The rear part of the fuselage was I chose to rivet these parts together and the plane in my driveway using a large the first part I covered. The pattern was make it look like it was hinged. drop cloth and a simple paint gun. spot on and took no more trimming After painting there were items that than the instructions said it might. The Finishing Touches needed to be added. The cockpit is lined mid-cowl has a cabane strut through it All the wood needed to be sealed. A with a coaming made of air hose. There and required oval holes. This worried me; good, high-quality sanding sealer is rec- is also a bit of air hose above the cockpit metal to metal, there isn’t much forgive- ommended. I put on about 2½ coats, on the back of the top wing. I’ve seen my ness, but again the patterns were spot on. using all of a quart to cover the inside granddaughter bump her head into the The lower cowl was flared around the and outside of all the wood (the inside back of the wing, so this was an excellent exhaust area, and the bending tool was didn’t get a full coverage of the last coat). design enhancement. built according to the instructions. This The metal needed to be primed before The wheels and the wheelpants have bending tool was used around the edges of painting; I just used a rattle-can grey very little tolerance, but the welding, the top cowl as well, so there are no sharp primer for the steel and aluminum. crankshaft bending, and assembly had

Wings and wheelpants after painting. Fuselage after painting.

KITPLANES December 2016 9

Aviation Products Christen Eagle

Plans Price ...... $25.75 Kits ...... Available, contact manufacturer Estimated Build Time ...... Varies Number flying ...... Hopefully none Number taxiing ...... Too many to count Powerplant ...... LG-2 (Two legs) Auxiliary Powerplant ...... Grandpa

AIRFRAME Wingspan ...... 44 in Length ...... 55 in Maximum taxi weight ...... 70 lb Seating capacity ...... 1

PERFORMANCE Cruise speed ...... 3 mph (LG-2 engine) Maximum speed . . 8 mph (Grandpa’s running speed) Cockpit view shows the coaming made from air hose and VFR instruments on the panel. Range (no reserve) ...... 2 blocks Approved aerobatics ...... Groundloops the hardware in the various parts of the mind a plain white airplane. When plane. The birthday party was to be on the time worked out, I brought the Saturday, and I was still assembling late plane back and put the decals on. an accumulation of errors. Aligning the into Friday night. They really add to the looks and make wheel flaw opposite the crankshaft flaw At the party, my granddaughter’s best it a more colorful airplane. was the best way to make the tolerance friend jumped in first. Both my grand- In the end, I didn’t care if anyone acceptable. At worse, there was about daughter and her friend really seem to liked the plane; I really enjoyed build- 1/4-inch runout; at best, I got it down to like it. The seat only holds one, and they ing it. The building process brought me less than 1/8-inch runout. took turns for a while. Eventually one or back to building my Cozy, and it gave Reassembly took much longer than the other seemed to like wing walking. I me a sense of accomplishment every I anticipated. Many of the screws had hope it brings them many years of service. step of the way. The plans are very com- never been installed. I needed to be care- The decals didn’t arrive until the plete and outline everything that needs ful to not scratch the paint replacing day after the party. No one seemed to to be done. J Pilot Report Preflight is easy since the aircraft is below the pilot’s shoulder. Simply glance at the tires and pedals, and you’re done. Climbing in can be accomplished from either side. Standard procedure is to step on the wing, throw a leg over the side, step on the seat, and then the other leg can come in. The center stick and pedals are in mostly standard locations. The single-axis control stick (tailwheel only) minimizes any risk of stalls or spins. Control harmony is ideal, and stick forces are easy to manage. Basic VFR instruments add to the pilot’s ability to imagine how well things are going. Instead of a conventional throttle, power is regulated by dual foot pedals. At startup the pilot simply presses on the higher pedal to get pilot’s legs and the length of their attention span. Once the flight is the aircraft moving, and the flight can continue until nap time. The complete, the shut-down checklist is extremely short: standard LG-2 (two legs) engine is adequate for straight-and-level • Stop pedaling. travel at leisurely cruise speeds, but is somewhat underpowered • Let someone else have a turn. climbing hills. Auxiliary pusher power is activated by shouting out • Don’t leave the plane in the driveway or on the sidewalk. to Grandpa or a nearby parent. For aviators who are small enough to fit into the cockpit, few Range is typically about two blocks, with no reserve. Longer other aircraft are likely to be so much fun. flights are possible, but are typically limited by the strength of the —T.B.

10 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes

Resin Infusion Taking the next step beyond vacuum bagging. By Dan Horton In the beginning, there was Rutan. The The next evolution, vacuum bagging, The vacuum is maintained until the 1975 arrival of the VariEze at Oshkosh went a long way toward eliminating the resin solidifies, and after cure, the bag, introduced homebuilders to structural resin ratio problem. The fabric is posi- bleeder ply, and peel ply are removed composite construction and spawned a tioned and saturated in the usual way, and discarded. The result is a leaner flood of new designs. The fundamental while purposely erring toward resin- resin-to-fabric ratio, without an appre- method remains popular; foam cores rich. Saturation is immediately fol- ciable loss of strength. Squeezing the are hot-wired to shape, then covered lowed by bagging. First, a peel ply layer fabric plies together simply leaves less with glass or carbon fabric. Epoxy resin is squeegeed onto the wet surface, fol- void space for epoxy. is applied to the fabric using brush and lowed by a bleeder ply, then the entire Resin infusion is a natural progres- squeegee, and worked into the weave layup is covered by an airtight plastic sion. The difference is that the fabric until it appears to be saturated. Exactly sheet. The plastic can be a bag envelop- plies are placed in the mold dry, and how saturated is a key part of the learning the entire component, or it can be remain dry, while the vacuum bag ing curve. Too much epoxy and the fin- a single cover sheet sealed around the is assembled. After the bag is sealed, ished part is heavier than necessary. Too perimeter of a mold. In either case, a little epoxy results in a loss of strength. vacuum line is attached, and a pump The Infusion Gang, L to R: Dean Bugner, Innegra; Brian Gardner, Sigmatex; Jan Hanna, An acceptable resin-to-glass ratio for evacuates the bag. Atmospheric pres- Innegra; Jeff Starcher, Scott Bader Co.; Tony wet layup is generally thought to be sure squeezes the layup, consolidat- Piaggi, lucky Corsair builder; Jimmy Carter, about 50-50, but the target can be hard ing the fabric layers and forcing out homebuilder; Russ Emanis, Innegra; Steve to hit. In this detail, the simplicity of excess resin, which passes through the Spence, Lockheed Martin; Mark Shioleno, wet layup is both a blessing and a curse. peel ply for capture in the bleeder ply. TeXtreme; and Jim Glaser, TeXtreme.

12 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes vacuum is applied, and the dry layup is so predictable. For example, if you know infusion for the home shop. Tradition- compacted. Only then is resin allowed to how much resin was drawn from the ally, composite builders have been forced enter the bag through an inlet line. Dif- bucket to saturate a top right wingskin, to do large layups in work sessions with ferential pressure forces the resin to flow you know exactly how much to mix for friends, as mixing, saturation, and bag- across the mold and through the fabric the next three skins. ging is often more than one person can Resin Infusion plies, saturating them with just enough A builder who likes his shop clean do within the available resin gel time. resin to fill the voids between individual and neat will love infusion. The process Scheduling those friends can really delay fibers. When the resin flow reaches the introduces resin into the layup directly a project. Using infusion, a homebuilder outlet, the inlet is closed with a valve, from the mixing bucket, via a plastic can prepare a mold, lay fabric plies, and and as with ordinary bagging, vacuum is line, which eliminates drippy brushes then bag and vacuum check the layup maintained until the resin solidifies. and cups, and mixing of multiple small over the course of many days, working batches. It’s also a lot safer, as it limits entirely alone in work sessions of any Why Do It? skin contact, and the chance of develop- length. When ready, he can also do the There are quite a few advantages to ing a chemical sensitivity. Vapor exposure infusion without help, but his friends using the infusion process, and of is also reduced, a significant factor if the will probably come over to watch and course a few negatives. Let’s take a look. resin choice includes a risky ingredient. offer high-fives. As compared to conventional wet bag- Finding an air leak quickly can be a So what’s not to like? First, understand ging, most users report a slightly better frantic experience with wet layup bag- that infusion success is entirely depen- resin-to-fiber ratio. The key appears to ging. Resins have a gel time, and once dent on the setup, and every mold is dif- be better fiber compaction. The fabric mixed, the clock is running. Resin ferent. The first attempt (or perhaps the is squeezed while dry, rather than after must be applied, worked into the fab- first several) may fail. Although general saturation with a viscous resin, so there ric, bagged, and placed under vacuum principles always apply, trial and error is no need to squeeze excess resin out of before the gel time expires, or the whole may be required to determine the best the layup. An operator is not required setup is wasted. In contrast, infusion placement for inlet and vacuum lines. to judge saturation, a big factor when introduces no resin until after the bag Get it wrong, and the resin, which flows working with an opaque fabric like car- is shown to be air tight. As much time in a more or less direct path from inlet to bon, and there are no variations between as necessary can be spent chasing leaks; outlet, will bypass an area. You’ll need to different operators. Although infusion the bag can even be modified or dis- modify the setup and try again. has some additional setup cost, the uni- mantled if necessary. Familiar materials may require new formity can save money when working Actually, unlimited setup time is thinking, and there will be new materials. with large layups, because the process is probably the best reason to consider For example, infusion is generally faster Oshkosh Infusion Demonstration Builders had a unique opportunity to see a live demonstration of resin infusion during AirVenture 2015. The demo was a cooperative effort by a group of industry professionals, each contributing materials and knowledge. The result was a set of very light, non-structural fuselage shells for a scale F4U Corsair.

Corsair builder Tony Pileggi supplied the molds. Here composites Second ply, heavy-duty 400gsm Sigmatex non-crimp 12K pro Jim Glaser lays the first of three plies, 130gsm TeXtreme spread carbon. 3M Super 77 spray adhesive is used to tack the plies into tow. It’s a mix of carbon and Innegra olefin fibers. Carbon is stiff, place, in an otherwise dry mold. The third ply, a conventional strong, and brittle. Innegra adds fracture toughness (among 200gsm 0-90 plain weave carbon from Saati Composites, went other properties), a nice marriage. into the mold in a similar fashion.

Photos: Dan Horton KITPLANES December 2016 13 in loose weave and continuous fiberglass plies, and slower in tight weaves, or carbon and aramid fabrics. The bag setup may need to be adjusted for the different flow rates. Many reinforcement fabrics will require the addition of flow media, a ply which can be incorporated as a permanent core in the laminate, or as a disposable spacer added to the top of the laminate stack. If added as core, flow media may require engineering review by the aircraft’s designer. Resin choice may be the biggest change. Experienced homebuilders tend to Figure 1. Very basic resin infusion setup. Following dry assembly, atmospheric pressure become familiar with a resin system forces resin through the fibers. and stick with it (pun intended) for- ever. However, the popularity of infu- After cleaning, sealing, and the appli- flow media will probably top off the ply sion in commercial production (notably cation of a release agent, the first fabric stack, if one was not incorporated into boat hulls and wind turbine blades) has reinforcement ply is laid into the mold. the laminate. spurred the development of low-viscos- Unless the mold is flat, the fabric will The arrangement of resin supply and ity structural resins designed for free try to slide around and pile up in the vacuum tubes must be carefully con- flow. Compared to typical laminating bottom. To tack the fabric into place, sidered if resin is expected to flow to all resin, these infusion resins may seem the mold can be dusted with a very areas of the laminate. Supplying resin at like water. A builder may be uncom- small quantity of 3M Super 77 spray individual points won’t work. Instead, fortable when faced with unfamiliar adhesive where required. Used in small resin is introduced through a spiral cut labels and new mixing ratios. amounts, it won’t interfere with the plastic tube, which extends across the resin bond. Second, third, and subse- entire length of the mold. Resin fills the A Typical Infusion Setup quent reinforcement plies are stacked in tube, then flows out through the spiral Although not strictly required, most the mold just like the first, again using cut all along the length in a relatively even resin infusion is done in a prepared very small quantities of spray adhesive fashion. To improve flow in the immedi- mold. Building plugs and molds is as necessary. Depending on laminate ate area of the tube, it can be wrapped in beyond the scope of this article, so for design, one of the intermediate plies a strip of flow media before placement. now, merely note the Golden Rule of may be a flow media. The layup is -fin Vacuum tubes are placed around the Moldmaking: Time spent creating a ished by adding the disposable plies, mold perimeter, parallel to the sup- perfect mold pays a huge dividend later. starting with a peel ply or release ply. A ply tube(s). The sections of vacuum

Hot glue gun is used to attach MTI (Membrane Tube Infusion) …the peel ply can be added, trimmed, and tacked down at the vacuum hose to the perimeter of the mold. It only needs a dab edges, just outboard of the MTI hose. here and there, just enough to keep it in position until…

14 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes New Materials for Homebuilders Let’s face facts. We homebuilders tend to get stuck in the familiar, The mixed fibers also exhibit improved energy dissipation and vibra- which means we’re still using 1980’s vintage materials and meth- tion damping; carbon alone has little of either. ods. It was interesting to see the choices brought to the AirVenture The Sigmatex 400gsm 0-90 center ply takes the “no crimp” straight demonstration by industry professionals working on the leading edge, fiber concept to the max, which is interesting for those who think notably the reinforcements and resin. of fabric as a woven product. It is actually two layers of side-by-side unidirectional fiber tows, with the layers at 90 degrees to each other. Carbon and Innegra They are sewn together with just enough thread to maintain fiber Quite a few eyeballs will pop at the physical appearance of TeXtreme alignment; there is no over/under weaving at all. carbon/Innegra spread tow fabric (it has a serious “cool factor”), but The SAATI 200gsm 0-90 is a conventional over/under woven cloth. the appearance is really a sideshow. The science is far more interesting. The weave is relatively open, thus a good choice for the inner fabric A “spread tow” forms the fibers into a ribbon, rather than a round fiber layer closest to the flow media. As a plain weave, it offers a uniform bundle. A very thin ribbon lays relatively flat when woven in a classic appearance, and when infused using peel ply, it is a suitable surface over-under fabric pattern. The increased thickness of round fiber bundles, for subsequent bonding. on the other hand, crimps the tows into something more like a sine wave in order to pass over and under the equally thick perpendicular tows. Urethane Acrylate Resin When a stress is applied to this wavy tow, it tends to first straighten and Urethane adhesives have become popular, but so far, few builders lengthen before the fibers can really accept the load. The increased as- have worked with a urethane structural resin. The key reasons to do woven straightness of spread tow ribbon fabric translates into increased so are cured toughness and increased adhesion. Cautious builders will stiffness in the finished product. The ribbon weave also has less void space obtain an engineering review before building major components with and thus requires less resin to fill. Resin-to-fabric ratio is improved, too. a new resin system. However, those who wish to gain familiarity with The carbon fibers in this TeXtreme product are conventional, and urethane resin will find that its high impact resistance makes it an contribute the usual high specific strength and stiffness to the fabric. excellent choice for wheelpants, gear leg fairings, and wingtips. The general problem with carbon is that it is brittle; it has little or no The particular urethane resin demonstrated here is called Crestapol plastic region when approaching failure. Exceed the allowable stress 1250LV, from Scott Bader Co., a global supplier of resins and chemicals. and it snaps without warning. Intended for infusion, 1250LV’s viscosity is only about 200 centipoise, three The traditional approach to an improved failure mode (parts bend, to five times lower than a typical laminating epoxy. This particular formula delaminate, and eventually break, rather than shatter) has been to is optimized for adhesion to carbon. It can be purchased from Composites mix materials at the fabric level. For example, a mostly carbon lami- One (www.compositesone.com), or directly from Scott Bader Co. nate may have a ply of glass or aramid fabric somewhere in the layup. Here the approach is to combine a high modulus fiber with a tough, For More Information: ductile fiber by co-mingling yarns at the filament level. The addition of TeXtreme: www.textreme.com • Mark Shioleno, 803-522-0794 (North America) Innegra fibers brings several very desirable properties to the finished Innegra Technologies: www.innegratech.com • Russ Emanis, 864-631-2800 fabric. Innegra is roughly half the density of PAN carbon, so it doesn’t Sigmatex: www.sigmatex.com • Brian Gardner, 864-617-8311 add significant weight. Its stiffness is about 20 times lower, and its SAATI: www.saati.com • 864-601-8300 (Americas) elongation at break is about five times higher, so even when failing, a Scott Bader Co. Ltd.: www.scottbader.com • Jeff Starcher, 765-635-7521 carbon/Innegra laminate tends to remain intact and offer a warning. —D.H.

Next the resin inlet lines are added to the stack. Three spiral cut Next is a ply of green plastic mesh flow media, followed by the bag- plastic hoses are wrapped in a strip of plastic mesh flow media. ging film. The bag is sealed all around the mold perimeter with yellow One hose is placed in the bottom of the mold, and the other two sealing tape. Non-perforated inlet and vacuum hoses are joined to are placed about halfway up the mold wall. They’re tacked into the spiral cut hoses inside the bag, and the exit points are also sealed place with ordinary masking tape. with tacky tape. Vacuum pump on, no leaks found…we’re ready!

KITPLANES December 2016 15 Terms tube that will be imbedded inside the Resin: Any polymer matrix material with a suitable uncured viscosity and acceptable bag are also spiral cut. There are two mechanical properties when cured. In general, resins cure by combining them with a types, bare tube, and Membrane Tube hardener or catalyst. Polyester, epoxy, and vinylester resins are familiar to homebuilders, Infusion (MTI) hose, which adds a but there are a wide variety of other choices. two-part sleeve of non-woven bleeder ply material and a semi-permeable Vacuum Bag: Generally an airtight plastic film. The most basic might be an ordinary membrane around the cut plastic core. kitchen garbage bag, while complex contours might require a special stretch film, or even Plain spiral cut will allow excess resin a custom made rubber bag. into the tube itself, where it will flow Peel Ply: A disposable layer of polyester or nylon fabric, saturated with resin just like the toward the vacuum pump. MTI hose underlying layup. Peel ply is ripped away after cure, leaving a fractured resin surface on the attempts to block this flow; the mem- workpiece, ready for subsequent bonding. Ordinary polyester aircraft covering fabric works brane is very similar to common Gore- fine in the low-volume home shop. Professionals use specially prepared fabrics, including Tex fabric, which passes gas molecules, nylon fabric for high-temperature applications. Peel ply is used in non-vacuum wet layup, but not liquid. or with conventional vacuum bagging, or with resin infusion bagging. The allowable distance between the Release Ply: Used like peel ply, but made of a perforated plastic film. When removed after inlet and outlet tubes is governed by cure, the surface of the underlying part is generally smooth and slick. Release film is easily how easily the resin can flow through removed, as it does not bond to the surface of the part. the combination of materials in the laminate. A typical distance might Bleeder Ply: The common bleeder is a layer of unwoven, fluffy polyester batting. It is be two feet, but can be more or less. stacked on top of the peel or release ply in standard vacuum bag setup, where it serves two A small mold may work well with the purposes. First, it provides a pathway for air to reach the vacuum outlet. Second, it soaks up resin inlet tube along one edge, and excess resin when it is squeezed from the layup, and forced up through the peel or release plies. Bleeder plies are rarely used in resin infusion setups. the vacuum tube on the opposite edge (Figure 1). If the mold is four feet wide Sealant Tape: Soft, tacky synthetic rubber tape, commonly about ½-inch wide and 1/8-inch or less, a single inlet tube laid along the thick. It sticks to mold surfaces, plastic tubing, and bagging films on contact, creating an centerline may work well, as resin will airtight seal between two materials by merely squeezing them together. Different degrees flow toward both perimeter vacuum of tackiness are available under many trade names. tubes simultaneously. Wider molds may Flow Media: A material designed to facilitate resin flow across the mold face. A flow media require multiple parallel inlet tubes. ply may be incorporated into the finished part as a core, or it may be a disposable ply, Resin is supplied via the first until flow ripped from the part surface with the peel ply after cure. Flow media is usually nylon or reaches the second. The first tube is then plastic mesh less than 1mm thick. Most can be disposable, or used as core. Scored foam type clamped off at the source, and resin is flow medias are usually thicker, and are intended to remain as core. supplied through the second tube, from —D.H. where it can flow an additional distance

Jeff Starcher, from resin supplier Scott Bader Company Ltd., serves as And we’re off! The center inlet hose is submerged in the resin mixmaster. This is Crestapol 1250LV, a tough, low-viscosity urethane bucket, the valve is opened, and atmospheric pressure forces acrylate resin designed for carbon fiber infusion. It is hardened with resin into the mold. an MEKP catalyst, Triginox 239. Gel time at 77°F is 37 minutes, which tells a lot about how quickly the laminate will be infused.

16 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes toward the outlet. The infusion setup can be constructed with as many parallel inlet tubes as necessary, so that resin is never required to flow an unreason- able distance from any one supply tube. With the laminate and disposable components in place, everything is enclosed under the plastic bag layer. The perimeter is sealed to the mold surface with sealant tape. The spiral cut resin and vacuum tubes are connected to seamless tubes, which exit the bag at sealed points in the perimeter. Inlet tubes extend to the resin bucket. Vacuum tubes run first to a catch pot, then to the vacuum pump. The catch pot captures resin flowing from the mold before it can reach (and The end result: Here’s the surface of the laminate after removal from the mold. Note lack ruin) the vacuum pump. of voids and bubbles. Black fibers are carbon, white fibers are Innegra olefin. Let The Fun Begin! in the bucket, and open the inlet valve. pot was prepared with a mold release Start the vacuum pump, and give it time Make sure the end of the hose does not agent prior to use, any cured resin there to evacuate the bag. Make sure the sys- rise above the surface of the resin and will also pop out. Salvage all valves and tem pulls a full 29 inches Hg, or close to suck air during the infusion. Watch the fittings. The plastic lines, peel ply, exter- it. Less indicates a vacuum leak, which resin fill the spiral cut inlet hose, then nal flow media, sealant tape, and bag- will need location and repair. There is flow out into the surrounding strip of ging film are simply thrown away. no rush; many experienced fabricators flow media, then into the laminate and feel additional time spent under vac- creep toward the vacuum line. When Just Do It uum (prior to introduction of resin) is the laminate is saturated across the full Remember, we build our own airplanes beneficial. It tends to remove solvents width of the mold, close the inlet valve. for education and recreation, just like and moisture from the laminate, and Allow the vacuum pump to continue it says in the rulebook. Next time you offers an opportunity to inspect for running until the resin cures to solid. need to build a composite panel, set folds, bridging, and slipped fabrics. There isn’t much cleanup. Cured your brush and squeegee aside, and give When everything is ready, mix the resin in a smooth, clean plastic mixing infusion a try. You’ll surely learn some- resin. Submerge the end of the inlet hose bucket may just pop out. If the catch thing, and that’s always fun. J

Everyone loves it when a plan comes together. TeXtreme’s Jim There were a few dry spots, but these guys had a trick. Just pull Glaser, manning the bucket, allowed the flow to move up the and release a fold in the bagging film to “pump” resin into the sides to the midline inlet hoses before opening their feed valves. dry area. Experienced operators may also use a vacuum needle (a The flow easily continued up the sides toward the MTI vacuum small probe connected to the pump tubing), which can be poked hoses. Here it’s almost to the top. through the bag to focus vacuum on a dry spot. As the probe is withdrawn, the hole is sealed with a bit of tacky tape.

18 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes Panels in Days, Not Months

Pre-built panels are an easy way to save time and eliminate frustration during avionics installation. By Bruce Eicher

If you are planning a building proj- most when we ultimately fly our labors acquiring components, designing the ect, building now, or have been flying of passion. (Well, look out the window layout, cutting, fitting, wiring, install- your plane more than a few years, you more—unless you are flying IFR.) ing, then testing and troubleshooting are probably thinking ahead about a Experimental avionics are changing to get the panel I desired. Among other new instrument panel. I remember at a record pace, so the panel should be challenges, my intercom, headset jacks, forecasting and drafting my instru- the last purchase decision of the proj- and radio interfacing with the EFIS ment panel years ago, before I had ect. If you are anything like me, you was a real pain. I was getting so close even driven the first rivet in my RV-8. have spent the better part of five years to breaking something…other than the Many plan this well in advance of the building an airframe, rigging control bounds of gravity! airplane build sequence because the surfaces, installing an engine, maybe Now, for a reasonable price and a quick panel contains the toys, bells, whistles, painting and, of course, anxiously and easy install, there is a good solution and fun stuff to make our airplane go. dreaming of the day you get to fly. I spent to this often frustrating and always time- It is what we will be looking at the weeks—which turned into months— consuming project: the Quick Panel

Photos: Bruce Eicher KITPLANES December 2016 19 In one neat box is a complete panel system built for you. This is It will take longer to unwrap the components than to plug them one of the many exciting crates you open during the building into the ACM. The clearly marked harnesses make it easy to com- process, but this one has more instant gratification than any other! plete your avionics electrical connections.

System from Advanced Flight Systems. More monitoring features were added transponder, ADS-B, com radio, GPS, After spending some time with Rob to the system over a few short years, autopilot, engine monitor module, Hickman, founder of AFS, and witness- including angle-of-attack, attitude and and a lot more. The laser-cut alumi- ing his “ten days before Oshkosh” panel heading reference, autopilot, GPS naviga- num panel and sub panels are powder- upgrade (see sidebar), I became more tion, and communications integration. coated and custom silk-screened for a curious about the Quick Panel System, This made the AFS system a complete professional finish. Switches and com- so a factory visit was in order. EFIS glass panel. In July 2013, Dynon ponent trays are pre-mounted right Avionics and AFS joined forces, with out of the box. A Little History the acquisition of AFS by Dynon. The key component at the heart Back in the ’90s, most airplanes were of the Quick Panel System is the built with many round, single-purpose And Now Advanced Control Module or ACM. gauges. Rob Hickman built his own In July 2014, AFS announced the It integrates circuit protection, panel RV-4, but wanted a better, more complete Quick Panel System (QPS), a line of dimmer controller, flap controller, trim engine monitoring system than was cur- complete pre-built avionics panels. The controller, wig-wag light controller, rently available to fit a small panel. With panels are professionally wired, con- EFIS networking and a panel switch his background as an electrical engineer figured, tested, and ready to install in interface. AFS manufactures harnesses and software expertise, he made his own many popular kit aircraft. that go from the avionic components monochrome screen engine monitor. You can choose a VFR or IFR and simply plug into the ACM, which Other Experimental pilot friends asked panel designed around either the AFS is mounted on the forward sub panel, Rob to build them one, and then the AF-5600 Touch system or the Dynon low under the main panel. The ACM owner of a local avionics supplier told SkyView D1000T Touch system. In also contains 22 channels of circuit pro- Rob that if he produced them, he would addition to dual 10-inch touchscreens, tection in the way of blade-type fuses. sell them. So in 2002, Advanced Flight the panels include an air data/attitude/ In the unlikely event of a blown fuse, Systems was born. heading reference system (ADAHRS), you do need access to the bottom of the

Less than 15 minutes from crate to a working panel, including GPS signal. The two small subpanels laid down are for air vents and the pre-wired headset plugs.

20 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes A full IFR panel system will have six or so remote mounted sub- On another table, a quite capable VFR panel using Dynon panel components as seen here behind the main panel. Mounting SkyView touchscreens. If you add IFR capability later, the ACM these, plus antennas, engine and air sensors, and servos will take is ready to plug and play. the bulk of your system install time.

ACM for changing the fuse, once you opened on chest-type hinges, revealing done this before. But if you can hook have determined why it blew. the goodies inside. This was an actual up a computer system to its monitor, QPS shipment that we were going to speakers, and printer cables, you can do The Factory Demo quality control. We picked up the chest this too, and it may even be easier. Jef- I met with Jeffrey Hickman, son of Rob, and moved it to an empty table. Jeffrey frey explained that the majority of the at AFS. Buzzing in the background was pulled out the panel, along with each time will be spent mounting the remote a CNC milling machine making heat- of the modules and components, tak- modules on the subpanel; we just laid sinks for the EFIS systems. In the shop, ing more time to unwrap them from them on the table for this test. You two employees were at benches produc- the shipping bubble wrap and boxes would also need to do some crimp pin ing harnesses to be used to connect the than to slide and screw them into their connector construction for the servos panel components through the ACM. home on the panel and plug them into and engine and air sensors—supplies On top of several worktables were com- the ACM. are included. plete panels loaded with their magic All components for a complete IFR boxes. Jeffrey explained to me they were system were there (including a stand- Is It Worth It? waiting for their custom-built harnesses alone certified IFR GPS unit), but We are do-it-yourselfers or we wouldn’t to be completed. Then, they will be excluding the items a customer has most be building our own airplane, right? plugged in, powered up, and a complete likely already purchased and installed, But I have learned the hard way that array of tests will be performed with such as servos, engine and air sensors, you have to choose your battles to fight all modules. The customer gets a pro- and external antennas. In less than 15 or hats to wear. Like scratch building fessionally engineered, pre-calibrated, minutes from opening the box, Jef- or painting your airplane, you could thoroughly tested and proven system frey fired up the system. The big EFIS save some money doing it yourself, with the QPS. screens booted up, maps loaded, and we or you could waste time and material We made our way to a crate about even had GPS-source navigation in the when a mistake is made. Actually, after the size of a hope chest; in fact, it building. Now in all fairness, Jeffrey has adding up the costs of the individual components, it’s not much more to let AFS build you a Quick Panel. Because AFS and Dynon are also manufacturers of many of the components (not just a panel shop), the savings is passed on to the customer. And in a world where time is money, you’re not spending yours sourcing the components sepa- rately, building your own harnesses, and fussing with the connections. So, if you wish to get-’er-done—and done right—this is one of many good short- cuts available in the kit-built industry. For more information on products, ser- The forward sub-panel shown here is part of the airframe structure. It’s a good place to vices, and prices visit www.advanced- mount remote components and the ACM. (Photo: Rob Hickman) flight-systems.com.

KITPLANES December 2016 21 Rob Hickman’s 10-Day Personal Challenge Most homebuilders, in the last week or two before flying their pride and • Add new Aerosport Products RV-10 carbon-fiber three-screen panel. joy into the big fly-in, would only be installing some small, last-minute • Replace Garmin SL30 with an Avidyne IFD540 GPS navigator. addition, finishing a minor detail, or giving their polished aluminum • Replace AFS AF-5500T EFIS with three AF-5600T EFISes. a quick touch up. But not Rob Hickman, founder of Advanced Flight • Remove the Vertical Power module and add an AFS Advanced Systems (AFS). Rob decided his RV-10 should be proudly on static display Control Module (ACM). with a new three-screen, two-nav/com glass panel with all the latest • Replace old component wiring with AFS plug-and-play harnesses. bells and whistles. And he announced this personal challenge on a public • Wire trim servos to the AF-AP control module for auto trim and builder’s forum 10 days before his scheduled departure to Oshkosh! speed control. But why stop at just a complete panel rebuild? Rob also stated he • Rewire flap motor to use the Advanced Control Module. would be installing a complete four-seat interior upgrade with leather • Remote mount a PS Engineering PAC15 audio panel. seats, side panels, carpet, and center console. Forum responses to this • Add USB charging port. announcement ranged from “Knowing what a job this is, all I can say is • Install new Aerosport center console and throttle quadrant. ‘Wow!’” to “He’s renting a C-172 to go to Osh.” • Remote mount fuel selector valve. What motivates a person to reach farther or faster than seemingly • Add second ADAHRS. possible? Here’s Rob’s explanation: “We get a lot of calls and emails • Install new Aerosport seats, carpet, and side panels. from people who want to upgrade the panel in their RV. The big questions are, ‘How long does it really take?’ and ‘How hard is it?’ It’s been All in 10 Days’ Work a few years since I changed the panel in my RV-10, and we now have 10 The first task was to remove the old panel, along with center console, days until it leaves for Oshkosh. After flying the new Avidyne IFD540 seats, and side panels. With the unwanted wiring removed, the run- in Van’s new RV-14 and in a Glasair Sportsman, I really want one in my ning total on the panel upgrade hour meter was 2.0. RV-10. Aerosport Products has a new carbon fiber RV-10 instrument Next, Rob removed the VPX power module and Dynon SV Network panel that has room for three AF-5600T 10.4-inch EFIS screens and the hub from the sub panel (both of these items are in the Advanced Con- new big-screen IFD540. Installing our new Advanced Control Module trol Module). He also removed all wiring from the EFIS screens, GTN- will make the wiring easy—at least that’s what we tell people.” 650, VPX, SL30 and ARINC converter. All of this wiring gets replaced So, with a large portion of the Experimental population following with the AFS plug-and-play harness assemblies. his progress, Rob outlined the job and got to work. Here’s what he With the old gear removed, it was time to install the Aerosport hoped to change in just 10 days: Products aluminum panel backing plate and test fit the new carbon fiber

Rob’s RV-10 “old” panel before the upgrade. It was more advanced After day one the panel is taken out, along with the center console, and capable than 90% of the small airplane fleet operating today, seats, and side panels. I would guess.

The Vertical Power module and Dynon SV network hub were Rob’s son Jeffery takes his turn working with the wiring, while Rob removed from the sub-panel; both of these items were replaced is tossing more and prepping the new carbon fiber panel. with the Advanced Control Module.

22 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes panel and center console. Rob also checked the fit of both large screen control module, and the Avidyne IFD-540 NAV/COM/GPS. I then installed EFISes, both GPS navigators/com systems, and the new throttle quadrant. the fuses in the ACM and flipped on the master and avionics switches.” Things were taking shape quickly, and the total hour reading was 6.0. There was still a lot of work to do before Oshkosh, but over the next sev- At this point, Rob was quite positive about his progress. He eral days, Rob was able to wire the trim servos, starter, alternator, GTN650, reported to the forum, “It looks like I will not need that 172. It’s been control sticks, strobe lights, nav lights, and AP servos to the ACM module. three days since I started the panel upgrade in the RV-10 and it’s prov- He needed to remote mount the PS Engineering PAC15 audio panel. With ing to be far easier than I even imagined. Last night, in a few hours of these tasks completed, the panel upgrade hour meter was reading 12.0. work, I managed to install the Advanced Control Module, wire power By day nine, the RV-10 was almost ready for Oshkosh. In addition to and ground to it, and bolt the new instrument panel in for the final the tasks mentioned above, Rob also installed new engine cables and time. The new Aerosport instrument panel fit perfectly and all the two Tosten grips. He told the forum, “The new panel and interior look holes lined up just right. spectacular and we are looking forward to showing it at Oshkosh.” “It took about an hour to wire the Aerosport panel switches to the On day 10 Rob made four flights with the new panel, and all systems ACM module. If I had used our Advanced Switch Modules, it would have were working great. He even flew two different GPS approaches with only taken a few minutes to plug the switch PCB board ribbon cable both the IFD540 and the GTN650. into the ACM. It then took less than 15 minutes to plug in the harnesses A new panel and interior in just 10 days? Mission accomplished. J of the 3 EFIS screens, 2 ADAHRS, Mode S transponder, ADS-B receiver, AP —B.E.

An aluminum backing plate is installed on the existing nutplates Late on day two, with the new carbon fiber panel installed and the that will be covered with the molded carbon fiber panel. Here AFS Advanced Control Module mounted on the sub-panel, Rob is you can see some of the remote components of the EFIS system. ready to start the rewiring.

End of day three, and Rob has the panel rewiring done, the EFIS New Aerosport seats, center console, and side panels installed in and nav/coms installed, and the components plugged in and Rob’s hangar. powered up through the Advanced Control Module. The system was even getting traffic in the hangar.

Completed panel, new sticks, side panels and center console. If Yes, Rob and his RV-10 did make it to Oshkosh as planned, with the you look closely, the map screens show KOSH as the location. new panel and interior.

KITPLANES December 2016 23 Pick a Plane,

Introduction by Paul Dye Any Plane…DIRECTORY compiled by Omar Filipovic

24 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes By my count, the KITPLANES® online Buyer’s Guide con- Buy It or Build It? tains more than 1000 different designs for homebuilt aircraft. A question we hear quite often is, “Should I buy or should I In fact, the complete list is probably the largest single listing build?” Quite frankly, the commitment required to build an of homebuilt aircraft you’ll find anywhere—which is one of airplane from plans or an early kit is monumental enough the main reasons that the printed directory you are holding in that the answer most experienced homebuilders give is, “If your hands contains only the summary data for the many air- you have to ask the question, you definitely should buy!” That planes and rotorcraft that you might be thinking of building. pat answer—recognizing the reality of the amount of effort So many airplanes, so little space—and we’d like to make sure and commitment that goes into a traditional build—is slowly that we share them all with you! Whether you are planning beginning to be a little less definite in some people’s minds. to start a new project or doing some comparison shopping for With aircraft kits becoming more and more complete, plans buying a completed airplane, the printed directory will get you and manuals becoming well illustrated with clear, step-by-step started, and the online details will help you decide. instructions, and a wide community of knowledge spread on Building an airplane yourself is something that the vast the internet, airplane building is becoming easier. Yes, it still majority of the population probably considers impossible. If requires a huge, usually multi-year commitment of time and you’re reading this though, you are not in the majority. You’re effort, but it’s not like the old days when you had to start with a dreamer, a doer—someone who is willing to live outside the the seed from a Sitka spruce to grow the tree to carve your spars. norm and pick up the tools and skills necessary to carry those Choosing an Experimental aircraft—either to build or dreams off the surface of this planet. The Experimental com- to buy—is something that should take time. This directory munity is large, and at last count, the FAA estimates that they will give you a good start and encourage the dream, but then have licensed well over 30,000 homebuilt aircraft since the the real work will begin. Not that the work is unpleasant, category was created. A very large percentage of those are still of course. Going to fly-ins, traveling to kit companies, and flying (or flyable), and more and more change hands each year meeting others with similar dreams is not a bad way to spend as their original builders turn them over some time. And the time spent choos- to a new generation of pilots willing to Tucano Replica ing the right aircraft is valuable beyond care for and enjoy them. So we serve not measure. It is a sad thing to see someone Flying Legend’s 70% Tucano replica has only the primary builders, but the resale charge deeply into a project with a huge military origins, but is powered by a market as well. commitment of time and money, only Rotax engine and can be built to meet LSA requirements. It can also be built with fixed or retractable landing gear. See the May 2016 issue for details. (Photo: Edwin Borremans)

KITPLANES December 2016 25 to discover that it isn’t exactly right for them. Sometimes, the set of requirements. Once you have those requirements, the problem is unforeseeable—the loss of a medical for instance. directory can help you quickly eliminate a lot of aircraft and Other times, the need for a larger airplane comes along with a help you focus on those remaining that might fit the bill. growing family. Sometimes this could have been seen coming, other times not. More Decisions Many potential owners shop for a plane or project by look- Other important questions relate to construction tech- ing at all the shiny ads or their neighbor’s hangar before clearly niques and materials. Do you like to work with metal, defining their needs. It is not unusual to see a very expensive, wood, composites, or fabric? If you decide to go the “build well-equipped IFR machine that never leaves the vicinity of it” route, having an idea of what kind of construction you the airport—and the builder isn’t quite sure how his treetop want to spend a couple of years with is important. Just flyer project morphed into such a complex monster. remember—building an airframe structure is only a small For this reason, we feel that before you get serious about part of getting an airplane flying. Wiring, plumbing, and choosing a flying machine, take some time to write down control work is going to be similar in almost all cases, and your real requirements. Don’t worry, it’s more than OK usually takes new builders as much—or more—time as to leaf through the pages of the directory and explore the making the kit look like an airplane. details in the online Buyer’s Guide. But before you start Do you have an engine preference? While most aircraft are eliminating options, put it all down and scribble what you designed around a particular powerplant, many can be con- see yourself actually doing with the airplane. Honesty is the verted for other propulsion systems. In fact, many builders best policy—especially when dealing with your own wants find that to be the most interesting thing they do. Going with and needs. Will two seats do, or do you need four…or maybe non-traditional powerplants frequently means that it will take just one? Will you be setting out for a fly-in breakfast in the longer to get to a flying airplane, but many feel that the rewards immediate neighborhood, or striking out across the country of solving problems and coming up with innovative solutions on a frequent basis? Do you have a large airport handy, one more than make up for the extra time. Even going with a larger with lots of pavement and a tower to talk to, or do you live version of an engine designed for the airplane can lead to chal- near a grass strip with cows on the other side of the fence lenges in things like cooling, so keep that in mind if you pick and an old hangar full of Cubs that have never seen a radio? the perfect airplane, but feel it needs just a little more power. Will you be flying in and out of back-country strips on a Airplanes designed around a specific mission will invari- regular enough basis to need a true STOL machine, or will ably be more difficult to adapt to other tasks. A STOL air- the thought of flying a thousand miles plane capable of touching down and at 100 knots to get to those mountains stopping inside a ballpark is probably in the first place steer you in another SuperSTOL XL not going to go 200 knots. You’re also direction? Figuring out where you want While the standard SuperSTOL is going to have a difficult time cramming a to go, followed by how fast you want powered with a 100-hp Rotax 912, full IFR panel into an airplane designed to get there, and how much you need the Stretch XL model mounts the for simple VFR cruising. It can be a to carry—those are the beginnings of a new ULpower 520i rated at 180 hp struggle squeezing one of the modern and has a two-foot longer aft fuselage. See the January 2016 issue for details. (Photo: Richard VanderMeulen)

26 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes Carbon Cub EX What could be more fun than flying a big-screen EFISes into great plane to a beautiful mountain the low side when assuming what you the panel of a tandem lake surrounded by pine trees? With might put into your airframe. aircraft, so think about what avionics the amphibious-float-equipped Carbon With mission and a budget in mind, you might want while still selecting an Cub, that is exactly what you can do. At it is time to start thinking about the air- airframe—it’s all intertwined. the end of the day, you can fly back to planes you’d like to work on and be seen your favorite landlocked airport. See in. There’s a huge variety of choices, and The Bottom Line the March 2016 issue for details. while there might be a few bad ones, the With very few exceptions, cost is usu- difficulty most face is the plethora of (Photo: John Bliss) ally a significant driver when choosing good ones. Optimizing is something that an airplane or a project. Many people you can spend a lot of time on—some- shop on the price of a kit, and expect that to be their major times to the point where you never pull the trigger. In the end, expense. The truth is, we generally divide the projects into you have to decide what you want to see when you open the thirds: one-third is the kit price, one-third is the powerplant, hangar door, and what you will enjoy once it is in the air. and the remaining third is for avionics and interior. Oh... Use the Homebuilt Aircraft Directory to help you find as that doesn’t leave anything for paint or finish, so keep that much information as you can, then go shopping. Try to fly the in mind as well. Finished prices listed in the directory are planes at the top of your list, and contact the builder and owner provided by manufacturers, so make sure that when you get community for the type. Evaluate the kit company as well as down to discussing particular models, you understand what the airplane—you’re going to be spending a lot of time tied to their estimates include. Some manufacturers are very up them as you build. Don’t be afraid to dream, but make sure front about building costs, and others tend to be a little on that you stay honest as well. Aircraft Buyer’s Guide Online Access This year the online Aircraft Buyer’s Guide follows the format we Here’s how it works: Newsstand buyers should visit www.kitplanes.com established a few years ago and provides many useful features for and click on the “Buyer’s Guide” button. This will take you to the Buyer’s users. Among them is the ability to do side-by-side comparisons of Guide access page. Click on the “Create Newsstand Buyers’ Account" but- more than one aircraft using various selection criteria. Unlimited ton, and that will take you to a signup page. The access code is kit17. This access to the online Buyer’s Guide is free for subscribers, but for a will give you 30 days’ access (from signup date) to the online Aircraft limited time only, we are offering non-subscribers a chance to sam- Buyer’s Guide and will also allow you to explore the entire KITPLANES® ple the site, too. web site. So go log in and have a look around.

KITPLANES December 2016 27 Y Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price A-Air LLC (X-Air LLC) www.x-airlsa.com X-Air F 2 900 75 60 28 K  $22-27k ▼ X-Air H 2 1234 106 81 28 K $25-30k

X-Air S (Standard) 2 902 75 63 28 K $21-25k

AC Millenium Corp. www.arvcorp.com Griffin IV 2 1730 160 150 45 K

Griffin Mk III 2 1730 170 150 45 K

ACD IRECTOR www.klscomposites.com SQ-2000 4 2250 250 215 K $85-125k

SUA-7 7 5600 160 160 70 K D

Ace Aircraft, Inc. www.aceaircraft.com Baby Ace 1 950 110 100 35 K/P  $35-75k t ▼ Junior Ace 2 1320 115 109 38 K/P  $37-78k

af Aceair SA www.aeriks.com Aeriks 200 2 1433 178 161

Acrolite Aircraft www.acrolite.org Acrolite 1B 1 800 130 110 45 P  $10-25k

Acrolite 1T 1 720 110 90 44 P  $8-20k ▼ Acrolite 2M 2 1200 125 105 43 P  $12-30k

Adams Aeronautics Company, Inc. CA-2 (formerly Hummel) 1 520 80 63 26 P  $4-8k

Aircr www.adamsaero.com ▼

T-100D Mariah 1 504 80 63 27 P  $4-8k

Aeriane SA  www.aeriane.com P-Swift 1 520 93 72 25 K

Aero Adventure Aviation www.sea-plane.com Aventura HP 1 750 90 75 32 K  $24-32k ▼ Aventura UL 1 650 60 55 24 K  $20-24k

Aventura II 2 1430 105 85 30 K  $23-29k

Barracuda 2 1430 105 85 41 K  $21-27k ▼ Toucan 2 1050 85 62 28 K  $20-27k

Aero Concepts, LLC ▼

Homebuilt Discovery 2 1620 240 225 58 K $60-150k

Aero-Systems ▼ Cadet Model STF 2 1350 145 130 50 P $35-48k

*Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available. 2017

28 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes 2017 Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price AeroCad Inc. AeroCanard FG 4 2150 225 205 71 K/P $50-100k www.aerocad.com AeroCanard RG 4 2150 225 210 78 K/P $50-100k

AeroCanard SB 4 2050 220 200 78 K/P $50-100k Homebuilt ▼ AeroCanard SX 4 2150 225 205 71 K/P $50-100k Aerochia www.aerochia-lt1.com LT-1 1 793 161 138 55 K  Aerolab Mfg, Inc. (was Aerolab s.a.s.) www.goldenageaeroworks.com ▼ LoCamp 2 1320 132 106 45 K  $60-75k

AeroLites, Inc. AeroMaster 1 1000 90 75 32 K  $26-40k www.aerolites.com AeroSkiff 2 1125 90 65 38 K  $27-35k

Bearcat 1 700 70 65 27 K  $16-23k Aeromarine-LSA www.aeromarine-lsa.com Aviad Zigolo MG12 1 485 58 42 22 K  $12-20k

Merlin PSA ▼ 1 715 125 115 38 K  $20-50k Aircr

Aeromarine Marketing www.ppawd.com/ Harrier 3 1200 120 100 40 K aeromarine Aeroplane Manufactory Beaver RX-550 Plus 2 1050 85 73 37 K  $21-28k (was A.S.A.P.)

www.amplanes.com ▼ Beaver SS 1 650 85 67 30 K  $15-17k

Chinook Plus 2 2 1050 95 83 35 K  $21-37k af *Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available.

Merlin PSA t

The Merlin PSA grew out of a project in the Czech Republic and was brought to the U.S. D See the October 2016 issue for details. (Photo: Richard VanderMeulen) IRECTOR Y

KITPLANES December 2016 29 Y Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price Aeroplanes DAR Ltd DAR-21 2 990 88 78 38 K (was DAR Aviation) www.aeroplanesdar.com DAR-21S 2 1000 125 110 38 K

DAR-23A and Enclosed 2 900 95 75 37 K

DAR Duo 2 750 90 75 35 K  $32k ▼ DAR Solo 1 507 75 65 25 K $25-28k Air Command International, Inc. Falcon 2000 2 992 84 70 36 K www.aircommand.com IRECTOR Aircraft Designs, Inc. www.aircraftdesigns.com Stallion 6 3800 250 235 81 K $500k D Aircraft Spruce & Acro Sport 1 1350 152 130 50 P $40-55k

Specialty www.aircraftspruce.com Acro Sport II 2 1520 152 123 53 P $40-55k t Acroduster Too SA-750 2 1950 185 155 55 K/P ▼ Acrolite 1B 1 750 130 110 43 K/P  $7k

af Baby Great Lakes 1 850 135 118 49 K/P  $40k

Buddy Baby Lakes 2 1000 135 118 55 K/P $40k

Christavia MK 1 2 1500 135 105 40 K/P $8-14k ▼ Cozy Mark IV 4 2050 200 185 69 K/P

Nesmith Cougar 1 2 1250 195 135 53 P $38-40k

One Design DR 107 1 1140 180 160 60 K/P

Aircr Pober Junior Ace 2 1313 130 85 40 P  $32-42k ▼ Pober Pixie 1 900 83 30 P  $25-35k

Pober Super Ace 1 1030 160 110 44 P  $21-26k ▼ Starduster One SA-100 1 1080 147 132 50 P 

Starduster Starlet SA-500 1 1000 130 105 55 P

Starduster Too SA-300 2 1985 170 130 56 K/P

Starduster V-Star SA-900 1 1000 90 75 35 P  ▼ Super Baby Great Lakes 1 850 155 135 55 K/P

Super Starduster SA-101 1 1300 225 170 55 P

Wittman V-Witt Racer 1 700 180 150 48 P ▼ Wittman W10 Tailwind 2 1425 230 180 45 K/P $12-40k

Aircraft Technologies, Atlantis 2 1900 255 180 65 K Inc. Homebuilt www.airshowunlimited.com Meyer-360 1 1600 255 180 60 K

Airdale LLC Airdale 2 1400 130 108 48 K $26-56k www.airdale.com Airdale LSP 2 1200 120 90 35 K  $19-24k ▼ Avid Plus 2 1200 120 90 35 K  $25-55k

30 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes 2017 Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price Airdrome Bleriot Model XI 2 676 43 40 28 K  $8-13k Aeroplanes, Inc. (3/4 Scale) www.airdromeaeroplanes.com

Bleriot Model XI 1 1014 55 50 32 K  $14-21k (Full Scale) Homebuilt ▼ DeHavilland DH-2 1 596 63 61 29 K  $10-12k

Dream Classic Strut Braced 1 465 63 54 26 K  $6-9k

Dream Classic Wire Braced 1 491 63 57 26 K  $6-9k ▼ Dream Fantasy Twin 2 630 52 45 27 K  $8-15k

Eindecker E-III 1 480 63 57 28 K  $8-13k

Fokker D-VI (3/4 Scale) 1 568 78 73 30 K  $9-15k

Fokker D-VII (80% Scale) 1 770 105 94 34 K  $13-18k ▼ Fokker D-VIII (3/4 Scale) 1 517 92 80 32 K  $9-15k

Fokker DR-1 (3/4 Scale) 1 583 78 64 34 K  $13-15k

Fokker DR-1 (Full Scale) 1 872 94 72 32 K  $16-19k

Fokker E-III Eindecker 1 468 65 54 26 K  $9-15k

(3/4 Scale) Aircr

▼ Fokker E-III Eindecker 1 927 81 68 34 K  $11k (Full Scale)

Morane Saulnier L 2 640 65 63 31 K  $9-11k

Nieuport 11 (7/8 Scale) 2 720 80 74 34 K  $12-15k ▼ Nieuport 17 1 872 97 89 40 K  $17-22k

Nieuport 24 (Full Scale) 1 836 95 83 36 K  $15-18k af ▼ Nieuport 28 1 1212 95 84 39 K  $25-30k

Sopwith Baby 2 1095 95 81 K  $15k

Sopwith Camel (Full Scale) 1 1243 103 85 40 K  $33-40k t

Sopwith Pup (Full Scale) 1 596 95 81 37 K  $27-30k D ▼ Sopwith Schneider 2 1233 91 78 40 K  $18-22k

Sopwith Tabloid 2 1201 91 78 40 K  $18-22k IRECTOR

Spirit of St. Louis 2 1185 105 93 39 K  $28-32k ▼ Taube 2 1145 80 65 35 K  $18-20k

Alfa Air Service LLC www.aboutalfa.com ALFA HB-207 2 1540 187 161 52 K

Alisport Silent 2 1 540 136 50 37 K  $47-53k www.alisport.com Silent 2 Electric 1 660 136 56 40 K  $116-122k

Silent 2 Self-Launch 1 660 136 56 40 K  $60-68k ▼ Silent 2 Targa Self-Launch 1 660 136 56 40 K  $69-76k

*Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. Y For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available.

KITPLANES December 2016 31 Y Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price Alisport Silent Club 1 530 124 50 36 K  $40-46k www.alisport.com Silent Club Electric 1 661 112 40 K ▼ Silent Club Self-Launch 1 639 124 53 38 K  $55-60k

Alpaero www.alpaero.com Exel 1 683 75 39 K

Altitude Group LLC Formula GT 2 2650 230 218 68 K www.altitudegroupllc.com P85 2 2475 283 252 70 K $95-105k IRECTOR ▼ Radial Rocket RG 2 2575 267 254 70 K $111-151k D Radial Rocket TD 2 2550 255 242 70 K $105-145k

Alturair BD-5B 1 860 232 205 66 K $20-35k t www.alturair.com ▼ BD-5G 1 660 232 229 55 K $20-35k af Ameri-Cana Ultralights Eureka 1 480 63 60 27 K

American Ghiles Lafayette 4S Revolution 4 1653 199 178 51 K Aircraft Inc. www.aircraftkit.com Lafayette Bushplane 2 1080 208 188 40 K

Lafayette Classic Storch 2 937 84 78 35 K

Lafayette Mountain 2 1080 185 181 40 K

Lafayette Sportster 2 1080 226 204 57 K Aircr Lafayette Super Storch 2 1102 132 118 35 K

Lafayette Texan 2 1080 149 140 40 K

Lafayette Touring 2 1080 211 190 49 K

Lafayette Wallaby 2 937 81 71 31 K American Homebuilts’ Corp. John Doe 2 1320 125 110 30 K  $35-45k American Legend Aircraft Legend Cub 2 1320 115 98 38 K  $60-84k www.legend.aero ▼ Super Legend 2 108 100 35 K  $150-240k

Texas Sport TX-3 2 1320 115 98 38 K  $55-84k

American Patriot Aircraft LLC Patriot II 2 1320 138 135 44 K  $33-36k ▼ Homebuilt Patriot Supercruiser 2 1320 138 135 50 K  $35-75k

AmeriPlanes/ A-10B 1 550 80 63 28 K  MitchellWing www.ameriplanes.com A-10D 1 550 76 60 28 K 

T-10D 2 850 78 65 32 K 

32 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes 2017 Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price

Amphibian Airplanes SeaMax 2 1158 125 115 38 K  of Canada Ltd. www.seastaramphibian.com ▼

Seastar Sealoon 2 1430 112 100 40 K  $85-105k Homebuilt Super Petrel 2 1150 112 100 45 K  $80-100k

Andrew Budek-Schmeisser (was Townsley, Mike) Jungster 1 Biplane 1 1000 150 110 55 P $12-25k https://sites.google.com/ site/jungsterbipe/home ▼ Jungster 2 1 1139 200 160 50 P  $10-20k

Apis Sailplanes Inc. APIS 13 Meter 1 540 139 55 34 K www.apisgliders.com Apis 15 Meter 1 661 139 51 36 K $34-37k

Apis Electric Self-Launch 1 710 139 51 36 K $72-76k

Arion Aircraft, LLC Lightning 2 1425 184 155 46 K $60-85k www.flylightning.net ▼ Lightning LS-1 2 1320 138 138 51 K  $96-115k

Lightning XS 2 1625 195 180 63 K $80-100k

Arnet Pereyra, Inc. Buccaneer II 2 1200 90 70 32 K Aircr

Buccaneer SX 1 810 90 70 29 K

Sabre II 2 1100 90 70 32 K

Zephyr II 2 1100 90 70 32 K

Associate Air LLC Liberty 181/183 4 3500 145 135 35 K Atec Aircraft USA www.atec-alas-llc.com Zephyr 2 1200 170 130 41 K af Auriga Design Inc. Aerocat SR 4 3400 185 170 53 K $225-350k www.auriga.on.ca/aerocat.html ▼ Aerocat SRX 4 3330 164 150 53 K $250-300k

Aerocat TR 4 3400 220 201 53 K $200-350k t

Aerocat TRX 4 3400 205 185 53 K $200-350k

AviaBellanca Aircraft D Corporation SkyRocket III 6 4200 340 327 68 K www.aviabellanca.com IRECTOR Aviat Aircraft, Inc. Eagle II 2 1578 184 165 58 K $200-225k www.aviataircraft.com ▼ Pitts S-1-11B 1 1500 205 187 54 P $100-300k (Super Stinker) Pitts S-1S 1 1150 176 155 62 P Aviation Development Alaskan Bushmaster 4 3000 150 125 44 K International Ltd. Aviator Enterprises, Inc. Aviat Solo 1 900 115 85 35 P

Avid Aircraft Avid Champion 1 594 65 63 26 K www.avidair.com Bandit 2 1000 95 80 30 K

*Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. Y For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available.

KITPLANES December 2016 33 Y Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price Avid Aircraft Catalina 3 1200 80 75 36 K www.avidair.com Magnum 3 1750 155 130 40 K Mark IV Aerobatic 2 1150 135 120 46 K Speedwing Mark IV High-Gross STOL 2 1150 135 95 36 K Azalea Aviation www.azaleaaviation.com ▼ Saberwing 2 1500 200 160 55 K $40-45k IRECTOR

D Backcountry Super Cubs (Turbine Cubs of Wyoming LLC) Mackey SQ2 2 2200 120 115 20 K $106-126k www.supercub.com Supercruiser 3 2400 130 115 28 K $100-120k t ▼ Supercub Replica 2 2400 120 112 28 K $100-120k

Bakeng Deuce Airplane af Factory www.bakengdeuce.com ▼ Bakeng Deuce 2 1500 140 110 51 P/K $75-100k

Ballard Sport Aircraft www.ballardsportaircraft.com Pelican PL Turbo 2 1400 155 152 50 K $65-85k ▼ Pelican Sport 600 2 1320 135 130 44 K  $55-75k Aircr

Barr Aircraft www.barraircraft.com Barr 6 6 4500 248 207 62 K $146-310k Barry Jay Aviation, Inc. www.barryjay.com Acroduster 1 1 1190 180 165 70 P BD-Micro Technologies, BD-5B 1 830 190 170 62 K $44-67k Inc. www.bd-micro.com BD-5J Microjet 1 860 290 240 67 K $100-145k

BD-5T Turboprop 1 910 240 195 66 K $89-105k ▼ FLS Microjet 1 860 288 184 74 K $200-220k Bearhawk Aircraft Co. (AviPro Aircraft, Ltd.) Bearhawk 4 2700 175 160 45 K $75-110k www.bearhawkaircraft.com ▼ Bearhawk LSA 2 1320 138 120 30 K/P  $50-65k

Bearhawk Patrol 2 2000 165 150 35 K/P $60-85k

Bedecorp LLC BD-12C 2 1310 215 200 54

Homebuilt www.bedecorp.com BD-17 1 1000 148 142 56 K $32-60k

▼ BD-17L 1 950 138 132 46 K  $32-60k ▼ BD-18 2 1200 190 180 56 K/P $24-70k

BD-22L 2  *Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available. 2017

34 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes 2017 Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price Bedecorp LLC BD-4B 4 2400 240 190 55 K/P $46-66k www.bedecorp.com BD-4C 4 2400 240 190 61 K/P $30-90k

▼

BD-6B 1 850 180 150 50 K/P $18-60k Homebuilt

Belite Aircraft LLC Belite UltraCub 1 550 80 62 28 K $10-20k www.beliteaircraft.com ▼ ProCub Lite 1 550 80 62 28 K  $15-20k

Superlite 1 550 63 62 28 K  $13-15k

Trike 1 550 63 55 28 K  $10-26k Berkut Engineering www.berkut.com Berkut 2 2200 298 275 65 K Better Half VW Double Eagle 2 900 85 70 35 K/P  $10-13k www.betterhalfvw.com ▼ Legal Eagle 1 500 63 60 25 K/P  $3-5k

Legal Eagle UL 1 500 55 28 K  $4-5k

Legal Eagle XL 1 575 63 60 25 K/P  $5-7k

Biplanes of Yesteryear Mifyter 1 755 95 75 40 K  $23-25k www.mifyter.com

Mifyter II 2 1150 85 70 43 K  $29-33k Aircr

Blanton, D. L. Sport Racer 2 1825 200 175 62 P $25-35k

V6 STOL 4 2200 135 120 48 P $25-35k ▼ Wichawk 3 2000 140 127 56 P $20-40k

Blue Yonder Aviation, Inc. E-Z Harvard 1 1300 120 90 32 K  $21-35k

E-Z King Cobra 1 1200 120 90 32 K  $21-35k

EZ Flyer 2 1320 100 75 38 K  $25-30k af ▼ EZ Fun Flyer 1 600 50 17 K $14k

D IRECTOR

Bede BD-17L The Bede BD-17L strikes one much like a flying jet ski—strap it on and explore the neighborhood. See the November 2016 issue for details. (Photo: Richard VanderMeulen) Y

KITPLANES December 2016 35 Y Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price Blue Yonder Aviation, Inc. Merlin EZ 2 1450 110 85 30 K $48-65k

Twin Engine E-Z Flyer 2 1450 100 70 38 K $36-75k

Boeve Aircraft Inc. MJ-7 2 2550 265 230 69 K/P

Bonner Aircraft www.cafes.net/ Scout 1 550 70 60 35 P bonneraircraft Bowers (Bowers, David R.) www.bowersflybaby.com ▼  IRECTOR Bowers Fly Baby 1 925 110 87 45 P $10-12k D

Bradley Aerospace www.vortechonline.com/ Aerobat 1 720 180 150 43 K bradley t Breezer Aircraft USA, LLC www.breezeraircraftusa.com ▼ Breezer II 2 1320 135 120 43 K  $46k af

Buethe Enterprises, Inc. www.flybarracuda.com Barracuda 2 2300 220 200 61 P BX-Aviation Cherry BX-2 2 1222 136 124 52 P  $20-50k C-N-C Aviation ▼ Supercat 1 650 100 80 32 P  $7-12k Aircr Cadcor www.cadcor.com Chanute 2 2250 265 240 67 K Cameron & Sons Aircraft www.cameronaircraft.com P51 Mustang 2 6000 500 420 87 K $150-450k Canadian Museum of SE5A Replica 1 1150 110 85 40 P  $5-15k Flight Carlson Aircraft, Inc. Carlson Skycycle 1 800 139 100 55 K www.sky-tek.com Criquet 2 1950 135 95 16 K

Sparrow II 2 990 130 95 36 K 

Sparrow II XTC 2 1300 115 110 39 K  $40-45k

Sparrow Sport Special 1 775 100 85 31 K  $28-32k

Sparrow Ultralight 1 504 63 58 27 P  $9-13k

Cassagneres, Ev Ryan ST-R (replica) 2 1575 140 120 45 P $10-20k

Homebuilt CFM Aircraft Ltd. Shadow-DD 2 860 124 90 38 K

Star Streak 2 900 144 115 45 K

Streak Shadow SA 2 900 140 110 40 K CinCo Enterprises, Inc. www.northwestartists.com/ Russia AC4-KC 1 605 130 42 K russiakits *Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available. 2017

36 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes 2017 Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price Circa Reproductions 7/8 Nieuport 11/17 1 550 85 75 30 P  www.nieuports.com Nieuport 11 EXP (87%) 1 675 80 70 32 P 

Nieuport 12 EXP (87%) 2 1070 94 75 33 P Homebuilt

Classic Aero Enterprises H-2 Honey-Bee 1 750 70 65 35 P  $8-15k www.members.cox.net/ classic-aero H-3 Pegasus 1 575 85 70 30 P  $8-15k

Classic Sport Aircraft S-18 2 1600 215 180 63 K $30-45k

Clifford Aeroworks www.cliffordaeroworks.com Spad XIII 1 800 90 80 45 K/P Clutton, Eric ▼ Fred 1 820 80 75 40 P  $5-12k

Collins Aero Dipper Amphibian 2 1760 124 120 48

Comp Air Inc. Comp Air 3 3 2450 175 145 45 K $33-43k www.compairinc.com

Comp Air 4 4 2590 175 155 39 K $56-90k Aircr ▼ Comp Air 6 6 3200 175 165 39 K $66-100k

Comp Air 7 6 3700 250 230 53 K $87-325k ▼ Comp Air 7SLX 6 4200 250 210 54 K $98-375k

Comp Air 8 8 4800 227 210 48 K $187-425k

Comp Air 9 8 7200 288 253 71 K $770-1200k ▼

Comp Air 10 10 5700 200 180 56 K $250-425k af

Comp Air 12 10 10800 356 340 84 K $750-2400k

Comp Air Jet 10 10900 400 375 71 K t Merlin GT-582/912 2 1300 120 85 35 K 

Merlin GT-912 2 1300 120 93 38 K D

Composite Aircraft Express 2000 FT 4 3400 230 207 55 K $200-250k

Technologies IRECTOR

www.compairtechllc.com ▼ Express 2000 RG 4 3800 290 200 50 K $200-250k

S300 RG 4 3600 320 300 60 K

Series 2000 FT 4 3600 230 190 53 K Corivi Aviation www.magini.it/ Pegaso 2 1100 155 142 45 K coriviaviation.htm CSN ▼ Corby Starlet CJ-1 1 750 160 130 35 K/P  $15-27k

*Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. Y For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available.

KITPLANES December 2016 37 Y Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price CubCrafters, Inc.

www.cubcrafters.com ▼ Carbon Cub EX-2 2 1865 138 115 32 K  $100-150k

Top Cub 2 2300 140 115 43 K

Culp’s Specialties www.culpsspecialties.com Culp’s Special 2 2300 240 170 72 K/P $70-250k ECTOR ▼ ▼ Sopwith Pup 2 2300 220 170 72 K/P $90-240k IR Custom Flight Ltd. www.customflightltd.com Lite Star 2 1320 120 100 45 K  $35-60k D

North Star 2 2350 120 115 25 K $80-100k t

D & E Aircraft, Inc. Kodiak Cruiser 2400/3200 2 3000 150 130 25 K f www.de-aircraft.com

Dakota Cub a www.dakotacub.com Super 18-160 2 2050 125 100 49 K $100-125k

Super 18-180 2 2300 148 100 51 K $100-130k ▼ ▼ ▼ ▼ Super 18-LT 2 1320 110 90 44 K  $90-110k

DCS, Inc. www.teenietwo.com Mini Coupe 1 850 110 100 48 P  $8-20k

Teenie Two 1 590 120 110 48 P  $7-20k Aircr Tinni Three 2 1200 180 160 50 P $15-35k

Design Resources

J. D. Special 1 939 170 140 38 P $11-40k

DFE Ultralights, Inc. Ascender 3A 1 455 55 40 25 K  $7-8k

Ascender 3B 1 490 55 40 28 K  $8-10k

Ascender 3C 1 585 55 40 28 K  $8-10k

Dova Aircraft  www.dovaaircraft.com Skylark 2 1200 130 120 42 K

Dream Aircraft Inc. www.dreamaircraft.com ▼ ▼ Tundra 4 2550 132 118 52 K $110-160k Homebuilt

Duccini www.campavia.com Morin M85 2 1200 100 90 37 P  $10-25k

38 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes 2017 Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price Dyke Aircraft ▼ Dyke Delta JD II 4 1950 210 180 60 P $9-30k

Homebuilt Early Bird Aircraft Co. ▼ Jenny, 2/3rd scale 2 800 70 60 35 P  $8-13k

Earthstar Aircraft eGull Electric 1 700 63 63 24 K  $30-35k www.thundergull.com Gull 2000 1 550 63 63 27 K  $17-22k ▼ Odyssey 2 1000 108 87 37 K  $22-35k Soaring Gull 1 550 63 63 26 K  $18-23k Thunder Gull J 1 550 63 63 25 K Thunder Gull JT2 2 850 87 87 34 K

Ed Marquart Marquart MA-5 Charger 2 1600 125 116 48 P

EDRA Aeron§utica Ltda

www.edraaeronautica. Super Petrel 2 1103 110 85 32 K com.br/pt Aircr Eklund Engineering, Inc. www.thorpt18.com ▼ Thorp T-18 2 1600 205 200 59 P $20-45k

Elmwood Aviation Christavia MK 1 2 1500 118 105 40 P

Esqual North America, LLC Esqual Retractable 2 1200 230 210 50 K

Esqual Sport 2 1232 132 132 34 K  af VM-1 Esqual 2 1232 195 175 43 K EU-WISH Aircraft

www.groups.yahoo.com/ Sidewinder S & GA 2 1550 210 167 60 P $23-85k t group/Sidewinder2

Europa Aircraft Europa XS Monowheel 2 1370 175 160 51 K $75-125k www.customflightcreations. com Europa XS Motor Glider 2 1370 155 143 52 K $95-125k D ▼

Europa XS Trigear 2 1370 161 150 51 K $75-125k IRECTOR Europa XS Trigear Light 2 1320 138 138 51 K  $75-150k Sport

Evans Aircraft  www.evansair.com Volksplane 1 (VP-1) 1 685 95 75 45 P

Excalibur Aircraft Excalibur 2 1050 100 90 32 K  $29-30k www.excaliburaircraft.com Excalibur Four Stroke 2 1075 100 90 33 K  $37-39k ▼ Excalibur Stretch 2 1060 100 90 32 K  $30k

Extra Flugzeugproduk- tions GmbH Xtra 200 2 1858 265 172 61 K $240-300k www.extraaircraft.com

*Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. Y For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available.

KITPLANES December 2016 39 Y Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price Falcomposite Ltd www.falcomposite.com ▼ Furio LN 27 RG 3 2756 219 201 54 K $200-250k

Falconar Avia Inc. AMF-14H 2 1200 115 92 36 K/P  $19-40k www.falconaravia.com AMF-Super 14D Maranda 2 1850 130 120 39 K/P $28-40k ARV-1K Golden Hawk 2 890 130 100 40 K ▼ Cubmajor 2 1300 120 100 40 P  $10-33k IRECTOR F11A Sporty 2 1300 130 123 38 K/P  $20-40k

D F11E 2 1050 120 100 42 P  $10-37k ▼

F11E Sporty 2 1100 130 110 41 K/P  $20-40k t F12A Cruiser 2 1800 175 150 51 K/P $22-45k ▼ Falconar F9A 1 700 116 100 43 K/P Falconar F10A 1 875 130 120 35 P  $9-30k af Falconar F11E 2 1050 100 42 P  $10-37k Fauvel AV36/361/AV362 1 570 137 60 30 P  $9-20k ▼ HM 290/293 1 600 90 28 P  $5-26k HM 360 1 700 120 95 28 P  $7-34k ▼ HM 380 2 1100 120 95 28 P  $7-34k Ladybug 380L 2 1330 124 113 28 K/P

Aircr Mignet Flying Flea 1 580 110 90 28 K/P  $11-20k 290E/293E

▼ SAL Mustang (2/3) 2 2180 200 176 60 K/P $40-80k Turbi D5 2 1089 108 81 34 K/P  $20-35k Fighter Escort Wings FEW P51 2 2000 250 210 62 K www.fighterescortwings.com P51D 2 2500 240 210 65 K TF51 2 2200 240 210 65 K Fisher Flying Products Avenger 1 600 63 60 28 K/P  $9-11k www.fisherflying.com Avenger V 1 650 100 85 31 K/P  $10-12k ▼ Celebrity 2 1230 95 85 40 K/P  $20-25k

Classic 2 850 100 85 39 K/P  $15-17k

Dakota Hawk 2 1150 100 100 35 K/P  $25-35k

FP-202 Koala 1 500 75 55 26 K/P  $10-12k ▼

Homebuilt FP-303 1 450 70 60 25 K/P  $8-10k

FP-404 1 540 80 72 30 K/P  $11-13k

FP-505 Skeeter 1 500 63 60 26 K/P  $10-12k ▼ FP-606 Skybaby 1 500 63 60 26 K/P  $10-12k

Horizon 1 2 1050 100 95 40 K/P  $17-20k

40 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes 2017 Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price Fisher Flying Products Horizon 2 2 1050 110 100 38 K/P  $22-25k www.fisherflying.com ▼ R-80 Tiger Moth 2 1150 100 80 35 K/P  $25-30k

RS-80 Tiger Moth 2 1300 100 80 40 P  Homebuilt Super Koala 2 900 95 75 32 K/P  $17-20k

Youngster 1 650 110 85 32 K/P  $13-15k ▼ Youngster V 1 650 110 85 32 K/P  $13-15k Flight Addictions LLC (Alarie, Russell)

www.daisymae-biplane.com▼ Daisy Mae 2 1300 100 80 40 P  $17-30k

Flightstar, Inc. eSpyder 1 500 80 50 24 K  $15-18k www.flyflightstar.com Flightstar Loadstar 1 950 95 70 36 K

IISC 2 992 83 65 36 K  $30-35k

IISL 2 950 80 65 36 K  $23-29k

Spyder 1 680 80 65 36 K  $16-18k

Flying Flea Archive USA Flying Flea HM-14 1 500 70 55 25 P  Aircr www.valkyrie. net/~flyingflea Flying Flea HM-160/1/2 1 472 80 65 20 P 

Flying Flea HM-290/1FB 1 580 85 75 26 P  Flying Legend www.flyinglegend.it/en ▼ Tucano Replica 2 1433 158 40 K  af Four Winds Four Winds 192 4 2480 255 200 51 K www.fourwindsaircraft.com Four Winds FX210/FX250 6 3400 287 215 66 K $196-249k

Free Bird Innovations, Inc. LiteSport Classic 2 900 85 80 32 K  $15-19k t www.flyfbi.com LiteSport II 2 900 80 75 32 K/P  $10-15k

LiteSport Ultra 2 500 62 55 22 K/P  $9-15k D

Freedom Aviation Freedom Aviation 4 3500 230 215 75 K $230-350k

www.freedom-aviation.com IRECTOR Glasair Aviation Glasair III 2 2400 300 278 78 K $125-300k www.glasairaviation.com Glasair Super II FT 2 2100 228 210 73 K $80-200k ▼ Glasair Super II RG 2 2100 238 221 73 K $80-200k

GlaStar 2 1960 167 161 49 K

Sportsman 4 2350 186 172 48 K $80-200k

▼ Two Weeks to Taxi 4 2350 186 172 48 K $189-250k Sportsman

Two Weeks to Taxi 4 2500 186 172 50 K $204-250k Sportsman Carbon

*Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. Y For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available.

KITPLANES December 2016 41 Y Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price Golden Circle Air, Inc. T-Bird Cargo 2 1176 88 65 39 K  www.goldencircleair.com T-Bird I 1 600 78 60 26 K  $50-150k T-Bird II 2 1016 90 70 38 K  T-Bird Side-by-Side 2 1000 95 70 36 K Great Plains Aircraft Supply Co., Inc. www.gpasc.com ▼ Easy Eagle I Bi-Plane 1 725 110 100 45 P  $8-12k IRECTOR Green Sky Adventures, Inc. Micro Mong 1 650 100 80 35 K/P  $14-30k D www.greenskyadventures.com

▼ Zippy Sport 1 680 120 110 45 P  $10-25k t Griffon Aerospace www.griffon-aerospace.com Lionheart 6 5200 232 213 56 K Groppo Avio af www.groppo.it ▼ Trail 2 1300 130 100 35 K  $50-60k

Grosso Aircraft Inc. Easy Eagle 1 725 110 100 45 P Easy Eagle II 2 1150 110 100 45 P Hansen Aero www.tecnam.com Tecnam P92 Super Echo 2 1320 140 123 39 K Harper Aircraft Fascination D4-BK 2 1300 172 160 38 K Aircr Lil’ Breezy 2 800 75 65 28 K 

Sky Scooter 1 650 62 55 28 K Ultrasport 1 500 60 60 30 K Hatz Biplane Association www.hatzbiplane.com Hatz CB-1 2 1400 105 90 38 P $12-80k ▼ Kelly-D 2 1500 105 90 40 P $12-80k

Hensley Aircraft www.hensleyaircraft.com H-1 Wolf/Wolf 4 3000 225 210 55 K Hevle Aviation LLC www.hevleaviation.com ▼ Hevle Classic 2 1320 135 105 45 P  $19-40k

Higher Class Aviation  www.sporthornet.com Hornet 2 1320 115 109 40 K $32-52k

Homebuilt Hinz BL1-KEA 2 1590 168 155 53 P

Hipp’s Superbirds, Inc. J-3 Kitten/Super Kitten 1 500 63 59 24 K/P  $10-30k www.geocities.com/Paris/ J-4 Sportster/Super LeftBank/7993/plane.html 1 500 63 59 24 K  $10-30k Sportster Reliant SX 1 600 100 75 31 K/P  Reliant/Reliant SX 1 500 63 60 24 K/P  $10-31k *Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available. 2017

42 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes 2017 Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price

HP Aircraft, LLC  www.hpaircraft.com HP-24 Sailplane 1 825 150 42 K $36-45k Hummel Aviation CA-2 1 520 63 50 26 P  $4-11k

www.flyhummel.com H-5 ▼ 1 850 130 120 42 K/P  $17-32k Homebuilt Hummelbird 1 550 125 115 38 K/P  $8-15k ▼ UltraCruiser 1 575 95 75 28 K/P  $10-28k UltraCruiser Plus 1 950 135 125 36 K/P  $20-30k ICP Srl Bingo 4S 2 1234 84 75 28 K  $35-45k www.icpaviazione.it Savannah 2 1235 110 85 30 K  $45-50k Savannah ADV 2 1235 125 115 34 K  $55-60k ▼ Savannah S 2 1320 123 115 30 K  Savannah VG 2 1235 110 95 30 K  $45-50k Savannah VGW 2 1235 110 95 30 K  $45-50k Indy Aircraft, Ltd. www.indyaircraftltd.net T-Bird I 1 575 78 60 26 K  $15-30k ▼ T-Bird II 2 1071 90 66 36 K  $17-55k

Ion Aircraft www.ionaircraft.com Aircr ▼ Ion 100 2 1320 138 138 43 K  $47-75k

Jabiru Aircraft Calypso 2 1100 127 103 44 K  $35-55k www.jabiruna.com J450 2 1540 155 138 52 K $65-100k Jabiru J170 2 1320 132 115 51 K  $45-60k Jabiru J200 2 1540 159 138 55 K $60-90k ▼ Jabiru J230 2 1320 138 138 51 K  $65-100k af Jabiru J250 2 1320 138 138 51 K  $60-90k *Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available. t

D IRECTOR

Hummel H-5 The Hummel H-5 can be built by those of modest means who just want to get in the air and have a little fun. See the July 2016 issue for details. (Photo: Mariano Rosales) Y

KITPLANES December 2016 43 Y Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price Jabiru Aircraft Jabiru J400 4 1540 152 138 55 K $65-95k

www.jabiruna.com ▼ Jabiru J430 4 1540 138 138 57 K $65-100k Jabiru SP 2 1540 154 130 50 K Jabiru UL 2 990 139 115 40 K 

Javron Aviation  www.javronaviation.com Super Cub PA-18 ▼ 2 1320 115 38 K $84-152k Jim Kimball Enterprises Inc. www.pittsmodel12.com ▼ Pitts Model 12 2 2300 239 170 64 K/P $115-140k IRECTOR

D Jim Maupin, Ltd. Carbon Dragon 1 300 70 20 P www.jcpress.com/ JMaupinLtd Windrose II 1 780 132 75 52 P Woodstock 1 450 100 35 P t Johnston Aviation Tiger Cub II 2 1320 125 105 35 K  $34-61k www.tigercubaircraft.com Tiger Cub UL 1 600 90 65 25 K/P  $16-21k Junqua-Diffusion af www.junqua-aircraft.com Ibis RJ.03 2 1034 158 126 57 P Jurca Plans, c/o Ken Heit MJ-10 Spitfire (75%) 1 2860 230 180 65 P MJ-100 Spitfire (100%) 1 6035 355 300 62 P MJ-12 P-40 (75%) 1 2860 275 225 65 P MJ-2 Tempete 1 950 120 102 62 P MJ-5 Sirocco 2 1860 225 200 64 P MJ-77 Mustang (75%) 2 2860 330 230 65 P MJ-8 FW-190 (75%) 1 3000 240 200 P Aircr Just Aircraft Escapade 2 1320 132 110 42 K  $55-85k

www.justaircraft.com ▼ Highlander 2 1320 132 105 39 K  $58-85k

SuperSTOL 2 1320 132 100 K  $55-85k

Javron Super Cub PA-18 Javron’s focus is on reproducing the Super Cub in its purest form. It makes for a plane that flies as much as possible like a Piper Super Cub. See the June 2016 issue for details. (Photo: Darwin Schroeder) Homebuilt

2017

44 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes 2017 Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price Kitfox Aircraft LLC Kitfox Lite 1 550 63 55 27 K  www.kitfoxaircraft.com Kitfox Model (Classic) IV 2 1200 115 110 37 K  $32-55k ▼ Kitfox S7 Super Sport 2 1550 125 120 41 K  $35-60k Tailwheel Homebuilt Kitfox S7 Super Sport 2 1550 125 120 41 K  $35-60k Tri-gear Kitplanes for Africa www.web.penta-net.co.za/ Bushbaby 2 1100 120 90 35 K kitplanes Kolb Aircraft Co LLC Fire Star II SS 2 850 90 68 34 K  $15-40k (The New Kolb Aircraft Co) www.kolbaircraft.com FireFly 1 500 63 63 28 K/P  $15-18k ▼ FireStar 2 725 90 80 27 K/P  $22-28k Kolb Flyer 2 1000 50 30 K  Kolbra 2 1000 110 75 45 K  $26-39k Kolbra Ultralight Trainer 2 1000 100 75 35 K Mark III Classic 2 1000 100 80 41 K  $28-42k ▼ Mark III Xtra 2 1100 100 90 27 K  $32-45k Pelican Sport 2 1320 145 132 44 K

Slingshot 2 900 115 85 41 K/P  $21-38k

Lancair International Inc. Evolution 4 4550 345 325 61 K $1400-1500k Aircr www.lancair.com Lancair ES/Super ES 4 3550 230 215 70 K $250-350k Lancair IV 4 3550 300 285 75 K $300-400k Lancair IV-P 4 3550 330 300 73 K $400-500k ▼ Lancair Legacy FGC-550 2 2200 250 240 65 K $200-295k Lancair Legacy RG-550 2 2200 276 270 65 K $250-300k Lancair Propjet 4 3550 370 74 K $375-550k Lancair Sentry 4 3550 380 74 K af Lancair Turbine IV-P 4 3550 370 75 K/P ▼ Legacy FG-390 2 2200 215 200 65 K $180-225k

Legend Aircraft, Inc. t www.turbinelegend.com Turbine Legend 2 3300 356 333 66 K $180-500k

Legend Lite Inc. Skywatch SS-11 2 950 90 80 29 K D Legendary Aircraft www.legendaryaircraft.com P51 2 2500 290 225 59 K $125-200k Leichtflugzeuge, B & F FK 9 Mark IV 2 1100 140 120 42 K IRECTOR GmbH - FK-Lightplanes www.fk-lightplanes.com FK 12 Comet 2 1100 131 118 42 K FK 14-B Polaris 2 1100 170 155 42 K Light Miniature Aircraft LM-1A-W (85% J-3) 1 675 85 75 32 P  $10-20k www.lightminiatureaircraft.com LM-1X (75% J-3) 1 600 75 65 26 K/P  $8-10k LM-2X-2P-W 2 875 85 75 38 P  $8-14k (75% Taylorcraft) LM-2X-2P-W 2 875 100 85 40 K/P (87% Taylorcraft) LM-3X-W Aeronca Champ 1 575 75 65 26 P  $8-12k Replica

*Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. Y For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available.

KITPLANES December 2016 45 Y Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price Light Miniature Aircraft LM-5X-W Super Cub 2 1275 90 80 42 K/P  $16-25k www.lightminiatureaircraft.com Replica LM-J3-W Piper Cub Replica 2 1250 85 70 38 K/P  $16-25k LM-TC-W Taylorcraft 2 1250 95 85 42 K/P  $16-25k Replica Light Wing Sport Aircraft Savannah 2 1144 110 100 28 K  X-Air 2 993 75 65 30 K  X-Air F 2 993 87 68 27 K  X-Air H 2 1079 105 93 33 K  IRECTOR Liteflite Pty Ltd Connie 1 570 90 65 35 K www.liteflite.com.au

D Dragonfly 582 2 1080 66 54 28 K  ▼

Dragonfly 912ULS 2 1080 66 54 28 K  Dragonfly C-Model 2 990 65 55 22 K  $35-44k t Tempest 1 440 80 26 K Littner, S. C.P. 60 Super Diamant 4 1875 160 155 55 P www.slittneraircraftplans.com C.P. 80 Zephyr 1 840 200 175 50 P af C.P. 90 Pinocchio 1 1015 150 140 45 P C.P. 150 Onyx 1 475 62 50 22 P  ▼ C.P. 328 Super Emeraude 2 1545 150 142 56 P C.P. 750 Beryl 2 1850 185 160 56 P C.P. 1320-Saphire 4 2075 200 167 53 P ▼ Champion V 2 992 155 143 47 P Jewel 2 992 186 177 40 P

Aircr Junior VI 2 950 125 100 38 P 

Supercab 2 1250 162 143 35 P Vega 2 1600 150 120 52 P ▼ Whisky IV 2 1060 183 130 37 P Lockwood Aircraft, Inc. www.lockwoodaircraft.com Air Cam 2 1680 110 85 39 K $115-135k ▼ Super Drifter 2 1000 85 75 34 K  $47-55k

Loehle Aircraft Corp. 5151 Mustang 1 900 90 80 30 K  $22-59k www.loehle.com 5151 RG Mustang 1 960 95 85 30 K $24-61k ▼ Fokker D-VII 1 525 70 65 20 K  $19-41k Jenny (67% Curtiss Jenny) 2 900 70 60 35 K KW-909 1 900 95 85 30 K $21-61k ▼ Loehle Spitfire 1 1200 140 105 38 K $70-90k P-40 1 900 90 85 30 K $21-61k Homebuilt SE5A 1 525 70 65 20 K  $22-41k

▼ Spad XIII 1 525 70 65 20 K  $22-41k Sport Parasol 1 600 70 65 22 K  $13-21k Lucas, Emile L 5 2 1900 165 145 54 P www.emile-lucas.com L 6 2 1713 143 125 50 P *Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available. 2017

46 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes 2017 Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price Lucas, Emile L 7 3 1750 142 125 56 P www.emile-lucas.com L 8 2 1600 192 165 60 P

L 11 2 990 125 103 42 P 

L 12 2 990 125 103 42 P  Homebuilt Luceair www.luceair.com ▼ Wittman Buttercup 2 1300 155 125 45 K/P  $15-23k

M-Squared, Inc. Breese 2 DS 2 1320 93 75 32 K  $25-60k www.msquaredaircraft.com Breese 2 SS 2 1320 87 55 28 K  $26-60k Breese DS 1 900 93 65 26 K  $26-35k ▼ Breese SS 1 900 82 46 24 K  $25-35k Sport 1000 2 1320 103 74 39 K  $36-60k Sprint 1000 2 1320 94 58 27 K  $35-60k

Main Planes  www.alltrade.ws Beach Boy ST-II 2 650 85 75 22 P Makelan Corporation

www.hatzclassic.com ▼

Hatz Classic 2 1700 150 100 43 K/P $45-60k Aircr

Mann, Roger RW1 Ultra-Piet Pete 1 550 85 55 28 P  $5-10k www.rogermann.org RW2 Special I 1 550 125 70 30 P  $8-18k ▼ RW4 Midwing Sport 1 550 95 70 28 P  $5-10k RW5 Heath Replica 1 550 85 60 28 P  $5-10k RW6 RagWing Parasol 1 550 85 66 28 P  $5-10k RW7 Duster 1 660 95 65 28 P  $5-10k af ▼ RW8 RagWing Pt2S 2 900 95 75 36 P  $10-25k RW9 Motor Bipe 1 525 95 60 36 P  $5-10k t RW11 Rag-A-Bond 2 850 105 78 38 P  $8-25k ▼ RW16 Aerial 1 580 90 60 28 P  $5-10k

RW19 Stork 2 1000 105 75 22 P  $15-30k D RW20 Stork Side-By-Side 2 1000 105 75 22 P  $10-25k IRECTOR ▼ RW22 Tiger Moth 2 1050 110 80 35 P  $10-25k RW26 Special II 2 950 135 85 38 P  $10-20k Maverick Air, Inc. www.twinjet.com Twinjet-1500 6 5200 405 380 86 K Meyer Aircraft www.littletootbiplane.com ▼ Meyer’s Little Toot 1 1320 138 125 51 P  $20-45k

Microleve Com. Ind. LTDA Corsario MK-5 2 1100 95 85 30 K www.microleve.com.br ML500 2 980 95 80 20 K

*Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. Y For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available.

KITPLANES December 2016 47 Y Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price Mini-IMP Aircraft Co. www.mini-imp.com ▼ Mini-IMP 1 1000 200 180 45 K/P $15-27k

Mirage Aircraft, Inc. www.mirage-aircraft.com Celerity 2 1825 225 205 60 P $27-59k ▼ Marathon 2 1825 205 190 60 P $23-42k IRECTOR Montagne Aircraft LLC Mountain Goat 2 2475 165 159 27 K

D Morrison Aircraft www.morrisonaircraft.com Morrison 6 6 4500 240 240 62 K $170-332k Murphy Aircraft Mfg. Ltd. Elite 2 1800 145 132 42 K $75-85k www.PattersonAeroSales.com

t Maverick 2 950 110 80 32 K  $30-40k Moose 6 3500 165 140 52 K $100-130k Radical 2 1900 130 110 36 K $80k ▼

af Rebel 3 1650 140 120 40 K $55-70k Rebel LSA 2 1320 115 90 36 K  $50-60k ▼ Renegade Spirit 2 950 105 90 36 K/P  $48-55k Super Rebel TD 4 3000 160 150 46 K Yukon 4 2550 145 135 46 K $100k Mustang Aeronautics www.mustangaero.com Midget Mustang 1 950 202 175 57 K/P $25-40k ▼

Aircr Mustang II 2 1850 225 220 58 K/P $40-75k

National Aeronautics Co. www.cassutt.lornet.com Cassutt IIIM 1 850 225 190 65 K/P $25-40k Norman Aviation Int’l Inc. Mini Explorer Nordic 8 2 1232 110 90 35 K/P  $60k www.normanaviation.ca/ Norman VI-912 2 1200 110 103 34 K/P ▼ Norman VI-912-SW 2 1058 110 103 34 K/P  $45k Norman VI-914 2 1058 135 115 34 K  $55k Northbrook International SportStar 2 1232 129 121 45 K NuVenture Aircraft www.questairventure.com ▼ Questair Venture 2 2000 305 276 70 K $130-250k

nV Aerospace (was Rand-Robinson KR-1 1 950 200 165 52 P $9-15k Engineering, Inc.) www.nvaero.com KR-2 2 1050 200 165 52 K/P $12-24k Homebuilt ▼ KR-2S 2 1100 200 170 52 K/P $21-28k

Orion Aviation www.orionaviation.cc Orion-TS 6 4560 325 300 70 K Orlando/Sanford Aircraft www.airplane4sale.com Pioneer 200 2 992 108 100 34 K *Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available. 2017

48 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes An opportunity like this only comes along once an airplane. (Unless you add a second as your HSI).

G5 Electronic Flight Instrument with optional autopilot capability for your experimental or LSA. Or integrated backup to complete your G3X® or G3X® Touch system. Learn more at Garmin.com/experimental.

34527 G5 Experimental Opportunity Ad Rev-7.875x10.5-Kitplanes.indd 1 9/2/16 9:11 AM 50 2017 Homebuilt Aircr af t D IRECTOR Y For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Fixed-Wing Aircraft Fixed-Wing LSArequirements. meet to built be also can Aircraft limitations. LSA exceed may shown *Specifications Web Site Web Manufacturer/ PAW www.cgsaviation.com www.pipistrel-usa.com Pipistrel-USA com www.pietenpolaircraftcompany. Company Pietenpol Aircraft LLC Phoenix Manufacturing, com www.phantomaeronautics. LLCPhantom Aeronautics www.pazmany.com Pazmany Corp. Aircraft Aerocraft Paxman’s Northern Lite www.skyarrowusa.com Pacific Aerosystem, Inc. www.ospreyaircraft.com Osprey Aircraft www.piumaproject.com Danieli)(Tiziano Piuma Project Partenair DesignPartenair Inc.

(was CGS Aviation) KITPLANES December 2016 KITPLANES

▼ ▼ ▼ ▼ ▼ ▼ ▼ X-1e (enclosed cockpit) Virus SWVirus (Short Wing) Piuma TwinPiuma Evolution Pietenpol Air Camper Pazmany PL-9Pazmany Stork P92-S Echo Super P92-S Echo Sky Arrow 1450L Arrow Sky Piuma Evolution Piuma Apis Bee Electro Pazmany PL-4A Pazmany Free Spirit MkII Spirit Free Original Piuma Original Hawk Arrow II Arrow Hawk Taurus Electro Pazmany PL-2Pazmany Pazmany PL-1Pazmany Piuma Tourer P92-2000 RG Hawk Classic Hawk Arrow S45 Mystere S45 Phantom X1 Hawk Sport Hawk Ultra S45 Mark II Mark S45 Hawk Plus Sky Scout Sky P96-Golf Osprey 2 Osprey Apis Bee Model Taurus Sinus Viper Virus GP-4 Seats 1 1 1 1 2 3 1 1 1 2 2 2 2 1 2 2 2 2 1 1 1 1 2 2 1 2 2 2 2 2 2 2 2 1 2 Weight Gross 1040 1000 1000 1900 1300 1290 2100 1020 1673 1925 1235 1570 2150 1320 1433 1210 1416 1215 1215 1212 1212 1212 600 600 600 980 650 700 850 770 770 530 530 570 550

Speed Max Max 250 285 100 100 100 140 148 146 180 103 138 138 138 120 130 138 138 138 120 149 155 135 175 110 116 90 80 90 80 63 72 65 70 59 93 Speed Cruise 250 104 140 240 160 160 138 130 130 142 127 133 115 115 119 84 84 84 80 80 85 65 50 65 98 62 57 97 52 55 52 75 55 92 75 Information based on manufacturer-supplied data. All are in speeds m.p.h. on manufacturer-supplied based Information Listings in blue are for reference only—not currently available. currently only—not reference for are blue in Listings

Speed Stall www.kitplanes.com &www.facebook.com/kitplanes 40 44 40 40 40 54 58 30 65 38 38 38 36 27 30 36 52 35 45 35 52 26 39 39 39 39 39 35 35 39 35 33 55 37 55 Plans Kit/ K/P K/P K/P K K K K K K K K K K K K K K K K K K K K K K K P P P P P P P P P Legal* LSA                    

$80-100k $82-100k $82-100k $82-100k $82-100k $50-68k $28-40k $29-45k $28-45k $20-26k $25-35k $22-28k $24-28k $22-28k $19-26k $18-25k $67-76k $67-76k $17-19k $4-16k $6-16k Price $4-5k $4-5k $4-5k $6-7k 2017 Homebuilt Aircr af t D IRECTOR Y 51 $33k Price $18-19k $14-16k $32-33k $22-27k $19-23k $19-29k $16-22k $16-23k $22-26k $22-28k $25-27k $38-45k $30-50k $40-55k $30-40k $60-90k $46-60k $75-110k $85-110k $80-110k $100-140k $150-200k

                LSA Legal* P P P K K K K K K K K K K K K K K K K K K K K K K/P K/P K/P K/P K/P K/P K/P Kit/ Plans KITPLANES 2016 December 15 35 32 32 37 37 55 55 35 35 55 70 55 27 27 26 28 30 30 28 65 58 38 38 63 50 54 22 25 25 25 Fixed-Wing Aircraft Stall Stall Speed

Listingsin blue are for reference only—not currently available. 61 75 75 55 95 95 95 85 50 80 80 90 80 96 80 90 90 60 90 60 Information based manufacturer-supplied on m.p.h. speeds in are All data. 175 175 155 157 150 165 165 185 140 250 300

Cruise Speed 70 70 63 73 90 90 90 90 60 90 115 110 175 175 120 120 105 105 190 190 190 207 207 168 100 100 360 300 200 Max Speed

535 497 520 850 500 500 500 500 960 960 800 660 1100 1100 1232 1232 1430 1450 1450 1250 1200 1200 1600 1600 3500 1060 1000 2400 1400 2500 3000 Gross Gross Weight 2 1 2 1 2 2 2 2 1 2 1 2 1 2 2 1 4 1 2 2 2 2 1 2 2 1 2 1 2 4 2 Seats Zing XS-50 Vision LA912 LA582 Searey Stinger Model N-3 Pup Pulsar III Vision EX Ultra Pup Ultra Cloudster Pinocchio STOL King STOL Super Pup Super Pulsar 150 Fergy F-II B Challenger II Super CruiserSuper Super Cyclone Super Moskitto M-10 Prowler Jaguar Prowler S-51D Mustang Personal CruiserPersonal Super Pulsar 100 Challenger UL-103 Challenger Special Challenger II SpecialChallenger II Challenger II CW LSS Sport 150 Taildragger Sport 150 Challenger Light Sport Light Challenger Challenger II LSS XL-65 LSS II Challenger ▼ ▼ ▼ ▼ ▼ ▼

Precision Aero LLC Engineering, Produits Aviatech Inc. Aviatech Produits www.quadcitychallenger. com www.pulsaraircraft.com www.searey.com www.produitsaviatech.com Progressive Aerodyne, Inc. www.pro-composites.com www.precisionaeroeng.com www.fergy.net www.preceptorair.com Plane Perfection BRM Plane www.planeperfection.com Pro-Composites Inc. Pro-Composites PRIMAC ind. e com. ltda PrecisionTech Aircraft PrecisionTech Prowler Aviation, Inc. AircraftPulsar Corporation Preceptor AircraftPreceptor Company Pop’s Props Pop’s Quad City Quad Ultralights Aircraft Corp. Manufacturer/ Web Site *Specifications shown may exceed LSA limitations. Aircraftcan also be builtto meet requirements.LSA For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. visit models, of comparison side-by-side a For 52 2017 Homebuilt Aircr af t D IRECTOR Y For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. LSArequirements. meet to built be also can Aircraft limitations. LSA exceed may shown *Specifications Fixed-Wing Aircraft Fixed-Wing Web Site Web Manufacturer/ RANS Designs, Inc. (Pty) Ltd. (Pty) Rainbow SkyReach www.quicksilveraircraft.com Inc. Manufacturing Quicksilver www.bearhawkaircraft.com www.rans.com www.fly-skyreach.com/ www.rdaerosports.com www.gregagn-1.com LLC Enterprises J. Grega R. R&D Aerosports LLC Aerosports R&D R&D Aircraft R&D Raceair Designs Flyers, Inc. Flyers, Rainbow of Div. Quikkit R &BAircraft KITPLANES December 2016 KITPLANES

▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼ RANS S-12XL Super Airaile RANS S-6S Super Coyote II Coyote Super S-6S RANS RANS S-6ES Sport Wing Wing Sport S-6ES RANS RANS S-18 II RANS Stinger RANS S-12XLRANS Airaile RANS S-6S Coyote II II Coyote S-6S RANS RANS S-4/5 Coyote S-4/5 RANS RANS S-7S Courier RANS RANS S-16RANS Shekari RANS S-10RANS Sakota RANS S-17 Stinger Bearhawk (plans)Bearhawk RANS S-14RANS Airaile Keleher JK-1Keleher Lark RANS S-7 Courier RANS Bearhawk Patrol Bearhawk GN-1 Aircamper RANS S-9 Chaos S-9 RANS Bearhawk LSA Bearhawk MXL II Sport II MXL Mong Sport Glass Goose MX II Sprint II MX Sport Wing Sport Legallight MX Sprint MX MX Sport MX Coyote II Sport 2S Sport BushCat Model GT 400 GT Zipster GT 500 GT Skylite

Seats 2 2 2 2 1 4 2 1 2 2 2 1 2 1 1 2 1 2 2 1 1 2 2 2 2 2 1 1 1 1 2 2 Weight Gross 2000 2500 1000 1800 1200 1200 1450 1320 1320 1320 1320 1320 1100 1100 1100 1100 1100 1010 540 960 856 587 587 720 525 525 720 570 520 550 750 810

Speed Max Max 100 140 125 125 156 103 130 130 130 130 138 130 130 172 130 142 145 115 90 60 80 90 60 54 63 97 78 69 59 55 61 61 Speed Cruise 100 140 140 160 105 125 130 120 120 135 110 110 118 115 115 90 90 60 58 50 85 54 85 83 87 52 70 49 51 59 47 59 Information based on manufacturer-supplied data. All are in speeds m.p.h. on manufacturer-supplied based Information Listings in blue are for reference only—not currently available. currently only—not reference for are blue in Listings

Speed Stall www.kitplanes.com &www.facebook.com/kitplanes 48 25 25 58 36 36 36 36 28 30 50 57 27 27 27 43 42 27 35 35 43 27 42 27 35 33 35 42 35 32 41 24 Plans Kit/ K K K K K K K K K K K K K K K K K K P K K K K P P P P K P P K P Legal* LSA                        

$34-44k $30-40k $25-40k $43-46k $43-46k $24-40k $22-40k $55-80k $25-45k $27-48k $55-58k $60-75k $22-30k $31-56k $47-52k $21-30k $19-22k $16-18k $15-17k $6-18k $8-16k $6-12k Price 2017 Homebuilt Aircr af t D IRECTOR Y 53 Price $5-15k $4-10k $17-19k $17-18k $18-28k $26-38k $50-55k $25-50k $73-150k $70-150k $70-150k $70-100k $70-100k $150-250k $100-200k $100-200k

             LSA Legal* P P P K K P P K P P K K K K K K K K K K K K K K/P Kit/ Plans KITPLANES 2016 December 24 35 33 42 45 70 70 45 30 30 30 62 38 30 28 50 29 38 68 60 66 68 40 40 40 Fixed-Wing Aircraft Stall Stall Speed

Listingsin blue are for reference only—not currently available. Information based manufacturer-supplied on m.p.h. speeds in are All data. 75 38 58 85 60 86 80 60 90 112 110 110 155 136 188 168 207 207 100 100 100 100 220 200 200

Cruise Speed 45 63 62 63 98 80 110 110 110 242 130 120 120 138 120 265 265 140 100 260 260 225 200 Max Speed

375 550 550 500 860 800 900 900 1150 1455 1320 1320 1279 1764 2450 3575 1950 1780 1200 3500 1800 3500 1600 2200 2000 Gross Gross Weight 1 1 4 2 1 2 1 2 2 1 3 1 4 4 2 2 2 1 1 1 2 2 1 1 Seats R-7 R-9 R-8 Pelican Model Raven 2XS Fokker DR1 Fokker RAI-1 Tango Rihn DR-109 SE5A Replica SE5A Ravin 500 RG RAI-6 Foxtrot S-21 Outbound S-21 RAI-1 Tango XR Tango RAI-1 Coot AmphibianCoot RAI-6 Foxtrot XR RANS Raven S-20 RANS S-19 VenterraRANS S-19 Redfern DR1 Fokker M-19 Flying Squirrel Flying M-19 Primary Glider, 1929 Primary Glider, Ridge Runner Model II Model Runner Ridge Ridge Runner Model III Model Runner Ridge Ridge Runner Model IV Model Runner Ridge Ridge Runner Ultralight Runner Ridge Redfern Nieuport or 24 17 ▼ ▼ ▼ ▼ ▼ ▼ ▼ ▼

Rocky Mountain Wings, Wings, Rocky Mountain LLC Richard Steeves Richard Rihn AircraftRihn Corp. Ravin Aircraft USA, Inc. www.ronsandsreplicas.com www.flysquirrel.net www.realflying.com www.members.aol.com/danrihn www.robbins-wing.com www.coot-builders.com (formerly TEAM Tango) (formerly www.revolutionaviation.net [email protected] www.saravin.com www.ravenaircraft.com RANS Designs, Inc. Designs, RANS www.rans.com Robbins Wings Robbins Replica Plans Replica Ron Sands Replicas Sands Ron Redfern Plans Redfern Rogue Air Parts Raven Aircraft Corp. Refly, Inc. Revolution Aviation, Inc. Aviation, Revolution Manufacturer/ Web Site *Specifications shown may exceed LSA limitations. Aircraftcan also be builtto meet requirements.LSA For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. visit models, of comparison side-by-side a For 54 2017 Homebuilt Aircr af t D IRECTOR Y Fixed-Wing Aircraft Fixed-Wing LSArequirements. meet to built be also can Aircraft limitations. LSA exceed may shown *Specifications For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Web Site Web Manufacturer/ SAM Aircraft Shark Aero Siers Flight Systems, Inc Systems, Flight Siers Sherpa Aircraft Seaflight (NZ) Ltd. (NZ) Seaflight Sauser Inc. Aircraft Australia Pty Ltd Pty Australia Sapphire Aircraft Aircraft Sapphire S.G. Aviation America Inc. America Aviation S.G. Shirl Dickey Enterprises Seawind/SNA, Inc. Seawind/SNA, SeaStar Aircraft Inc. Aircraft SeaStar www.sgaviation.com www.scaled.com (RAF) Factory Aircraft Rutan www.sherpaaircraft.com www.sharkaero.com www.serenityaviation.com www.seqair.com www.seawind.net www.seastaraircraft.com www.seaflight.co.nz stevendumesny www.users.bigpond.com/ www.sam-aircraft.com Serenity AviationSerenity Sequoia Corp. Aircraft KITPLANES December 2016 KITPLANES

▼ ▼ ▼ ▼ (a.k.a. Revolution) (a.k.a. P6E Replica (82%)P6E Replica Storm Century Storm Seawind 3000 Seawind 2500 Sea Storm Z4 Storm Sea E-Racer MK-I E-Racer Spacewalker Spacewalker Shearwater VariViggen Storm 400 Storm Storm 500 Storm Storm 300 Storm Barracuda F.8L Falco Storm RG Storm Rally 105 Rally Sapphire Shark UL Shark Long EZ Long Model SeaStar Defiant SAM LS SAM Quickie Vari EZ Vari K650T

Seats 2 2 2 2 4 2 4 2 2 2 2 2 4 7 2 1 4 2 2 2 4 4 8 2 5 Weight Gross 3400 2040 3400 5000 2640 2300 3086 6500 1000 2997 1800 1880 1050 1234 1850 1700 1450 1325 1323 1320 1455 1455 1455 2145 704

Speed Max Max 200 206 205 240 235 180 180 180 185 165 165 163 165 187 275 120 195 145 149 178 178 216 155 212 112 Speed Cruise 200 220 260 144 144 148 140 190 125 165 134 150 150 130 173 172 173 197 178 170 155 191 90 98 Information based on manufacturer-supplied data. All are in speeds m.p.h. on manufacturer-supplied based Information Listings in blue are for reference only—not currently available. currently only—not reference for are blue in Listings

Speed Stall www.kitplanes.com &www.facebook.com/kitplanes 44 48 46 48 34 34 50 34 50 62 57 62 45 59 42 42 59 59 32 55 37 Plans Kit/ K/P K/P K/P K K K K K K K K K K K K K K P P P P P K P P Legal* LSA  

$995-1150k $130-170k $130-175k $45-120k $50-65k $13-50k Price Avemco Insurance Company will be there through all of the long days and long nights, insuring your baby as you build it, while you ﬂ y it and even if you should ever sell it. We never charge extra for liability-only coverage and we automatically include Bodily Injury and Property Damage Liability for covered claims up to one year after you sell*. Call us and one of our Aviation Insurance Specialists will handcraft a policy for you.

Call (888) 241 7890 or visit Avemco.com/Kitplanes Get a quote and a free hat.

Avemco.com/Kitplanes

*Not all coverages or products may be available in all jurisdictions. The description of coverage in these pages is for information purposes only. Actual coverages will vary based on local law requirements and the terms and conditions of the policy issued. The information described herein does not amend, or otherwise affect, the terms and conditions of any insurance policy issued by Avemco. In the event that a policy is inconsistent with the information described herein, the language of the policy will take precedence. Bodily Injury and Property Damage Liability coverage for up to one year after the date of sale, or the period that the aircraft was insured by Avemco, whichever is less. Free hat offer not available in New Mexico. A subsidiary of HCC Insurance Holdings, Inc. ADS0148 (10/15) Y Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price Silence Aircraft GmbH www.silence-aircraft.de ▼ Twister 1 880 146 145 47 K $65-90k

Sinoaustral Aviation BushCaddy L160 3 2250 125 115 42 K $60-110k Technology PTY LTD (fmr. Bushcaddy BushCaddy L162 Max 4 2650 140 125 37 K $60-110k International Inc.) www.bushcaddy.com BushCaddy L164 4 2650 140 125 42 K $80-120k

IRECTOR BushCaddy R120 2 1500 120 110 34 K $60-90k ▼ BushCaddy R80 UL/Sport 2 1320 120 110 32 K  $50-65k D Sky Classic Aircraft www.skyclassic.net ▼ Smith Miniplane 2000 1 1000 135 125 60 P $7-25k t

Sky Raider LLC Frontier 2 1320 130 105 38 K  $35-45k www.skyraiderllc.com af Sky Raider II 1 1050 85 80 32 K  $22-30k ▼ Super Sky Raider 2 1050 95 80 32 K  $24-32k

Sky Ranger Aircraft SkyRanger II 2 1212 116 105 36 K  $25-50k Company, Inc. www.skyrangeraircraft.com SkyRanger SS 2 1212 116 100 33 K  $25-50k SkyCraft International Inc. www.arv-super2.com ARV Super2 2 1168 137 115 58 K Skyline Technologies Sparrow II 2 990 130 95 36 K  Aircr Sparrow II XTC 2 1250 115 110 39 K  $40-45k

Sparrow Sport Special 1 775 100 85 31 K  $28-32k Sparrow Ultralight 1 504 63 58 27 P  $9-13k Skypaths Inc. www.skypaths.net Pathmaker JK-05 2 1232 128 110 42 K SlipStream International Genesis 2 1200 100 75 40 K  $28-32k (Slip Stream International LLC) www.slipstream.bz Revelation 2 1100 90 66 37 K  $22-32k

Scepter 1 1300 85 60 27 K  ▼ Ultra Sport 2 1150 100 70 40 K  $28-32k SLO Air Inc. www.sloair.com NXT 2 2600 375 345 88 K $250-450k

SoneraiWorks LLC Sonerai I 1 700 200 150 45 P $10-20k www.sonerai.com Sonerai II Original 2 950 200 140 45 P $10-20k ▼ Sonerai II Stretch 2 1150 200 140 50 P $10-20k Homebuilt Sonex Aircraft, LLC Onex 1 950 155 135 45 K  $27-40k www.sonexaircraft.com Sonex-B 2 1100 150 130 40 K  $36-46k SubSonex Personal Jet 1 1000 287 240 58 K $110-150k ▼ Waiex-B 2 1100 150 130 40 K  $36-46k Xenos Sport Motorglider 2 1275 120 100 44 K  $35-50k *Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available. 2017

56 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes 2017 Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price Specter Aircraft, Inc. Specter II 2 1600 170 140 54 K Spencer Aircar ▼ Spencer Air Car 4 3250 155 140 53 P Homebuilt

Sport Aircraft Works LLC Dynamic WT9 2 1150 155 150 37 K $85-95k www.sportaircraftworks.com Dynamic WT9 RG 2 1150 178 168 37 K $95-110k Mermaid 2 1430 132 115 40 K $80-95k Parrot 2 1320 138 132 28 K  $70-90k Sport Cruiser 2 1320 160 133 34 K $55-70k Sport Performance Aviation LLC www.flywithspa.com ▼ Panther 1 1115 170 138 51 K  $28-50k

Sportair Aviation, Inc. Corsario MK-5 2 1320 100 85 42 K  $45-60k www.sportairaviation.com ML500 2 980 80 65 K SportairUSA, LC www.sportair.aero Sting Carbon 2 1450 190 43 K Sportflight Aviation Talon Magnum 1 735 105 80 38 K  $22-32k Aircr www.sport-flight.com Talon XP 2 1050 95 72 41 K  $23-35k St-Just Aviation International Inc. Super Cyclone 4 3500 175 165 38 K www.supercyclone.com

St. Croix Aircraft Pietenpol Aerial 2 110 85 40 P www.stcroix.50webs.com Pietenpol Aircamper 2 1020 90 75 40 P ▼

Sopwith Triplane (1916) 1 120 100 40 P af

Starflight Industria Fox V5 Advanced/ V5 Super 2 919 84 75 35 K Aeron§utica LTDA www.starflight.com.br Fox V5 Tandem 2 919 80 75 34 K Fox Vector V6 2 919 90 78 35 K t

Steen Aero Lab, Inc. Firebolt 2 2000 214 170 61 P $40-105k www.steenaero.com

Great Lakes Sport Trainer 2 1618 138 125 40 P $50-120k D ▼ Knight Twister 2 865 180 145 56 P $25-90k

Pitts S1-C 1 1150 200 154 64 P $25-75k IRECTOR Skybolt 2 1970 210 170 68 P $35-100k

Stewart Aircraft Co. 265/275 2 1320 130 90 43 K  www.stewartaircraft.com ▼ FooFighter 1 1100 120 115 48 P 

Headwind B 1 750 90 85 40 P  $10-35k

Storch Aviation Australia Slepcev Microlight Storch 2 990 85 78 27 K Pty Ltd www.storch.com.au Slepcev Storch 2 1200 85 78 25 K Slepcev Storch Moose 4 3400 118 100 35 K Slepcev Super Storch 2 1900 100 90 29 K

*Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. Y For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available.

KITPLANES December 2016 57 Y Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price

Sunshine Aero Composites Dart 2 1350 200 160 65 P $15-30k

Super-Chipmunk Inc. www.super-chipmunk.com Super Chipmunk 2 2400 180 160 60 K Supermarine Aircraft LLC Mk 26 Spitfire www.supermarineaircraft.com 2 1653 220 180 48 K $130-145k (80% or 90% Scale) ▼ Mark 26B Spitfire 2 1985 253 187 51 K $230-260k

Swick Aircraft Swick T 2 1280 140 130 42 P IRECTOR Tapanee Aviation Inc. Levitation 2 2 2300 125 115 35 K $60-170k www.tapanee.com D Levitation 4 4 2500 130 120 38 K $65-180k

Pegazair 80 2 1058 110 95 15 K ▼ t Pegazair 100 2 1450 115 105 28 K/P $45-125k Taylor, T. www.taylortitch.co.uk Taylor Monoplane 1 700 115 100 40 P  $9-11k af ▼ Taylor Titch 1 760 200 160 52 P $11-15k

Team Mini-Max LLC 1030R MAX 103 Ultralight 1 560 62 55 26 K/P  $8-10k (was JDT Mini-Max LLC) www.teammini-max.com AeroMax 1 738 100 75 33 K/P  $12-14k Enclosed Cockpit, 1300Z 1 560 100 75 31 K/P ▼ Enclosed Cockpit, 1600R 1 560 75 72 28 K/P  $7-9k Enclosed Cockpit, 1 700 80 75 33 K/P  $10-12k Aircr 1650R Eros ▼ Hi-MAX, 1700R 1 560 75 70 31 K/P  $7-10k MAX-103 1030H 1 500 90 55 27 K/P Mini-MAX, 1100R 1 560 75 65 31 K/P  $8-10k Open Cockpit, 1200Z 1 560 100 65 31 K/P ▼ Open Cockpit, 1500R 1 560 75 65 31 K/P  $8-10k

V-MAX, 1550V 1 700 85 75 38 K/P  $8-10k

Team Rocket Aircraft F-1 Evo 2 2100 265 235 50 K $90-175k www.f1aircraft.com F1 Rocket 2 2000 257 230 56 K $70-175k ▼ F4 Raider 2 1750 215 198 52 K Thatcher Aircraft Inc.

www.thatchercx4.com ▼ Thatcher CX 4 1 850 130 125 40 P  $12-18k ▼

Homebuilt Thatcher CX 5 2 1320 120 42 K/P $25-32k

The Airplane Factory www.airplanefactory.com Sling 2 2 1540 155 132 45 1  $65-80k ▼ Sling 4 4 2024 161 138 54 1 $80-100k

58 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes 2017 Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price The Butterfly Aircraft L.L.C. (The Butterfly LLC) Banty 1 500 60 50 27 www.thebutterflyllc.com

The Light Aircraft Sherwood KUB 1 550 99 64 25 K  Company Ltd. (TLAC) Homebuilt www.g-tlac.com Sherwood Ranger ST 2 1040 90 70 38 K  $45-69k

Sherwood Ranger XP Aero 2 1040 90 70 40 K  $40-60k ▼ Sherwood Scout 2 1100 132 92 39 K  $37-58k Thorp Central (Classic Sport Aircraft) www.thorpcentral.com ▼ S-18 2 1600 215 180 63 K/P $30-45k

Thunder Mustang LLC (Gut Works, LLC) www.thundermustang.com ▼ Thunder Mustang 2 3200 375 345 68 K $350k

Thunderbird Aviation, Inc. www.hiperlightaircraft.com Hiperlight SNS-8 1 500 93 58 27 K  $20-30k Aircr ▼ Hiperlight SNS-9 2 875 113 85 39 K  $31-50k

Titan Aircraft T-51 Mustang 2 1450 170 150 42 K $80-100k www.titanaircraft.com T-51 Mustang - V6 2 1800 197 175 48 K $80-150k ▼ T-51 Mustang LSA 2 1320 170 140 42 K  $80-100k Tornado I Sport 1 750 113 95 30 K  $20-35k *Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available. af

Thatcher CX 5 Available as a taildragger or t with tricycle gear, the Thatcher

CX 5 is powered by an 85-hp Revmaster R-2300 engine. See D the April 2016 issue for details. (Photo: Sheldon Heatherington) IRECTOR Y

KITPLANES December 2016 59 Y Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price Titan Aircraft Tornado II FP 2 1200 120 100 40 K  www.titanaircraft.com Tornado II Trainer 2 1000 125 110 35 K  $35-45k Tornado MG 1 750 130 100 35 K  $16-25k Tornado MG II 2 1000 150 120 35 K ▼ Tornado S 2 1140 125 125 35 K  $35-50k Tornado SS 2 1200 125 125 40 K  $38-60k Toxo Aircraft North America Toxo Sportster 2 1536 180 175 40 K

IRECTOR www.mytoxo.com Turbine Design TD-2 2 4100 400 330 65 K D Turner Aircraft, Inc. T-40 1 1060 170 145 45 P $8-20k

www.turnert-40airplanes.com ▼ T-40A 2 1600 160 147 56 P $12-30k t T-40A Super 2 1650 175 155 62 P $20-35k U-FLY-IT Light Sport Aircraft, LLC af www.fly103.com ▼ Aerolite 103 1 600 75 70 27 K 

U.S. Aviation www.ultralight-soaring- Cumulus 1 640 90 75 32 K  $12-19k aviation.com Ullmann Aircraft Company www.ullmannaircraft.com Panther 4 3050 200 200 67 K $100k Ultimate Biplane Corp. 10-100 1 1350 190 140 55 K/P Aircr www.ultimatebiplane.com

10-200 1 1350 190 170 60 K/P $60-90k 10-300 1 2000 195 190 60 K/P $95-190k ▼ 20-300 2 2000 200 190 58 K/P $108-213k Ultravia Aero Int’l Inc. Pelican PL 2 1400 155 145 49 K www.ultravia.ca Pelican PL/912S 2 1400 140 130 50 K Pelican Sport 2 1320 132 126 44 K Unger, Carl H ▼ Breezy R.L.U.-1 3 1200 105 80 28 P $8-12k

Van’s Aircraft, Inc. RV-3 1 1100 207 196 51 K $35-63k www.vansaircraft.com RV-4 2 1500 204 192 51 K $37-73k RV-6/6A 2 1600 210 199 49 K ▼ RV-7/7A 2 1800 216 206 51 K $41-97k Homebuilt RV-8/8A 2 1800 222 212 51 K $41-98k

RV-9/9A 2 1750 196 188 50 K $44-82k RV-10 4 2700 208 197 63 K $95-121k ▼ RV-12 2 1320 135 131 47 K  $65-70k ▼ RV-14/14A 2 2050 205 195 53 K $75-95k *Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available. 2017

60 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes 2017 Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price Velocity, Inc. Velocity Elite RG 4 2250 230 210 70 K www.velocityaircraft.com Velocity SE-FG 4 2300 201 184 70 K $70-140k ▼

Velocity SE-RG 4 2300 219 200 72 K $75-150k

Velocity SUV 4 2250 183 175 65 K Homebuilt Velocity TXL-RG-5 4 2900 290 288 72 K $175-250k ▼ Velocity V-Twin 4 3200 230 207 82 K $235-400k Velocity XL-FG 4 2700 238 213 75 K $110-180k Velocity XL-FG-5 5 2900 219 200 75 K $110-185k Velocity XL-RG 4 2700 242 219 75 K $125-195k ▼ Velocity XL-RG-5 5 2900 247 230 75 K $125-195k Velox Aviation Inc. www.veloxrev.com Rev1, Rev2 2 1980 230 200 63 K Venom Aircraft www.venomaircraft.com Venom 2 3750 375 320 67 K $350-750k Viking Aircraft www.vikingaircraft.com ▼ Cygnet SF2-A 2 1100 110 100 48 P  $18-20k

Vintage UltraLight Betabird 1 650 80 80 45 P  $2-5k

Association Aircr www.vula.org Gypsy 1 475 55 45 22 P  $2-5k ▼ J3-JR 1 550 55 45 25 P  $2-4k Mr. Easy 1 485 63 50 28 P MW-7 1 600 85 55 35 P  $2-5k Skypup 1 400 69 50 26 P  Whing Ding 1 310 45 35 24 P  $2-5k ▼ Woodhopper 1 345 40 30 18 P  $2-5k

*Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. af For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available.

Van’s RV-14 t When the tailwheel RV-14 was released, the nosewheel version was re-designated the RV-14A. See the February 2016 issue D for details. (Photo: Richard VanderMeulen) IRECTOR Y

KITPLANES December 2016 61 Y Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price Viper Aircraft Corp. www.viper-aircraft.com ViperJet Mk II 2 5200 538 400 88 K $650-795k VSR www.snoshoo.com ▼ SR-1 Snoshoo 1 760 260 200 65 P $15-30k

VSTOL Aircraft Corporation SS2000 2 860 67 50 20 K www.vstolaircraft.com SST2000 2 1500 100 60 22 K $85-105k

IRECTOR VX Aerospace Corporation www.vxaerospace.com FX 300 4 K

D W.A.C.O. Aircraft Company Ohio, Inc. ▼

WACO M-F 3 2500 140 120 48 K $120-150k t

Wag-Aero Group, The Sport Trainer 2 1320 94 85 38 K/P  $35-45k www.wagaero.com

af Sportsman 2+2 4 2200 128 124 38 K/P $45-60k ▼ Wag-A-Bond 2 1320 126 124 43 K/P  $29-40k

WAR Aircraft Replicas A6M2-Zero 1 900 155 135 55 P $18-24k www.waraircraftreplicas.com F-4U Corsair 1 900 155 135 55 P $18-28k

F8F Bearcat 1 900 155 135 55 P $17-26k ▼ Focke Wolf 190 1 900 155 135 55 P $16-26k

Aircr Hawker Sea Fury 1 900 155 135 55 P $16-26k

Hurricane 1 900 155 135 55 P $17-26k ▼ Messerschmidt BF-109 1 900 155 135 55 P $18-24k

P-40 Warhawk 1 900 155 135 55 P ▼ P-47 Thunderbolt 1 900 145 135 55 P $14-26k

P-51 Mustang 1 900 155 135 55 P $17-26k

Warner Aerocraft, Inc. Revolution I/Spacewalker I 1 850 140 120 38 P www.warnerair.com Revolution II/Spacewalker II 2 1400 125 120 42 P

Sportster 2 1320 125 110 43 K  $45k Weedhopper Plans www.freeweedhopperplans.com ▼ Weedhopper 40 1 550 60 55 20 P  $9-11k Homebuilt Weedhopper, Inc. Weedhopper Standard 1 485 55 50 25 K  $4-10k

Weedhopper Super 1 830 65 60 25 K  $12k

Weedhopper Two Place 2 840 65 55 28 K  $14k Western Aircraft PGK-1 Hirondelle 2 1475 157 145 55 P Supplies Ltd. *Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available. 2017

62 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes 2017 Fixed-Wing Aircraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price Williams, Lynn www.flitzerbiplane.com ▼ Flitzer Z-21 1 800 105 93 42 P  $10-25k

Homebuilt

Wings of Freedom LLC www.wingsoffreedomaviation. Flitplane 1 600 70 63 28 K/P  $7-12k com

▼ Phoenix 103 1 650 75 63 28 K  $12-15k

World Aircraft Company www.worldaircraftco.com Spirit 2 1320 125 110 35 K  $60-75k ▼ Vision 2 1320 125 105 27 K  $60-75k

World War I Aeroplanes Fokker D.VII 1 1870 117 P

SE5A 1 2048 136 P

York Enterprises Laser Z-200 1 1400 180 165 64 P $30-50k www.yorkaircraft.com

▼ Laser Z-2300 2 2050 250 195 60 P $30-50k Aircr Ultimate Series 1 1380 220 170 60 P

Zenair Ltd. CH 750 Cruzer 2 1440 115 115 39 K  $20-55k www.zenair.com ▼ STOL CH 750 2 1440 105 100 35 K/P  $38-65k

STOL CH 801-HD 4 2200 110 105 39 K $60-100k ▼ Zodiac CH 640 4 2200 160 150 47 K/P $45-100k af Zodiac CH 650 2 1320 138 138 44 K/P  $35-65k

Zenith Aircraft Co. CH 750 Cruzer 2 1440 118 118 39 K/P  $21-50k www.zenithair.com t ▼ SAM-EX 2 1800 155 142 50 K $50-80k

SAM LS 2 1450 155 125 42 K  $50-65k D STOL CH 701 2 1100 100 90 30 K/P  $30-50k IRECTOR ▼ STOL CH 701 Amphib 2 1250 90 74 32 P  $38-64k

STOL CH 750 2 1440 110 100 35 K/P  $38-65k

STOL CH 801 4 2200 125 105 39 K $40-80k ▼ Zodiac CH 601 HD 2 1200 135 115 44 P  $8-46k

Zodiac CH 601 UL 2 1058 135 115 44 P  $8-45k ▼ Zodiac CH 650 2 1320 138 138 44 K/P  $35-65k

Zodiac XL 2 1320 138 134 44 K/P  $29-60k

*Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. Y For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available.

KITPLANES December 2016 63 Y Rotorcraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price A-B Helicopters A/W 95 1 450 65 65 P Aero-Works, Inc. Microlight 1 700 60 K  $19k www.aerolite103.com Single Place-High 1 700 65 K  $25k Performance Two Place Tandem 2 1318 70 K  $34k Ultralight 1 550 55 K  $17k

Aerotrek Aircraft ELA G8 Cruser 2 1100 100 90 K  $53-63k www.aerotrek.aero ▼ ELA G8 Ranger 2 1100 100 90 K  $50-60k IRECTOR ELA G10 Eclipse 2 1168 115 100 K  $82-90k D Air Command Commander Elite 447 1 552 63 50 K 

International, Inc. www.aircommand.com Commander Elite 503 1 590 75 55 K  $18-21k ▼ t Commander Elite 582 1 750 95 65 K  $21-23k Commander Elite 912 2 1155 110 75 K  $60-75k Tandem af Commander Elite 3202 1 590 75 55 K 

▼ Commander Elite EJ22 2 1155 110 75 K  $40-60k Tandem Commander Elite Mazda 2 1500 120 70 Commander Elite S/S F-30 2 750 84 65 K Commander Elite 1 750 95 65 K  $30-40k Single-Place EJ22 Aircraft Designs, Inc. www.aircraftdesigns.com

Aircr Bumble Bee 1 500 65 40 P  $3-5k

▼ Sportster 2 1100 90 75 P  $6-25k

American Sportscopter, UltraSport 254 1 525 63 63 K  $35k Int’l. Inc. www.ultrasport.rotor.com UltraSport 331H 1 650 104 65 K  $38k Ultrasport 496 RT 2 1100 104 69 K UltraSport 496H Hornet 2 1180 104 70 K  $68k

Auto Gyro USA Calidus 2 1234 120 100 K  $75-78k www.autogyrousa.com ▼ Cavalon 2 1234 120 90 K  $96-99k

MTO Sport 2 1234 120 100 K  $60-63k

Aviomania Aircraft G1sa Genesis Solo 1 660 105 80 K  $19-27k www.aviomania.com G2sa Genesis Duo 2 1200 120 90 K  $35-50k

Homebuilt Genesis CE (model G1sB) 1 750 100 75 K  $17-27k ▼ Genesis Sport (model G1sE) 1 800 110 80 K  $23-35k Barnett Rotorcraft Barnett J4B 1 850 120 97 K/P  www.barnettrotorcraft.com Barnett J4B-2 2 1085 112 93 K/P  $19-39k BRC540 Coupe 2 1248 138 110 K/P  $44-58k *Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available. 2017

64 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes 2017 Rotorcraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price CH-7 Helicopters CH-7 Angel 1 792 100 80 Heli-Sport S.r.l. www.ch-7helicopter.com CH-7 Kompress 2 1100 129 100

Chayair Manufacturing & Aviation Sycamore Mk1 2 1058 90 80 K Homebuilt www.limpopo.co.za/chayair.htm Composite Helicopter International Ltd. www.compositehelicopter.com ▼ KC 518 Adventourer 6 3200 155 K $395k

Eagle R&D, LTD www.helicycle.com ▼ Helicycle 1 850 110 95 K $40-45k

Eagle’s Perch, Inc. Eagle’s Perch 1 1200 113 85 K

Engineering System Co., GEN H-4 1 420 100 60 K Ltd, Aviation Division

FD Composites GmbH www.arrow-copter.com Aircr ▼ ArrowCopter AC-20 2 1230 121 90 K/P $150k

Groen Bros. American Autogyro www.americanautogyro.com ▼ SparrowHawk Gyroplane 2 1500 100 75 K  $46-60k af

Gyro-Kopp-Ters Midnight Hawk 1 810 90 60 K  $14-16k www.gyro-kopp-ters.com

Mosquito Hawk 1 700 80 55 K  t ▼

Twin Eagle 2 1210 90 60 K  $19-23k

Helo Werks, Inc. D www.helowerks.com ▼ HX-2 Wasp 2 1225 107 81 K $125-130k IRECTOR

Hillberg Helicopters RotorMouse EH 1-01 1 1300 180 160 K/P Shark Mouse EH 1-02 2 1927 185 145 K/P Two Place EH1-02 2 1800 170 130 K/P

Hinchman Aircraft Co. H-1 Racer 1 550 85 65 P HoneyBee G2, LLC HoneyBee G2 High 1 809 75 60 K  $25k www.honeybeeg2.com Performance Single HoneyBee G2 Microlight 1 700 60 K  $19k

*Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. Y For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available.

KITPLANES December 2016 65 Y Rotorcraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price HoneyBee G2, LLC www.honeybeeg2.com HoneyBee G2 Two-Place ▼ 2 1318 85 60 K  $34k Tandem

HoneyBee G2 Ultralight 1 532 63 55 K $17k

I’m Fly’N Mfg. LLC www.imflyn.com SnoBird Charger 1 600 100 70 K Innovator Technologies Mosquito Air 1 530 70 60 K $30-37k www.innovatortech.ca Mosquito XE 1 610 85 70 K $34-42k

IRECTOR Mosquito XE3 1 720 100 80 K $39-47k ▼ Mosquito XEL 1 585 75 65 K $35-43k

D Mosquito XET 1 820 100 80 K $51-58k

JAG Helicopter Group, LLC www.jaghelicopter.com JAG 2 3200 178 145 K t Joe Souza Gyroplanes Bandit Two Place 2 1000 70 40 K www.rotorcraft.com/bandit/ index.htm Bandit Ultralight 1 598 63 55 K Super Bandit 1 700 85 65 K af Ken Brock Mfg. KB-2 Gyroplane 1 600 95 70 K/P  www.kenbrockmfg.com KB-3 Gyroplane 1 600 63 60 K/P  Little Wing Autogyros, Inc. LW 3+2 2 1100 100 75 K/P www.littlewingautogyro.com LW-3 1 950 100 75 P  $10-40k LW-4 2 1100 100 75 P  $20-75k ▼ LW-5 2 1100 100 75 P  $20-75k Magni USA, L.L.C. M-14 2 1212 115 90 K  $68-78k www.magnigyro.com M-16 2 1212 115 90 K  $75-85k Aircr M-18 1 771 105 70 K  $39-40k

M-22 2 1212 115 95 K  $76-86k ▼ M-24 Side by Side 2 1212 105 90 K  $97-99k Neico Aviation Inc. CH-7 Kompress 2 1100 130 100 K North American Pit Bull UL 1 525 63 58 K Rotorwerks Pitbull II 2 1025 88 70 K Pitbull SS 1 610 85 70 K PAM Group www.flying-platform.com PAM 100B 1 1060 60 45 K

Raven RotorCraft Inc.  www.raven-rotor.com Raven Lite 1 504 65 60 K $16-19k Rotary Air Force SA Pty Ltd RAF 2000 GTX SE 2.2 FI 2 1540 120 70 K $28k (Rotary Air Force Marketing, Inc.) Gyroplane www.rafsa.co.za RAF 2000 GTX SE 2.5 FI 2 1540 140 85 K $32k Gyroplane ▼ RAF 2000 2 1540 140 85 K $71k Homebuilt

Rotor Flight Dynamics www.rotorflightdynamicsinc.com Dominator 1 650 114 65 K/P ▼ Dominator Tandem 2 1200 95 70 K $41-45k

66 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes 2017 Rotorcraft Manufacturer/ Gross Max Cruise Stall Kit/ LSA Web Site Model Seats Weight Speed Speed Speed Plans Legal* Price RotorWay International

www.rotorway.com ▼ A600 Talon 2 1500 120 95 K $105-110k

Exec 162F 2 1500 115 95 K $70-75k Homebuilt

Safari Helicopters (CHR International, Inc) Safari 2 1500 100 85 K/P $90-135k www.SafariHelicopter.com ▼ Safari 400 2 1650 100 85 K/P $133-185k

Showers Aero Skytwister 1 680 80 65 P Sport Copter, Inc. Lightning 1 600 65 50 K  $23-29k www.sportcopter.com Sportcopter II 2 1700 120 100 K $185-218k Super Sport 2 1650 120 100 K $82-105k Super Sport Tandem (SST) 2 K Vortex 1 760 80 75 K  $30-34k ▼ Vortex M912 1 934 110 95 K  $36-65k Star Bee Gyros www.starbeegyros.com ▼ Star Bee Light 1 485 65 55 K  $15-16k Aircr

The Butterfly Aircraft L.L.C. Aurora Butterfly 1 950 90 70 K  $51-58k (The Butterfly LLC) www.thebutterflyllc.com Emperor Butterfly 1 520 63 55 K  $19-26k Golden Butterfly 2 1400 95 70 K $60-70k ▼ Monarch Butterfly 1 630 70 60 K  $23-31k Super Sky Cycle 1 1100 90 70 K  $80-87k

The Ultralight Butterfly 1 507 63 55 K af ▼ Turbo Golden Butterfly 2 1800 95 70 K $70-86k Ultralight Butterfly 1 509 63 50 K  $18-22k

Vertical Aviation t Technologies Hummingbird 300L 4 2800 120 110 K/P $172-250k www.vertical-aviation.com

D ▼ Hummingbird 300LS 4 2800 120 100 K/P $172-250k IRECTOR Vortech, Inc. A/W 95 Helicopter 1 500 75 60 K/P $26-32k www.prismz.com/helio G-1 1 420 63 50 K/P  $18-19k ▼ Hot Rod Helicopter 1 1350 103 90 K/P $20-30k Kestrel Jet Helicopter 1 425 63 55 K/P $18-20k New Choppy Helicopter 1 600 80 65 K/P $33-36k New Choppy Ultralight 1 500 63 55 K/P $27-30k Shadow Gyroplane 2 1290 100 70 K  $28-33k ▼ Skylark Helicopter 1 700 95 70 K/P $34-36k The Sparrow 1 500 63 60 K  $9-11k Zeus Helicopter Inc. Zeus 2 1580 110 95

*Specifications shown may exceed LSA limitations. Aircraft can also be built to meet LSA requirements. Information based on manufacturer-supplied data. All speeds are in m.p.h. Y For a side-by-side comparison of models, visit www.kitplanes.com/aircraftdirectory. Listings in blue are for reference only—not currently available. J

KITPLANES December 2016 67 CNC Mold Blank

FabricationBy Eric Stewart

Part 1

Last year we featured a pair of tooling foam in (relatively) inexpensive, Wing mold for the author’s SR-1 speed- articles [“Fifties Fuse, Teeny Wings,” non-production-quality CNC molds for plane after machining at Catto Propellers. March 2015 and “Black Beauty,” April vacuum-bagged parts. (By non-produc- Although Catto primarily uses its CNCs for propeller manufacturing, the large table 2015] that provided an overview of tion quality, we simply mean that the size makes them perfect for wing molds. fabricating a Formula 1 raceplane number of parts you can expect to make wing using CNC-based rapid proto- from these molds is limited; they are best are mounted to a CNC and machined typing. The scale of the project was employed for prototypes, one-offs, or according to a computer aided manufac- too large to get into the nitty-gritty parts made in small quantities.) turing (CAM) file generated from the details, but in this series of articles With the costs of CNC machines CAD program. we’re doing just that—and a lot more. and concomitant shop rates dropping The first step—learning CAD/CAM— We’ll look at making a mold blank, to a point of affordability for the aver- is not a trivial undertaking, but nor is familiarizing yourself with the materi- age amateur aircraft builder, it is now it rocket science. For example, using als and methodology vis-à-vis coupon possible to fabricate your own molds tutorial books such as Paul Tran’s Solid- testing and, finally, provide a detailed, for composite parts at a reasonable Works Part I: Basic Tools and Part II: step-by-step procedure for making a price. Producing such molds is basically Advanced Techniques, along with Matt vacuum-bagged part such as a wing. a three-step process: First, the molds Lombard’s excellent reference book We’ll also provide a video link where must be designed with a 3D computer SolidWorks Bible, you should be able you can watch a typical layup. aided design (CAD) program like Solid- to create advanced models in approxi- In this first pair of articles, we are Works or Inventor. Next, mold blanks mately 300 hours ab initio. If you have no going to look at the use of lightweight are assembled. Finally, the mold blanks CAD experience, teaching yourself can

68 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes be extremely frustrating. In that case, I highly recommend taking a university or community college course to get started. This will also allow you to purchase the student versions of CAD software for hundreds of dollars vs. the thousands you would pay for commercial versions. An even better deal for EAA members is that you can now get a student copy of SolidWorks for free (visit http://tinyurl. com/jeqa8s2 for details). The last step—machining—is probably something many builders have some familiarity with, but we’ll also assume most of you don’t own your own CNC A model of the CNC table part attach points can help when determining dimensions of the frame. (Courtesy of Catto Propellers) and will have a friend or shop do this for you. So the first and last steps are gluing the block to a mounting board of reinforcement or very small (less than beyond the scope of this article. How- MDF or plywood is sufficient. This base 18 inches) molds, in which case it is ever, the middle step of assembling is then bolted to the table (don’t forget to generally easier to simply use a sheet of the mold blanks is certainly within leave enough edge room on your base for MDF as noted previously. the grasp of homebuilders, and is what bolting), and you are ready to machine. If possible, keeping the frame rectan- we’ll cover here. Seal exposed wood as necessary to pre- gular, irrespective of mold shape, will help vent warping that could be caused by with positioning on the CNC table, by Step 1: Fabricate the Steel Frame moisture absorption. which we mean setting home (i.e., where Once your part has been modeled in For larger objects, such as wing or the machine reads the zero point of the x, CAD, you will have a good idea of the fuselage molds, you will need a frame y and z axes) and establishing the orienta- dimensions of the foam blank and req- that ensures that the shape CNC’d tion of the mold (i.e., aligning the x axis uisite mounting frame. The first consid- while on the table is preserved when of the mold parallel to the x axis of the eration is how you will mount the mold the mold is removed from the table, CNC machine). Non-rectangular molds blank to the CNC table. Most CNC and will stand up to the rigors of may save a certain amount of weight and tables will have threaded holes to which layup, assembly, and storage. The easi- materials cost, but will require more time you can bolt your frame. The CNC oper- est method is to simply weld the frame fiddling with alignment/orientation ator should be able to provide you with a from 16-gauge (1/16-inch wall thick- while on the table. Consider whether the bolt hole diagram for their table. You’ll ness) mild steel tubing. For smaller material and weight savings are worth also want to find out the maximum x, objects such as control surfaces or tail the extra time spent at the table. If you y, and z axis travel of the tool head to feathers, 1.5-inch square tubing is suffi- are paying for CNC time by the hour, ensure that your mold will fit within the cient. For larger objects, such as a wing, a mold that allows quick setup will save parameters of the machine. use at least 2-inch square tubing, and/ you money in the long run. The downside For smaller block-shaped molds (for or heavier gauge tubing. One-inch tub- of a frame that is larger than the actual example, a spinner or wheelpant), simply ing is too small and flexible for all but mold is marginally greater cost and

(Left) Smaller block-shaped molds (i.e., for a spinner or wheelpant) can simply be bonded to a sheet of MDF/plywood, which is then bolted to the CNC table. (Center) High-density (30-pound) mold finished with PPG DP90LV. Higher density foams finished this way obviate the need for the vacuum bag release layer used with lower density foams. (Right) You can also get a nice finish by applying a thin coat of Evercoat Ever-Glaze spot putty with a squeegee, sanding to a smooth finish with 220 grit, and shooting with epoxy primer.

Photos: Eric Stewart KITPLANES December 2016 69 weight. The foam itself should be cut to actual mold shape in order to minimize waste, since it will be the most expensive material per square foot. Two final frame considerations are how to incorporate portability and storage into the frame. Wing and fuselage molds can be extremely heavy and awkward to move, so consider welding handles of 1x1-inch angle to the frame. Molds can also be quite large, so give consideration to how you will store and stack them in order to minimize the shop footprint and also protect the mold surfaces (i.e., stacking wing (Left) Although the wing mold is tapered, the frame itself is rectangular for ease of construction and alignment on the CNC table. The foam is cut as close to the mold shape molds face to face so that the vulner- as possible, since it is quite expensive. Foam cutoffs can be bonded into blocks for new able machined surfaces are facing blanks. Consider storage options when planning your molds. The rolling steel frame inward). All handles, mounting feet, under the mold serves as storage and supports the mold during wing assembly. Shelves etc. should have rounded corners to underneath provide storage space for layup materials. (Right) Retracting bolts allow the avoid poking holes in humans and vac- frame support to be precisely leveled when constructing the wing. uum bags, and open tube ends should be closed to avoid sucking the vacuum The melamine is stripped in the areas steel frame, as well as the exposed par- bag into the frame. where it will be bonded to the steel ticleboard edges, in order to minimize frame with a 4.5-inch ceramic flap disc entry points for moisture that could Step 2: Attach the Base mounted to an angle grinder. Likewise, cause warping of the MDF or rusting Once the frame is welded, the next step the frame should be lightly roughed up of the steel. is to attach the base. The base adds stiff- with a grinder wheel where it will be As mentioned previously, for small or ness to the frame and provides a large bonded to the base to ensure a good block shape molds, the melamine par- surface area to which the tooling foam is grab for the adhesive. The particleboard ticleboard serves as both frame and base adhered. MDF/melamine particleboard is then glued to the steel frame with when steel is not used. works well, since the homogeneous construction adhesive and weighted nature of the particleboard means it is evenly for a good bond. Once the adhe- Step 3: Prepare/Attach the Foam usually quite flat, and the melamine acts sive has cured, use the remaining adhe- The final material to be added is the to prevent moisture absorption and con- sive, or a latex acrylic caulk, to fillet the tooling foam. This article will assume sequent warping. seams between the particleboard and the use of a high-density urethane foam

(Left) An angle grinder with an abrasive flapper pad is used to roughen up the frame before bonding on the MDF base. The flapper works great for most applications, but the cutting disk on the left can be used if serious metal removal is required. (Right) Round all sharp points that could potentially poke a hole in the vacuum bag. Here you can see a piece of angle iron tacked to the frame as a handle, as well as an end plate tacked over the open end of tubing to prevent the vacuum bag from getting sucked into the tubing. A well-constructed blank will prevent headaches when it comes time to vacuum bag. You’ll have plenty to worry about during a layup without chasing down leaks poked in your bag by the mold.

70 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes (Left) CalPoly Mechanical Engineering student and SR-1 Project intern Brian Paris lays down a bead of construction adhesive to bond the mold base to the frame. Note that the melamine has been sanded off the mold base bond line (see red arrow). (Right) After bonding to the frame, you may wish to seal the edges of the base to avoid moisture absorption. such as Coastal Enterprises’ Precision Precision Board comes in a large vari- used on the F1 wing mold mentioned Board Plus (distributed by Revchem ety of densities, from 4 to 75 pounds per at the beginning of the article, is obvi- Composites). Lower density foams cubic foot. The price is approximately ously much less expensive, can be moved (such as the blue or pink rigid extruded $6.00 per cubic foot per pound and is without a forklift, but has visible poros- polystyrene [XPS] board available from linear: 20-pound foam is twice the price ity and is easily dented with a fingernail. home centers) will compress under vac- of 10-pound, and 40-pound is four times As such, it requires extreme care in han- uum and as such are not appropriate for the price. Forty-pound foam provides dling. Go with the highest density you vacuum-bagged parts, but are fine for excellent machined surfaces with no vis- can afford (and lift). Ten-pound foam is non-bagged wet layups. ible porosity. Ten-pound foam, such as the absolute minimum recommended for

KITPLANES December 2016 71 The tooling foam will be bonded to the frame using vacuum bag pressure, so it is necessary to fill the open frame space underneath with cheap insulation foam (otherwise the vacuum bag has a tendency to rupture when bridging large gaps between the steel frame and MDF sheet). The tabs at the bottom of the sheet are strips of duct tape to pull the foam out afterwards so it can be recycled on other molds.

vacuum-bagged parts, and will probably The two surfaces are then clamped or only allow for a few pulls (i.e., part layups) vacuum bagged, with full cure occurring before “hangar rash” becomes a problem. in approximately 240 or 30 minutes, The Iscold F1 wing featured in last depending on whether you use the slow year’s article had four molds (upper sur- (PB Bond 240) or quick cure (PB Fast face left and right, lower surface left and Set). Because the PB Bond expands, small STATEMENT OF OWNERSHIP, right), each of which used approximately irregularities between the foam and base, MANAGEMENT, AND CIRCULATION 12 cubic feet of 10-pound foam. So the or in the application of the adhesive, are (Required by 39 U.S.C. 3685) 120 cubic-pound feet on each surface filled by the expanding foam. 1. Publication Title: KITPLANES. 2. Publication Number: 0891- 1851. 3. Filing Date: 9/9/16. 4. Issue Frequency: 12 issues cost about $840, and each complete For small pieces, PB Fast Set and per year. 5. No. of Issues Published Annually:12. 6. Annual Subscription Price: $29.95. 7. Complete Mailing Address of mold blank—steel, base, and foam— strong clamping provides excellent Known Office of Publication: Aviation Publishing Group, LLC, weighed well over 200 pounds. results quickly with a hairline bond an affiliate of Belvoir Media Group LLC, 535 Connecticut Ave, Norwalk CT 06854. Contact Person: Greg King, Phone: 203- Precision Board can be cut with width. For larger pieces, you will need to 857-3119. 8. Complete Mailing Address of Headquarters or General Business Office of Publisher: Aviation Publishing typical woodworking tools like table use PB 240 and vacuum bag the assem- Group, LLC, an affiliate of Belvoir Media Group LLC, 535 Connecticut Ave, Norwalk CT 06854. 9. Publisher: Phil Penny, or band saws; no special blades are bly (Coastal Enterprises web site has an 535 Connecticut Ave, Norwalk CT 06854. Editor-in-Chief: required. The melting temperature of Paul Dye, 535 Connecticut Ave, Norwalk CT 06854. Managing Editor: Mark Schrimmer, 535 Connecticut Ave, Norwalk CT the foam is too high to permit hot-wire 06854. 10. Owner: Aviation Publishing Group, LLC, an affiliate of Belvoir Media Group, LLC, 535 Connecticut Ave, Norwalk cutting. Note that Precision Board is CT 06854. 11. Known Bondholders, Mortgagees, and Other not UV tolerant and will visibly tan Security Holders Owning or Holding 1 Percent or More of Total Amount of Bonds, Mortgages or Other Securities: very quickly (within minutes) when None. 12. Tax Status: Has Not Changed During Preceding 12 Months. 13. Publication Title: KITPLANES. 14. Issue Date for exposed to sunlight. Short term this Circulation Data Below: October ’16. 15. Extent and Nature of does not pose a problem, but long term Circulation (Average No. Copies Each Issue During Preceding 12 Months/No. Copies of Single Issue Published Nearest can result in degradation of the foam. to Filing Date): a. Total Number of Copies (Net press run): (38,817/36,900) b. 1. Paid/Requested Outside-County Mail Therefore you will want to store your Subscriptions Stated on Form 3541: (21,178/20,591). 2. Paid foam (and molds) away from sunlight. In-County Subscriptions Stated on Form 3541 (0/0). 3. Sales Through Dealers and Carriers, Street Vendors, Counter Sales, Although the foam can be bonded and Other Non-USPS Paid Distribution: (3,989/3,743) 4. Other Classes Mailed Through the USPS: (0/0) c. Total Paid and/or to the MDF base with epoxy, this is Requested Circulation: (25,167/24,334) d. Free Distribution unnecessarily expensive and overly com- by Mail: 1. Free or Nominal Rate Outside-County Copies included on PS Form 3541: (32/32). 2. Free or Nominal Rate plicated. Coastal Enterprises offers a In-County Copies as Stated on PS Form 3541: (0/0). 3. Other Classes Mailed Through the USPS: (0/0). 4. Free or Nominal one-part urethane adhesive that is faster, Rate Distribution Outside the Mail: (706/535). e. Total Free easier, and cheaper than epoxy. This or Nominal Rate Distribution: (738/567). f. Total Distribution: (25,905/24,901). g. Copies not Distributed: (12,912/11,999). adhesive is a moisture-cured isocyanate Precision Board is easily cut with a circular h. Total: (38,817/36,900) j. Percent Paid and/or Requested Circulation: (97.2%/97.7%).16. Publication of Statement of (i.e., expanding foam) that is applied saw. A length of 2-inch steel tubing serves Ownership: Dec.16 17. I certify that all information furnished to one or both surfaces to be bonded. as a straightedge. on this form is true and complete: Greg King, VP, Circulation.

72 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes excellent video on how to use PB adhesive, as well as a variety of other infor- mational videos and literature on PB Board [http://tinyurl.com/nl6h4sj]). Of course, in addition to bonding the foam to the base, you can use PB adhesive to join several cutoffs into one large block, or to make topographical blanks that economize foam usage. Avoid the temptation to bond the foam to the base with construction or similar adhesive. You will not get an even bond line, and any unbonded pockets will deflect under the pressure of the tool head, ruining the accuracy of your mold. That’s all we have space for this month. In Part 2 of this article, we will discuss vacuum bagging blanks to the CNC frame, mounting the blanks to the CNC table, and a few other options for rapid prototyping. Following that, we will then explore fabricating coupons, in order to dial in your layup process, as well as get a feel for composite structures. J Products/Vendors listed in this article: Coastal Enterprises Precision Board Plus tooling foam, PB Bond adhesives www.precisionboard.com Revchem Composites (Distributor of Coastal Enterprises products) www.revchem.com Catto Propellers, Coastal Enterprises, and Revchem Composites are spon- sors of the SR-1 Project. Eric St Eric Eric Stewart is designing and building the SR-1, a ...and leave your engine speed plane for setting monitoring to EIS. records in the FAI c-1a/0 Trusted with everything from 2-strokes to turbines for over two decades. category (takeoff weight less than 661 pounds, including e pilot and fuel). You can see wart more at facebook.com/ FLY IT TheSR1Project, including like you stole it... additional photos and videos of the subjects in this series of articles. www.grtavionics.com • (616) 245-7700 Proud sponsor of Tiger Airshows and airplane “thief” extraordinaire, Hotwire Harry!

KITPLANES December 2016 73 Got Wings? Here’s what you get in EVERY ISSUE of KITPLANES ® • Aircraft Flight Reviews • Construction Hints & Tips • Hands-On Projects • The Latest in Avionics • New Products for Experimentals • Real-World Builder Experience

Expert advice on how to plan, build and complete your own aircraft!

Subscribe to KITPLANES® and receive these extras: • Unlimited online access at www.KITPLANES.COM • FREE access to our Editorial Archive of articles • FREE searchable Aircraft Buyer’s Guide • FREE searchable Supplier Directory

For fastest service, visit us at www.kitplanes.com/subscribe or call us toll free at 800/622-1065 Stressing Structure Analysis Tools By David Paule

We don’t use slide rules anymore. Back in the day, they were handy calculation tools, but limited because they don’t have addition or subtraction.

We all know and enjoy tools, so this the number has five significant digits, 35,300 psi is the same as 3.53 * 104 psi time we can discuss the analytical tools. the one on the left, the 1, is the most sig- 29,000,000 psi is the same as 2.9 * 107 psi Probably the most important are paper, nificant digit, and the one on the right is (and it’s often written as 29 * 106 psi.) pencil, and eraser. These are the easiest the least significant digit. way to make notes and put down calcu- This suggests that the position of the 3.890 * 10-3 in4 is the same as .00389 in4 lations. One thing that’s important is to decimal point matters a lot. We call and is the area moment of inertia of a add enough documentation that a year that the order of magnitude, and big- piece of tubing that has a diameter of .5 from now, you can figure out what you ger means more. There’s even a special inches and a wall thickness of .035. did. Things to include are the date and way to write numbers that separates Since the right-hand digit of the basic what the topic is. the digits themselves from the position number has so much less importance of the decimal point. It’s called scien- than the left-most digits, we can drop Number Terminology tific notation and our number 158.42 it or round it off as necessary. The most (and, Yes, Slide Rules) would be expressed as 1.5842 * 102. common engineering need is to keep the The slide rule was a handy calculation Another way to write it down would three left-most digits and the exponent. tool, somewhat limited because it doesn’t be the way text programs write it on If we do that, generally speaking, we’re add or subtract. But for long equations computer output: 1.5842E2. In this being plenty accurate. After all, how well that don’t have addition or subtraction, case, the “E” is short for “the exponent can we assess the actual loads on a part it’s useful. You can even do some limited of 10 is.” Sometimes a lower-case “e” is or the actual strength of it? Usually not powers, typically squares or square roots, used for the identical meaning. Either as good as one part in a thousand, which or cubes and cube roots. Looking at the way it’s a handy shortcut. is the precision that the third digit from photo, you can see that any single num- With slide rules, we have to keep the left end represents. ber isn’t going to have very many digits. track of the exponent. We have to do This lesson was taught to the engi- Even though we don’t use slide rules it on paper, too, and in stress analysis neering community by slide rules, any more, it’s worth discussing what we there’s a lot of this sort of bookkeep- which are only accurate to three sig- learned from it for a moment. ing. Typical instances of big numbers nificant digits. It’s a valuable lesson, Here’s a number: 158.42. What do we are numbers in the thousands of psi for and now that we’ve abandoned them, know about it? Well, the most impor- stresses and millions of psi for modu- we still remember it. Therefore, don’t tant thing is that it’s a bit larger than 150, lus of elasticity. Cross-section areas bother carrying numbers out more while not as big as 160. And that the .42 and moments of inertia are often very than three places. They usually have lit- is not very important compared to the small amounts in units of in2 or in4, tle meaning after that. But don’t neglect 158. In fact, the importance of each digit or “inches squared” or “to the fourth the exponent, for there lies the overall drops as you move to the right. So while power.” Examples of these are: magnitude of the number.

Photo: David Paule KITPLANES December 2016 75 Calculators a lot of money. They are enormously use- have another general-purpose program My calculator is probably the single most ful for overall project management and that’s unfortunately not as common as it important analysis tool I own. Any decent much of the parametric analysis, where should be, called Mathcad. scientific one will handle exponents and you need to vary some of the parameters What it does is let you do math, show- powers and trigonomic functions. Addi- to find a workable design. Most of the ing all the units and carrying them along tionally, it’s helpful if they can do natural spreadsheets have math capabilities that in the equations. They aren’t just place- logarithmic numbers. It should be able to are more than ample, and many will let holders in the equations, but real work- handle at least one or two intermediate you write a “macro,” or small program, as ing parts of the equation. If your equation results, which we often see in equations. part of your analysis. uses length, for example, and you want to These are things like sums in parentheses One aspect of spreadsheets, though, add 10 millimeters to 2.0 inches, you can, in part of the equation. is that they don’t show you the equation and it will give you the choice of units to These days, the need for a program- directly, in a form that you can compare show the answer of 2.394 inches or 60.8 mable one is not as great as it was before to whatever reference you’re using. And millimeters. I have found this program to personal computers, so I have no rec- the contents of the cells are merely num- be extremely useful and regard it as one of ommendation for that. Your computer bers. They don’t carry any units along my must-have programs. handles that function pretty well, if you with them. In aeronautical engineering You can see a comparison chart of its learn to write programs. broadly, more than just stress analysis par- features at http://tinyurl.com/npr6as2. The nice thing about the calculator ticularly, that’s a significant detriment. It has links to the free version, which is that it’s portable and that you can get It makes following the work difficult, might be all you need, or the very expen- numbers anywhere when you need them. makes debugging it harder, and makes sive full versions. The free version has Mine flies with me, resides in the shop, verifying the end result pretty arduous. documentation and can do most of what and occupies a place next to my computer. If you are a spreadsheet whiz and can we generally need. As far as I know, Whichever calculator you like, roar around those issues, then feel at ease there’s no version for a Mac. Since I use a learn it well. Make it be an extension with doing your analysis on it. But for the Mac, I bought Parallels, loaded a copy of of your mind. rest of us, please consider how to differ- Windows on it, and installed one of my entiate pounds force from pounds mass, versions of Mathcad. Learning to Write Software Code or handle changes of units from feet to I’ve got to say that my experience with Your bookcase shelf of technical references inches, or millimeters to inches, or knots the program goes up through version is the heavy iron of the analysis toolbox. to feet per second. These sorts of things 14. I understand that some of the more Your personal computer is a close second. need to be clear and explicit so that you recent versions are not as good, so try the There are a few types of programs that are can verify that there aren’t any mistakes. free version if you can and see. especially useful to structural analysis, and Carrying the units sure helps that, and an The brief example below shows some if you plan to do this for years, it’s definitely even better thing to do is show the units. analysis that I did in Mathcad. It’s an worth learning to write some programs. incomplete smidgeon with some terms That’s right...to do stress analysis, one of Mathcad not included. Like some other pro- your talents is being able to write code. In I like spreadsheets and use them regularly, grams, things must be defined before the long term that’ll make life easier. In the but keeping in mind their limitations, I we can use them. Definitions use a short term it generally won’t. Whatever code language you choose Flange Bending to learn, if you decide to go for it, you . should be able to handle math quite well. ea := .22 in Edge distance of the reaction hole in the angle Not only the ordinary kinds of arithme- Da := .136.in Diameter of the #6 hole (a #8 hole would be weaker, less material left) tic, algebra and trigonometry, but defi- ta := .063.in Thickness of the angle nitely things like matrix math, too. I’ve Wa := .375.in + Da Effective width of the angle at the vertex that handles this load found that some higher math is handy Ba := .5.in Width of the flange, vertex to edge from time to time over my career, but I ts can’t recommend learning that merely to aa := Ba - ea - Moment arm aa = 0.248.in analyze one airplane; it isn’t used often 2 enough to justify the effort, and there are ba := 2.0.in Screw spacing coding packages available that you can a := .844.in Center of the bearing to the center of the flange obtain if you need them. P.a aa.6 σ := . Bending stress for the load in the vertical σ = 10497.psi v ba.2 Wa.ta2 direction, shared in 2 screws v Spreadsheets . . Most computers either already have a P aa 6 Bending stress for the load in the horizontal . σh := σh = 12437 psi spreadsheet, or you can get one for not 4.Wa.ta2 direction where load gets taken by all 4 screws

76 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes colon and an equal sign to denote that a few places where they do come in they are different than results, which handy, and occasionally they are very omit the colon. The first definition is a handy, indeed. decent example, where the symbol “ea” But a good, competent engineer will has a length of .22 inches. Mathcad always make a hand analysis that backs knows that “ea” is a length, now that up the FEA program. In fact, checking it’s been defined. The symbol “Wa” a finite element analysis model is practi- defines an equation. The equation has cally an art. So if you have access to one both a length as one of its terms and or spend the money and buy one, please another term that’s defined earlier, the be wary. The learning curve is steep “Da” symbol. indeed, and I don’t mean how to work The bottom two equations show the program, I mean how to get what how subscripts can be used to help you want out of it. identify similar symbols and how There are several decent FEA pack- superscripts are used for exponents. ages out there, ranging from free to Since the Greek symbol for Sigma is astonishingly expensive. My experi- often used for stress, I used it here. ence is primarily with a couple of older Dots are used to show multiplica- ones called Cosmos/M, now part of tion—you might remember that from the SolidWorks bundle, and Nastran. high school physics. I put the results of They are both powerful programs with the equations on the right, along with a wide variety of choices and options a brief text description. for materials, types of elements, loads, To me, the advantages of using this kinds of solutions, and so on. If I were program make it absolutely worth its starting afresh, I’d certainly get one cost. Nonetheless, it’s only as good as of the free programs available today, your engineering input. Get an equa- and might even pay for one. I’d look tion wrong and although it will show for documentation, particularly third- you what the resulting units are, even if party documentation, since that pretty the units still jibe, there might still be much suggests that there’s been some other errors remaining. For example, longevity and spread to the program. in the two stress equations at the bot- I’ve learned over the years that you tom, if I had accidentally omitted the don’t want an early generation version number “6,” the answers would have of an FEA program. It will be unreli- been that much lower, and that would able, no matter how good the numbers have been a pure engineering error, and pictures appear. One that’s been not the sort of error that Mathcad can around for a while and has a base of detect. Even so, you can see the num- users, though, will probably be reason- ber “6” in the equations and check that ably acceptable. Probably. J against its source. This is harder to do Davi in a spreadsheet. David Paule retired after 30 years of structural analysis Finite Element Analysis and is now building an Our final analysis tool is finite element analysis or FEA. This is the program RV-3B to keep from getting that presents those wonderfully colored d bored. The structural stress pictures that are often shown to engineering included a mix Paule Paule demonstrate sophisticated engineer- of aircraft and spacecraft. He ing. Let me tell you that there are more has been a private pilot since potential gotchas with FEA than you age 18 and can imagine. I might write an article about some of them one of these days. currently I’m reluctant to discuss FEA programs owns and because I don’t want you to think that flies a these are necessary programs, and they Cessna 180. aren’t, for most of our work. There are

KITPLANES December 2016 77 BEST PRACTICES Blind rivet selection and installation. Rivets have been popular fasteners in not. Thus some may be used for struc- Many low-cost commercial blind rivets aircraft construction for a very long time tural work, but others definitely not. will not reliably retain their stems under and remain so today. They provide an However, there are many places where difficult conditions. This is why they are excellent means of joining sheets of alu- non-structural blind rivets may do the generally never used for anything on an minum together in ways that are smooth job quite well. airplane that holds it together or keeps and strong. It is no surprise, then, that Just as with solid rivets, the shape and it running. many Experimental/Amateur-Built air- composition of the rivet makes a big dif- craft rely on these tried-and-true fasten- ference. With blind rivets, the composi- Types of Blind Rivets ers. While solid rivets remain the standard tion of the rivet stem or mandrel is also Cherry Aerospace, Avex, Avdel, Emhart, for most aircraft designs, the emergence an important factor. For example, alu- POP, and others make a wide selec- of aircraft-quality blind rivets, also called minum rivets can come with aluminum tion of blind rivets in various materials pull rivets or sometimes POP rivets, has stems or steel stems. Those with steel for many commercial and aircraft uses. made it possible to save builders a lot of stems are typically much stronger. They range from N rivets, non-structural time as they put their planes together. A While on the topic of rivet stems, the commercial rivets, to Cherry MS, Cherry- quick tour of vendors at the most recent ability of a rivet to retain its stem under MAX, and CherryLOCK structural rivets, AirVenture shows blind rivets being used conditions of high loads and heavy plus similar rivets by other manufactur- in kits by CubCrafters, Murphy, RANS, vibration separate aircraft rivets from ers. In between commercial and aircraft Van’s, Zenith and more. In addition to their commercial cousins. A rivet loses blind rivets, we have Q rivets that are their use in basic aircraft structures, blind much of its strength if the stem falls out. not strong enough to replace the same rivets also have many non-structural applications that are of interest to builders, among these securing baffle seals to engine baffles.

What is a Blind Rivet? A blind rivet gets its name from the fact that it can be installed in a hole that goes into a space that is inaccessible or not visible to the installer. In other words, it can be installed in a “blind” hole. On the other hand, the typical solid aircraft rivet must be bucked, so access to the back side is vital to its proper installation. There is a host of blind rivets in the This Zenith 750 on display at AirVenture was assembled with blind rivets. This simple marketplace, so a buyer must be careful design feature made it a good candidate for last year’s One Week Wonder project. Zenith to get the right rivet for the job. Some of uses a unique system for installing their blind rivets, so be sure to read the instructions these are aircraft quality, but many are and get the correct tools before starting your project.

Dave Prizio has been plying the skies of the L.A. basin and beyond since 1973. Born into a family of builders, it was only natural that he would make his living as a contractor and spend his leisure time building airplanes. He has so far completed three—a GlaStar, a Glasair Sportsman, and a Texas Sport Cub—and is helping a friend build an RV-8. When he isn’t building some- Dave Prizio thing, he shares his love of aviation with others by flying Young Eagles or volunteering as an EAA Technical Counselor. He is also an A&P mechanic, Designated Airworthiness Representative (DAR), and a member of the EAA Homebuilt Aircraft Council.

78 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes sized AD rivets, but do possess some structural strength and high-quality characteristics. N and Q rivets can easily be installed with any commercial blind rivet tool, but CherryMAX and Cherry- LOCK rivets are best installed with a special tool designed just for these stronger rivets. In a pinch CherryMAX rivets can be installed using a standard riveter, but that would not fall under best practices. Q rivets are available in steel, aluminum, stainless steel, and Monel. Stainless steel Q rivets would work well for assem- A pneumatic blind riveter really saves bling a stainless steel firewall in lieu of time and arm fatigue when building a using driven Monel rivets. Monel blind project with a lot of blind rivets. However, rivets also work well with stainless steel it probably represents an unnecessary expenditure for other builders. or titanium. Most kit manufacturers will also allow the next size larger Q rivet as a the CherryMAX as a replacement. How- substitute for an AD rivet, (1/8-inch Q rivet ever, probably not a problem is not the for an AN470AD-3 rivet), but this should same as never a problem, so it would be be verified on a case-by-case basis. In prudent to consult with your kit maker all cases, when substituting one type of or airplane designer before making such rivet for another, it is best to run it by the a substitution. One advantage of Cherry- airplane designers to be sure they agree MAX rivets is that they come in standard with the deviation from their design. sizes and 1/64-inch oversized for holes that If we need a 1/8-inch blind rivet to have been damaged. replace a 1/8-inch AD rivet, we have Just for the sake of clarity, do not another possibility—the CherryMAX casually use a substitute blind rivet of a rivet. A 1/8-inch aluminum CherryMAX different material just to gain strength. rivet has a shear strength of 664 pounds While it is certainly true that a Q rivet and a tensile strength of 285 pounds. made of plated steel, stainless steel, This makes it much stronger in shear or Monel would meet or exceed the than a 1/8-in. AD rivet, but weaker in ten- strength of a same sized AD rivet, such a sion. Since most rivets are loaded in substitution should only be made after shear, it is probably not a problem to use consulting with the aircraft designer

Hand-operated blind riveters will work for most projects where only a few blind rivets must be installed. The lower tool has a swiveling head, which can come in handy sometimes. The straight tool above works better in some tight corners where the larger nose of the swivel-head riveter just won’t fit.

Photos: Dave Prizio and courtesy of Cherry Aerospace KITPLANES December 2016 79 Here is an assortment of N rivets. They are available in aluminum These are aluminum Q rivets. They come with universal heads with aluminum or steel shanks and in plated steel with steel shanks. and 120-degree flush heads. They are not available with the They also come with universal, flush, or large heads for an assort- 100-degree flush heads commonly used in airplane construc- ment of non-structural applications. tion. They are, however, available in other materials such as stainless steel, plated steel and Monel. and after considering potential dissimi- Some builders of planes that are the specified blind rivets? I don’t think lar metal corrosion concerns. designed to use blind rivets may decide so, except that using AD rivets will be There is a cost issue with the various to use solid AD rivets instead. Some a lot more work. One special note on types of rivets. AD rivets in common Murphy Moose and Super Rebel build- this—if you are building an ELSA air- sizes typically cost less than two cents ers have done this, in hopes of making plane that is designed with blind rivets each if you buy a quarter-pound or their planes stronger, or at least more such as the RV-12, you may not substi- more. Q rivets in 1/8-inch diameter will durable. Whether they achieved their tute AD rivets without the kit maker’s cost about 18 cents each, roughly ten goals or not is hard to say. If the plane written permission. If you do, you will times more. CherryLOCK or CherryMAX was designed with blind rivets, then lose your ability to register it as an ELSA rivets will run about 75 cents each. Q riv- using those rivets should be a reason- and will instead be subject to Experi- ets seem like a good choice for firewalls able thing to do consistent with best mental/Amateur-Built rules. or non-structural applications such as practices. Is there a good case to be Let’s review the different types of engine baffles. made against using AD rivets in lieu of rivets available to the amateur airplane Selected Numbers and Strengths for 1/8-in. Diameter Blind Rivets

Material Head MS or NAS no. Part no.1 Shear-lbs. Tension-lbs. Aluminum Protruding n/a AAPS-04-x 120 150 Aluminum Large Flange n/a AALS-04-x 120 150 N Rivets Aluminum Flush-120º n/a AACS-04-x 120 150 Aluminum Protruding n/a AAPQ-04-x 225 250 Aluminum Large Flange n/a AALQ-04-x 225 250 Aluminum Flush-120º n/a AACQ-04-x 225 250 Monel Protruding n/a MSPQ-04-x 650 525 Monel Large Flange n/a MSLQ-04-x 650 525 Q Rivets Monel Flush-120º n/a MSCQ-04-x 650 525 Stainless Steel Protruding n/a CCPQ-04-x 700 600 Stainless Steel Large Flange n/a CCLQ-04-x 700 600 Stainless Steel Flush-120º n/a CCCQ-04-x 700 600

1 “x” in part number is placeholder for the grip length designation.

80 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes These are CherryMAX rivets in aluminum with universal and Rivet washers come in very handy when riveting metal parts to 100-degree flush heads. In most places they will work as a same- soft materials such as fiberglass or silicone baffle material. They size replacement for an AD rivet. They also come in 1/64-inch are usually available at any well-stocked hardware store. The oversize for holes that have been damaged by mis-drilling or combination of a washer and a large head rivet works well for prior rivet removal. baffle seal installation. builder and see where they may be interior trim items. The protruding head for the next-size-smaller AD rivets, with employed consistent with best practices. listed in the table is roughly the equiva- the approval of the aircraft designer. A lent of a universal head in structural riv- same size Q rivet is in no way a direct N Rivets ets. The flush-head version of these rivets replacement for an AD rivet. Like N rivets, N rivets are non-structural commercial only comes with a 120-degree counter- Q rivets only come with a 120-degree blind rivets made by a number of compa- sink, not the 100-degree countersink countersink angle. Q rivets do enjoy a sig- nies such as Avdel and others. The rated used in aviation. nificant benefit over N rivets in that they strength of these rivets is low because do reliably retain their stems. This makes they do not reliably retain their stems, Q Rivets them something of an intermediate step leaving only the hollow shank to resist Q rivets, now made by Avdel, are some- between true structural rivets and non- shear and tension loads. They should times called the poor man’s CherryMAX structural commercial rivets. These rivets only be used for things that do not hold rivets. However, that gives them too are available in aluminum, stainless steel, critical items. N rivets with large flanges much credit. They are not structural rivets plated steel, and Monel. N and Q rivets are popular for retaining baffle seals in any broad sense, although they may are easily installable with most any com- to aluminum engine baffles or joining sometimes be used as a replacement mercial rivet gun.

Material Head MS or NAS no. Part no.1 Shear-lbs. Tension-lbs. Aluminum Universal MS20600-4-x CR9163-4-x 388 265 Aluminum Flush-100º MS20601-4-x CR9162-4-x 327 265 Monel Universal MS20600M-4-x CR9563-4-x 678 590 MS Rivets Monel Flush-100º MS20601M-4-x CR9562-4-x 554 590 Aluminum Universal MS20470-4-x CR3213-4-x 664 285 Aluminum Flush-100º MS20426-4-x CR3212-4-x 664 285 Monel Universal MS20470M-4-x CR3523-4-x 975 400

CherryMAX Rivets Monel Flush-100º MS20426M-4-x CR3522-4-x 975 400 Aluminum Universal NAS1738B-4-x CR2249-4-x 619 345 Aluminum Flush-100º NAS1739B-4-x CR2248-4-x 619 345 Monel Universal NAS1738M-4-x CR2539-4-x 895 490

CherryLOCK Rivets CherryLOCK Monel Flush-100º NAS1739M-4-x CR2538-4-x 895 490

1 “x” in part number is placeholder for the grip length designation.

KITPLANES December 2016 81 Cherry® MS Rivets Cherry® MS rivets are the lowest grade blind rivets made to a military standard. They are much more deserving of the title of poor man’s CherryMAX rivets than Q rivets. They are technically obsolete but are still in wide use, having been replaced 5˚ max by the stronger CherryMAX rivet. MS rivets are available with 1/64-inch oversized shanks for use in holes that have been damaged and drilled out. As a true structural aircraft rivet, they are available as This diagram made from an image in the CherryMAX catalog shows the maximum slope of the material surface on the back or blind side. If the unevenness or slope exceeds five 100-degree countersink flush rivets and degrees, then the shop head of the rivet may not hold securely. with universal heads. The rated shear strength of MS rivets is dependent on Cherry recommends that their G27 rivet aluminum rivets have aluminum bodies the thickness and type of material being gun be used for these and CherryLOCK and steel stems. Monel rivets have Monel joined together. Consult Cherry Aero- rivets. Most aircraft parts vendors such as bodies and Inconel stems. They, too, are space publications for more information. Aircraft Spruce will stock limited sizes of available with oversized shanks and are The major drawback to these rivets is that CherryMAX rivets and the G27 rivet gun. best installed with a G27 riveter. they may be hard to find. CherryMAX rivets are also available with 1/64-inch oversized shanks for use in holes Stanley Engineered Fasteners CherryMAX Rivets that have been damaged and drilled Stanley now owns the Avex, Avdel, and CherryMAX rivets are popular structural out. CherryMAX rivets have aluminum or POP brand names. Their blind rivets aircraft rivets for many types of instal- Monel bodies and steel stems. They are come in a number of sizes and head lations where a rough equivalent to a available in a number of configurations designs, making them a good alternative solid AD rivet is desired but difficult or including 100-degree countersink flush for manufacturers seeking options other impossible to install. They are size-for-size rivets, and with universal heads. than those offered by Cherry Aerospace. equivalent to AD rivets in shear, but gen- For example, RANS uses structural rivets erally lacking in tension. This is usually not CherryLOCK by both Avex and Cherry in their kits. a problem, since most rivets are loaded in Cherry’s strongest blind rivets are the Zenith uses Zenair rivets that are essen- shear, but before making any substitution CherryLOCK series. Their main advantage tially Avex rivets. Note that Zenith uses a builder should check with the aircraft over CherryMAX rivets is their greater a special flush rivet that is shaped into a designer to be sure there is no problem. strength in tension. Since tensile strength universal-type head by means of a spe- These rivets typically have steel or Inco- is not typically an overriding concern to cial nosepiece on the rivet gun. This is nel stems, which gives them very good aircraft designers, these rivets are seldom well described in their assembly instruc- shear strength. These tougher stems used by amateur builders. Like CherryMAX tions. Consult the manufacturer’s litera- also mean that standard rivet guns can rivets, they are available in a number of ture or go online for more information struggle installing these rivets. Therefore, configurations and materials. CherryLOCK on these products.

These drawings from the CherryMAX catalog make the point that the rivet hole should be perpendicular to the surface of the material. The drawing on the right shows that any time you are drilling through two sheets of metal, you need to be sure to clear the chips out from in between the sheets, and never insert a rivet into a misaligned hole.

82 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes Installing Blind Rivets Installing blind rivets is pretty easy, but that does not mean that it should be done carelessly. Some stronger structural rivets should be installed with special rivet guns. Be sure to consult the manufacturer’s literature for their recommendations. Pneumatic riveters can be great time savers, but be sure that the correct nosepiece has been installed for best results. This recommendation also applies to hand riveters. The nosepiece needs to match the diameter of the stem to work well. Be sure that all parts have been drilled to the correct size hole and properly deburred. Any debris caught between sheets of material will cause the joint to be substandard. When riveting to material with an uneven backside, be sure that the slope of the material being secured does not exceed five degrees. Hold the rivet gun in such a way that the stem is perpendicular to the front- side surface. If you are securing a solid material to a soft material, consider the use of rivet washers on the back (soft) side if there is access. For example, if aluminum is to be attached to fiberglass or silicone baffle material, use a washer to support the rivet tail if possible. In the case of securing soft baffle seal material in particular, use a large-head rivet on one side and a washer on the other. This will hold the baffle seal more securely and minimize cracking around the rivet head.

Conclusion If you have an application that calls for blind rivets, do not feel that you are limited to the products in the Aircraft Spruce and Wicks catalogs. There is an incredible number of blind rivets available for many structural and non-structural uses that may be of interest to an airplane builder. Just be sure to check with your airplane’s designer before striking off on your own when it comes to blind rivets. You want to be sure that you are using the right product for the job you are doing. Best practices always say to do your homework before you build, to be sure what you are doing is going to give you a safe result. J

KITPLANES December 2016 83 CHECKPOINTS Maintenance A number of readers and customers for a while. Just a generation ago, most Another positive result is that the com- have asked me to share some thoughts homebuilt aircraft required a large vari- pletion rate has gone up dramatically in on aircraft maintenance, so in the next ety of skills, from welding to riveting, the last decade. However, I think a large few columns I am going to discuss this along with engine and systems knowl- number of builders realize that building topic based upon my experiences. Not edge. Sometimes a good portion of time is a lot of fun, and it truly can be educa- everyone who purchases an Amateur- was even spent constructing jigs prior tional and relaxing. Some find they really Built aircraft understands that they are to actually building airplane parts and miss the fabrication process and part permitted to perform any and all mainte- structures. Contrast that with today’s kits with their aircraft earlier than anticipated nance on their aircraft during the course that never require any welding, have all so they can start building again. of the year. The only caveat is that only of the holes match-drilled, which pre- There’s a saying, “boys and their toys,” the holder of the repairman certificate cludes any jig building, and they even that is very prevalent in the new gen- for that particular aircraft, or a licensed include prefabricated wiring harnesses! eration of Amateur-Built aircraft, and A&P mechanic, must perform the condi- Personally, I believe it has been a real win I am just as guilty. The last generation tion inspection. In the certified aircraft for everyone, and I also know there has airplanes were certainly much simpler, world, FAR Part 43 very clearly spells out been the commensurate positive impact usually just full of the necessary steam the limited amount of maintenance that upon safety. gauges for the engine and a radio or tran- an aircraft owner/operator can perform, sponder if really needed, as opposed to and this is usually the circle of reference today’s full-glass cockpits, weather, and for the new owner if this is their first foray entertainment systems. Usually by the into the Amateur-Built aircraft world. time they were sold, they had flown a My opinion is that if you are the least few years or longer, and the owners had bit mechanically inclined, you should worked out any of the operational bugs take the time to get to know the inside and corrected any of the wear areas. of your aircraft as well as the outside, With today’s fully equipped panels and within reason. With the vast amount systems, I think it is really hard to com- of knowledge so quickly available via pletely work through all of the systems the internet, and especially YouTube, it in the required 40 hours. is very easy to “learn by seeing” before With regards to the airplanes I have actually attempting the task yourself. built, I have had one really hard and fast Plus, with so many EAA chapters around, rule: Don’t trust the aircraft until it has there is a vast pool of resources just an acquired at least 100 hours, and after email or phone call away, so why not that, continue to keep a cautious eye. take advantage of them? Chances are I’ve been involved in a number of sales you will only improve upon your safety right at the 40-hour mark via a pre-buy with regards to flying. inspection, and having flown a number There was a time not too long ago when Take a close look and you will see that the of them back home with the new owner, I rudder cable is actually chafing the alumi- most Amateur-Built aircraft took quite a num tube. It had almost cut a hole in the can assure you that many of the bugs and while to build, and once completed they tube and was fraying the cable by the time wear items were not completely worked tended to stay with the original builder it was discovered. through on every single one of them.

Vic is a Commercial Pilot and CFII with ASMEL/ASES ratings, an A&P, DAR, and EAA Technical Advisor and Flight Counselor. Passionately involved in aviation for over 39 years, he has built 10 award-winning aircraft and has logged over 8000 hours in 70 different kinds of aircraft. Vic Vic Syracuse had a career in technology as a senior-level executive and volunteers as a Young Eagle pilot and Angel Flight pilot. He also has his own sport aviation business called Base Leg Aviation.

84 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes The First 100 Hours Let’s get started by talking about maintenance during the first 100 hours as a starting point. I’ve always made it a practice to make sure the cowling comes off after the first flight, performed an oil change at 10 hours, and then usually another oil change at 25 and 50 hours. You can’t have the cowling off too much during the Phase I test program. If you are a new non-builder owner and purchased the airplane right after the Phase I com- pletion, I recommend that you and your trusted mechanic remove the cowling and do a very thorough inspection of the entire engine compartment. If the time is close to an oil change, such as changing away from mineral oil, then do that now and consider putting the engine on a regular oil analysis program. Starting early is a much better way to gain some trending data. The spark plugs should also be removed, cleaned, and gapped. Carefully looking at the spark plugs will give you some insight as to the operation of the engine (lead deposits, color of insulator, etc.), as well as to the health of the engine (oil on plugs, etc.). Other than that, this is not a time to be tearing into systems in the engine compartment, but rather looking very close and verifying the security of each system, especially those that were installed by the builder, such as hoses, control cables, pressure and flow senders, etc. This is where the use of torque seal will really pay off if you used it. A quick glance at all jam nuts, AN nuts and bolts

Don’t forget to check that all items requiring safety wire do in fact have it installed. This is not a staged picture; the oil filter was never safety-wired.

Photos: Vic Syracuse KITPLANES December 2016 85 will reveal any movement by a broken torque seal. If you didn’t use it, then you really need to physically touch each and every fitting with a wrench to verify they are still properly torqued. It is also a very good time to inspect all of the engine controls to verify that they have complete and full travel from stop to stop. I am amazed at the number of airplanes I inspect that have incomplete throttle and mixture travel, some of which are the contributing factors to hot-running engines. The 40-hour mark is also a good time to take a close look at the cowling itself. Removing the cowling and setting it aside without a close examination may The cowling pieces can sometimes give you clues as to the location of leaks and pending fail to yield clues to various problems. failures. This telltale oil spray pattern points very clearly to an impending nose seal failure. Airframe vibrations can come from many sources, but one overlooked area cylinders are properly torqued. Leaking our phones today that you should make it is the cowling chafing against the alu- intake gaskets will usually leave a telltale a practice. That way over time, you can see minum baffling or exhaust pipes, which blue stain from 100LL around the gasket how things wear and change. will leave telltale marks on the cowling. and running down the intake tube. Oil leaks can be spotted more readily All hoses should be checked for any Other Considerations on the cowling, although sometimes rubbing or interference, as well as leaks At this point in the life of the airplane, I their source can be quite frustrating and deformations. In the case of a newly personally feel there are only a couple to find. And usually the rubber or sili- purchased aircraft, do check the hoses of other systems that really need close cone cowl baffle material is beginning for date codes. Most recently I inspected scrutiny if the original certification was to leave marks by this time, which will an airplane built in 2010 that had a 1969 done by a conscientious DAR or FSDO help show whether you have a good date code on the hose going to the oil inspector. I say that because there are seal around the upper cowling, or have cooler! Also visually check that all items a lot of moving parts with jam nuts and leaks in places. requiring safety wire were done, and the other fasteners beneath the skins and This is also the time to check that the wire is still in place. behind panels that are most likely still bolts holding the intake tubes to the cyl- A good and thorough inspection of the tight if they were really inspected 40 inders are still tight (I have seen airplanes engine compartment will take the better with these bolts completely missing) and part of an hour or two. Don’t rush it. Be to also check the exhaust gaskets for methodical, and do each system indepen- leaks. Leaking exhaust gaskets will leave dently. In other words, inspect the intake a telltale sign of whitish-looking residue system in its entirety, and then move on to if you are running 100LL. Also, check that the exhaust system, and then on to con- the nuts holding the exhaust stacks to the trols, etc. It’s so easy to take pictures with

Clearly there is too much cord showing on this tire to safely make another flight, as the This turnbuckle had no safety wire or locking pins and was on an airplane this way for author discovered for himself while landing many years. on a grass runway.

86 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes hours ago. If it was just a “paperwork” Since new pilots and newly transitioning ended up getting a flat tire upon land- inspection, then I wouldn’t trust it. As pilots can be hard on brakes and tires ing on a grass runway! an example, most everyone knows that during the early hours, the wheelpants As for the control systems, I like to one of my most-discovered items on ini- need to come off, if appropriate, and check that all bolts and nuts are tight, tial airworthiness inspections are loose tires and brakes given a good inspec- jam nuts are tight, and cotter keys are jam nuts. I almost always find some. And tion. Tight-fitting wheelpants seem to still in place. Also check the rudder cables now everyone is determined to have be the norm today, with properly faired for any rubbing or binding. It’s amaz- them all tight. Great. But I still check, gear legs and wheelpants giving us ing how moving parts can be impacted and just this past weekend I inspected retractable-like performance without all under flight loads. a meticulously built RV-10 that had a of the weight and complexity problems. That’s enough about maintenance this loose jam nut on the autopilot pitch However, it does make regular inspec- month. You know how I am always saying control arm, which is behind the bag- tion of the tires a lot harder. Typically, it’s important to keep the fun factor alive. gage compartment bulkhead. The we are moving the airplane out of the Well, I wrote this column during some builder was flabbergasted because he hangar and are paying attention to the downtime while at the airshow in Green- was certain he had them all tight. By the wings and tail to make sure we aren’t wood, South Carolina, where I and the way, on this same aircraft neither the going to hit anything. We tend to for- Stearman team performed our usual for- throttle or mixture went all the way to get to glance at the tires while they are mation demos. It was really hot, approach- the stops, having almost a 1/8-inch gap rolling so as to get a good look all the ing 100 degrees. But there I was, sitting in at full throw. That’s really hard on a new way around the tire. Any cord showing the required FAA pre-show briefing, and engine, not running full rich. through the rubber should be a reason guess who was sitting next to me? Patty So, if it was a thorough inspection, for grounding, in my opinion. It’s not Wagstaff! I didn’t venture a guess as to then the remaining key areas I like to worth risking the aircraft or an accident. whether she was slumming or we were check are the fuel system filters and Most recently I had one customer ask in the big times, but it was kind of neat to gascolator screens if so equipped. Usu- me to come and get his RV-10 to replace be sitting next to someone I had watched ally there is junk in them from the initial the tires. Against my better judgment I perform for a good part of my life. Some- build, and it’s good to get it out of there. took off with some cord showing and how it didn’t seem so hot anymore! J

KITPLANES December 2016 87 Home Shop Machinist Sphere turning. The project’s done, phase one is complete, and now you’re flying to your heart’s content. After so many years building, you’re finished. Done! Now what? You don’t want to start another project, but you need to deal with builder’s withdrawal. What you need is a day project (as in done in one day). If you are a regular reader of this column, you know what I’m talking about: knurls, doo-dads, and titanium washers, to name a few. (Past articles are available online to subscribers at www.kitplanes. com.) This month is another fun day project: spherical (ball) knobs. At first glance, turning a perfect sphere on a machine (the lathe) with only linear tool movement looks improbable, if not impossi- An assortment of lathe-turned spheres made using the OMW tool. Left to right: ble. Yet, with an accessory called a sphere and Delrin half-spheres for a set of control levers, a threaded Delrin knob, a split maple radius (or ball and radius) tool, it can be as easy hardwood knob, and a solid aluminum ball end. as one-two-three. Sphere (and radius) making tools come in a variety of configurations. Before CNC machines, ball and radius attachments were standard accessories for tool room lathes. The Hardinge example, in particular, combines the highest level of precision with stout robust- ness. Although they haven’t been available for years (Hardinge no longer makes manual lathes), these “obsolete” tools command top The top-of-the-line Hardinge radius attachment. dollar on eBay. Sphere-making tools for the home shop cost between a hundred and two hundred dollars. The cost factor equates to a light-duty tool that, while completely functional, is designed for occasional use and leaves precision up to the skill and persistence of the operator. For the examples in this column, I used a “large- diameter” OMW Radius/Ball Turning Tool. This can be purchased from LittleMachineShop.com The OMW radius tool (left) and two examples of shop-made ball and radius tools (right). for $140.00 plus shipping. (Tools on loan from Schwien Engineering and Copp Industrial Manufacturing.)

Bob Hadley is the R&D manager for a California-based consumer products company. He holds a Sport Pilot certificate and a Light-Sport Repairman certificate with inspection authorization Bob Hadley for his Jabiru J250-SP.

88 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes Example 1: Maple Hardwood Split Ball Another option is to make your own. There are dozens of how-to projects for sphere and radius tools online. Most are the basic C-frame style, but some are more complex and feature precision that rivals, or in some cases exceeds, commercial tools. The basic function is the same regardless of the design or origin (commercial or homemade) of the tool. A base or frame that has a The split ball is fixed with a countersunk socket head screw (left). The turning stub pivoting segment with a handle is clamped to is basically a length of bar stock machined on one end to replicate the ¼-inch x the lathe and the cutter height set to the lathe ½-inch lever that the sphere will be attached to (right). centerline. The workpiece is positioned in the lathe and the pivoting segment checked for clearance. The pivot is adjusted to the center of the sphere workpiece, and the dials set to zero. Back out the cross slide or carriage, start the lathe, and start to nibble away. Eventually you creep your way back to zero and have a sphere! The actual movement of the cutter is controlled by a handle that is connected Make two identical blanks with slots for the turning stub (left). Drill a clearance to the pivoting segment. It’s a little weird, hole through one side. Drill and tap the other for a coarse-thread screw. Maple, after using handles and dials, to move a cut- a tight-grain hardwood, can be coarse-threaded with regular taps (right). ter by direct hand control. But you immediately appreciate the direct feedback from the tool: take too heavy a cut and you feel the increased tool resistance. The instructions that came with the OMW tool were excellent. They provide every detail necessary to set up the tool and achieve good results from the start. Of course you’re not limited to spheres per se. You can create any Counterbore the clearance hole to the appropriate depth (left). Bolt and tighten radius you want (within the limits of the tool), the halves together, mount on the lathe, and rough turn to a cylinder (right). convex or concave. Making spheres requires some basic planning. How the sphere will be fixed to the end assembly determines the work holding strat- egy. If it’s a knob for push-pull control, it will screw onto a threaded rod. If it’s a handle for a quadrant, you might turn it from two halves clamped together. The examples I made illus- trate the basic process: Sketch out an idea, Setting the tool position to the correct radius with a planer gauge (left). Center prep the stock, set up the tool, and make chips! the OMW tool according to the instructions (right).

Using light cuts and very slow tool movements, start nibbling away at the corners. Lightly sand with 180-grit sandpaper to remove Eventually the sphere starts to emerge (left). For wood knobs, as you creep toward the tool marks. Finish with a light touch of 220, the final dimension, cut “downhill” on the grain. In other words out from the larger 320, and then 400 grit. diameter to the smaller diameter (red arrow). This will reduce the tendency of the wood to tear (right).

Photos: Bob Hadley KITPLANES December 2016 89 Example 2: Delrin Thread-On Knob

A 2D sketch (left) provides the basic detail for the depth of the threaded hole and the stem extension for chucking in the lathe (right).

As before, nibble away at the corners until the sphere starts to develop, then take a final, sweeping light cut (left). Because of the close proximity of the chuck to the tool (the mounting stub should have been a little longer), I had to change tools to shave the shoulder down. Note the fresh tool marks (right).

A light touch with 180, 200, 320, and 400 sandpaper is necessary to remove the tool marks. The cutter on the OMW tool comes to a sharp point so even the slowest feed rate and lightest passes still generate surface marks (left). The business end of the knob ready to be installed (right).

90 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes Example 3: Delrin Half-Spheres for Control Levers

Half spheres are a variation on the split sphere.

Procedurally, you turn them the same way except one half at a time bolted to the stub. The material is Delrin (a free-machining plastic). Unlike the maple wood example, Delrin has no grain structure and machines the same in either direction.

Print & Digital

A finished half ball after some sanding to remove the tool marks.

When fixed side-by-side in pairs, they add Either Format–Great Savings! a measure of elegance to your cockpit controls. J Subscribe now at www.kitplanes.com/subscribe

KITPLANES December 2016 91 Transfering an aircraft’s repairman certificate, replacing a lost airworthiness certificate, converting a certified aircraft to Experimental. By Mel Asberry

Question: A friend and I built an Answer: If you have copies of these (21.190). It is certificated in the Experi- Experimental aircraft that we have documents from the FAA, there should be mental category and must be built exactly flown for many years. When it was no problem obtaining a replacement air- in accordance with plans and instructions finished, my friend applied and worthiness certificate. Just call your local provided by the kit manufacturer. received the repairman certificate FSDO, and they should be able to help Three, Part 21.191(i)(3). This is an air- for the plane. He has since passed you. If you have the logbooks showing the craft that was previously certificated as an away, and I am the sole owner. Do Phase I sign-off, there should be no reason SLSA (21.190) and is being re-certificated you have any recommendations on to have to repeat Phase I flight testing. in the Experimental category (ELSA). how I might get the local FSDO to Question: Is there any way to Initially there was an option to con- assign a repairman certificate to me? change a certified aircraft to Experi- vert “heavy ultralight” aircraft to ELSA Since he has passed away, I would be mental, like a Champ that was regis- (21.191(i)(1)), but that option expired in the only repairman for that aircraft. tered at 1360 pounds gross weight January of 2008. Answer: Unfortunately the FAA will and will not qualify for LSA? The regulation for Light Sport com- issue only one repairman certificate for Answer: In simple terms, yes, a certi- pliance is that the aircraft must have an Experimental/Amateur-Built air- fied aircraft may be converted to Experi- met all LSA parameters continuously craft. If that person is deceased, then it mental. Unfortunately, that’s about the from its original certification. Your is gone. No other person may apply. end of the good news. It may not be con- example does not meet this require- Question: I purchased an Experi- verted to Light Sport. ment, simply because it has been cer- mental/Amateur-Built aircraft and There are only three routes to tificated at a gross weight higher than have copies of the airworthiness Light Sport: allowed. So, not only may this aircraft certificate, operating limitations, One, Part 21.190. This is an aircraft not be re-certificated as a Light Sport and proof of ownership. All the built by a factory and certificated in the Aircraft, It also maynot be flown by orginal documents were missing, Light Sport category. It is known as a a Sport Pilot or anyone flying under but I was able to obtain copies from Special Light Sport Aircraft (SLSA). Sport Pilot privileges. J the FAA. Will the copies work to get Two, Part 21.191(i)(2). This is an air- a replacement airworthiness cer- craft assembled from a kit that is certi- Please send your questions for DAR tificate (FAA Form 8130-7) and not fied by the kit manufacturer as an exact Asberry to [email protected] with have to do Phase 1? replica of an aircraft built as an SLSA “Ask the DAR” in the subject line.

92 KITPLANES December 2016 Photo: Mel Asberry BACK ISSUES List of Advertisers O NEW eBOOK O Please tell them you saw their ad in KITPLANES® Magazine. eBook download is exactly the KITPLANES® interactive makes it quick and easy for you to receive instant same magazine as on the newsstand. information about products or services directly from our advertisers’ web sites. The difference is: ➥ Go to: www.kitplanes.com/links for a virtual shopping tour via links to their web sites. you get it now! ➥ Call the phone numbers listed below and be sure to tell them you saw their ad & in KITPLANES® Magazine. no shipping costs for e-books! Advertiser page # telephone Advertiser page # telephone Aircraft Spruce & Specialty CV4 877-4SPRUCE Builders’ Marketplace (a big savings for our international customers) Aeroplane Manufactory 96 979-987-4087 Arion Aircraft 3 931-680-1781 eBooks download as a single, full size, Aerotrek Aircraft 95 812-384-4972 Avemco Insurance Company 55 888-241-7890 full color .pdf document which you can view Aircraft Covers 96 800-777-6405 Bearhawk Aircraft 83 877-528-4776 on your desktop, laptop or tablet computer. Airflow Performance 95 864-576-4512 Bede Corp. 77 See Advertisement PDF eMagazine issues are fully searchable Alturair 94 619-449-1570 Better Aircraft Fabric 91 907-229-6792 and are compatible with all Adobe Acrobat Beringer 94 864-214-4274 functions such as highlighting, page notes California Power Systems 77 800-AIRWOLF Better Half VW 97 281-383-0113 and spoken word audio. Experimental Aircraft Assoc. CV3 866-647-4322 Falconar Avia Inc 94 780-465-2024 Flight Data Systems 95 831-325-3131 O Individual monthly issues are $6.95 CubCrafters 87 509-248-9491 Flight Grip 96 800-204-7625 O A compiled Aircraft Buyer’s Guide Deland Sport Aviation Showcase 85 See Advertisement is $12.95 Funkwerk Avionics 96 812-384-4972 Dynon Avionics CV2 425-402-0433 Glen-L 95 888-700-5007 Garmin International 5 913-397-8200 Visit: Grove Aircraft 94 619-562-1268 Garmin International 49 913-397-8200 Homebuilt Help 94 See Advertisement www.kitplanesbooks.com to order Grand Rapids Technologies 73 616-245-7700 INFINITY Aerospace 95 See Advertisement Grand Rapids Technologies 83 616-245-7700 Kuntzleman Electronics Inc. 94 610-326-9068 ❏ November 2016 BD-17L, Spitfire Squadron, Preparing for First Matco Manufacturing 94 801-335-0582 Flight, Driving Down the Cost of Ownership Kitfox Aircraft 85 208-337-5111 Monocoupe 96 844-359-2292 ❏ October 2016 Merlin PSA, Pre-Buys, Grass Runways, Custom Kitplanes® Bookstore 90 800-780-4115 Maintenance Manuals, Vibration Problems Osprey Aircraft 95 See Advertisement Lycoming 17 See Advertisement ❏ September 2016 The Secrets of Speed at Reno, Findlay’s Flyer, RAM Aircraft 94 254-752-8381 Learning About Lycomings, Pre-buys MGL Avionics 103 877-835-9464 Recreational Power Engineering 95 800-583-3306 ❏ August 2016 Celebrating the RV-6, Avidyne IFD540 vs. NavWorx 91 888-628-9679 Garmin GTN 750, The Other OshKosh Sky Ox 97 800-253-0800

❏ July 2016 Hummel H5, National Test Pilot School, Smart Sonex Aircraft, LLC 79 920-231-8297 Smoking Airplanes 95 661-713-9050 Transponders, Top Overhaul, Ray Stits Stewart Systems 85 888-356-3490 Sportsman’s Market 96 800-SPORTYS ❏ June 2016 Javron Super Cub, ADS-B Options, Emergency Stewart Aircraft 95 See Advertisement Parachutes, Stall-Warning Device, Hand Propping SunMate Cushions 103 855-786-6283 TCW Technologies 97 See Advertisement ❏ May 2016 Tucano Replica, Light Aircraft Company’s Van’s Aircraft 71 503-678-6545 Sherwood Ranger, ECO-nomical Auto Pilot Tormach LLC 97 See Advertisement Vertical Power 79 See Advertisement ❏ April 2016 Thatcher CX5, Remembering Jim Bede Sr., Speed Tosten Manufacturing 97 760-803-6034 Deburring, 3D Parts Printing, Vacuum Forming Wag Aero 72 800-558-6868 UMA Instruments 95 800-842-5578 ❏ March 2016 Carbon Cub EX on Amphibious Floats, Audio Control Panels, Bendix and Beyond Wicks Aircraft Supply 73 800-221-9425 VAL Avionics 97 800-255-1511

❏ February 2016 2016 Engine Buyer’s Guide, RV-14 Taildragger, Zenith Aircraft Co. 11 573-581-9000 WhirlWind Propellers 97 619-562-3725 Aircraft Wiring Mistakes, Repairing Loose Rivets

KITPLANES December 2016 93

builders’ marketplace LANDING GEAR Your Complete Source for Wheels, Brakes & Landing Gear

Factory Direct www.groveaircraft.com 1800 Joe Crosson Dr. Grove El Cajon, CA 92020 Aircraft Landing Gear Systems Inc. 619.562.1268

PLANS - KITS - PARTS

2/3 Mustang F12 Cruiser and 10 other all wood designs

Info Packs $10/ea + $4 Postage Can’t Get Enough HIPEC Covering System - no ribstitching, no taping. Lo cost — Lo labor — proven ? www.falconaravia.com Get the latest. Follow us Email: [email protected] on Twitter at #Kitplanes. FALCONAR AVIA INC. Ph: 780-465-2024

94 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes 1204-8 Airflow 1/10/05 2:35 PM Page 1

Aircraft Multi-point Fuel Injection • Operates all engines from 65 to 800 HP • Applications for V6/V8 engines • Manual Mixture Control • Bolt on Kits for Lycoming Engines • No Carburetor heat required • Instant throttle response • All Mechanical, No Electronics • Increases mid-range HP • Approved for Aerobatic use • Compatible with all Fuels • Precise Fuel Metering under all conditions

111 Airflow Drive Spartanburg, SC 29306 (864) 576-4512 (864) 576-0201 (Fax) www.airflowperformance.com Email: [email protected]

“GP-4” MORE SPEED, LESS MONEY

240 MPH cruise on 200 HP. All wood, 2-Place, Oshkosh Grand Champion. Full builder HIRTH AIRCRAFT ENGINES support. Info Pak $15 ($18 overseas). 15 thru 110 hp. 1000 hour rated TBO. One year warranty. Plans $385 ($430 overseas). Sales, service, and parts. Highest power to weight ratio in the industry. BlueMax 2-cycle aviation oil. Contact: OSPREY AIRCRAFT RECREATIONAL POWER ENGINEERING 3741 El Ricon Way, Sacramento, CA 95864 5479 East County Rd. 38, Tiffin, Ohio 44883 Email: [email protected] Tel: 800-583-3306 • Fax: 419-585-6004. Visit us on the web at www.recpower.com

® Have You Seen Us Lately? The KITPLANES® web site is now better than ever! KITPLANES.COM is YOUR guide to the most comprehensive homebuilt information available, and access to our archives and aircraft database are FREE to registered subscribers!

Highlights: • Revamped and expanded Aircraft Buyer’s Guide for quicker, better search results • All New Classiﬁ ed Ads section for deals on aircraft and accessories • Unlimited access to back issues as an easy- to-use, tablet-friendly downloadable PDF It’s easy to register. Just visit WWW.KITPLANES.COM and click on GET WEB ACCESS.

“Like” us on Facebook, follow us on Twitter and get an RSS feed from our Newsline

KITPLANES December 2016 95

builders’ marketplace continued CUSTOMIZE OUR GRIP FOR YOUR AIRCRAFT Easy Installation Comfortable Rocker (shown) or push button trigger style Thumb Switches: Push Button, Toggle and/or 4-Way Trim Fit to 5/8" thru 1-1/8" sticks Next day shipping for virtually any conﬁ guration you desire.

812 Jacquelyn St. • Milton-Freewater, Oregon 97862 800-204-7625 • 541-938-0533 • Fax: 541-938-7242

THE CHINOOK PLUS 2 IS BACK! Full kit and parts now available. Call 1-979-987-4087 [email protected] • www.amplanes.com

Working with a Tight Budget?

Builders’ Marketplace reaches tens of thousands of homebuilders and pilots who are eager to buy new products and services. Call 805-382-3363 or email: [email protected]

96 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes GROUND ADJUSTABLE Buy a Plane COMPOSITE PROPELLERS

• ROTAX or Sell a • JABIRU Plane with

• CONTINENTAL a FREE • LYCOMING ad online.

619-562-3725

www.whirlwindpropellers.com

Portable Oxygen Systems or Windsocks www.SkyOx.com / 800-253-0800 Overcome Hypoxia

INTRODUCING THE LEGAL EAGLE XL Any individual may post a flying homebuilt or partial project

A NEW ultralight with a larger cockpit area. Empty 246 lbs., complete with photos wing area 120 sq. ft. Gross wt. of 575 lbs. STOL. Powered by Better Half VW aero engine. Wood wings, steel fuselage, at no cost for quick and aluminum tank construction. Airplane plans $80. Engine plans $20. 4 helpful DVDs, $25 each. Contact L.E. Milholland for plans, DVDs and wing and global response. fuselage parts. Work: 281-375-5453, Cell: 281-785-3777. Contact John Bolding for materials package and www.kitplanes.com/classifieds welded fuselages. 281-383-0113.

KITPLANES December 2016 97 Trikes. Last month, we looked at some nonlinear pitch behavior sometimes seen in conventional airplanes. This month, we turn our attention to a very different, and inherently nonlinear type of flying machine: the trike. Trikes have become a popular form of Light Sport aircraft. Trikes, which evolved from hang gliders, consist of a cart or pod that carries the pilot and (sometimes) passenger, the landing gear, and a pusher engine suspended under a hang-glider- like wing mounted to a mast on the cart. Trikes consist of a cart or pod that carries the pilot (and sometimes a passenger), the landing gear, and a pusher engine suspended under a hang-glider-like wing mounted to a One reason for trikes’ popularity is that mast on the cart. the wing can be folded like a hang glider. This ability to fold, combined with the different than those of conventional air- the wing and the mast, and swings the fact that the “cart” or pod is quite com- planes. A conventional airplane is con- pod forward or aft relative to the wing. pact compared to the fuselage of a controlled by deflecting control surfaces. Pushing the bar forward swings the pod ventional airplane, makes it possible to The control deflection changes the aft. This moves the CG aft and causes the store the trike in a relatively small space. shape of the airplane, which changes vehicle to trim at a higher angle of attack. It also makes it much easier to trailer. the aerodynamic forces and moments Pulling the bar in moves the CG forward, generated by the airflow. and reduces the trimmed angle of attack. Control Trikes have no aerodynamic control Figure 1 shows pitching moment vs. For this discussion, we will focus on surfaces. They are controlled by tilting angle of attack for an example trike for the longitudinal (pitch axis) character- the wing relative to the cart by pushing three different control bar angles. Figure istics of the aircraft. The stability and or pulling on a control bar attached to the 2 shows pitching moment vs. airspeed control characteristics of trikes are very wing. This changes the angle between for the same machine.

Figure 1: Example of trike pitching moment vs. angle of attack.

is a principal aerodynamics engineer for Northrop Grumman’s Advanced Design organization. A private pilot with single engine and glider ratings, Barnaby has been involved in the design of Barnaby Wainfan unconventional airplanes including canards, joined wings, flying wings, and some too strange to fall into any known category.

98 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes Figure 2: Example of trike pitching moment variation with airspeed.

Looking first at Figure 1, we can see “tucks under” and either tumbles or the The danger here is that the pilot, feel- that the curves cross at zero angle of pilot falls into the wing. Trikes are suscep- ing the wing unload in a down gust, or attack, which for this example vehicle tible to the same issue. after too aggressive a pull on the bar, is also zero lift. What this means is that It’s easy to see how the pilot will tend will instinctively push out to restore changing the bar angle has no effect on to think of the pod he is riding in as iner- positive lift. If there is still some positive pitching moment in this condition. tially fixed. He will perceive his inputs to lift, this will work. If the wing is already It is very important to understand the control bar as changing the angle of pushing down, the push-out on the bar that the ability to control the trike is attack of the wing directly, and hence will drive the vehicle to a more negative dependent on the wing lift. The pitch- will think “push out for more lift, pull in angle of attack, and it is likely to tuck ing moment to control the trike comes for less.” In fact, what is really happen- under uncontrollably. from the interaction between the lift of ing is that the control bar input is mov- A properly designed trike wing has an the wing and the weight of the pod act- ing the pod fore and aft relative to the aerodynamic feature that helps alleviate ing in opposite directions. At zero lift, the wing rather than controlling wing angle this problem and makes the vehicle safer pilot has no way of changing the pitching of attack directly. to fly. Turning once again to Figure 1, note moment. The lift is zero, and the aircraft When the wing is making positive that the pitching moment at zero angle of is in free fall, so the pod is functionally lift, pushing out on the bar moves the attack is positive (nose-up). A safe trike or weightless. Both of the forces that act pod aft, moving the CG aft relative to hang glider wing is deliberately designed together to pitch the vehicle are zero, so the wing. The nose-up couple caused to have a nose-up pitching moment at changing the relationship between the by moving the CG aft causes the vehicle zero lift, so the system will self-recover CG and the wing does nothing. While the to rotate nose up to a new trim point at from a zero or slightly negative lift angle of pilot of a conventional airplane can raise higher angle of attack. At negative lift, if attack if the pilot simply holds the control the nose by deflecting elevators to pro- the CG is aft of the wing’s aerodynamic bar steady and doesn’t push out abruptly. duce an aerodynamic down force on the center, the wing lift will tend to cause a For hang gliders, this characteristic is com- tail, a trike pilot cannot. nose-down rotation about the CG. monly called being “pitch positive.” Looking at angles of attack below zero lift on the figure, we can see another very important difference between trikes and conventional airplanes. At negative lift, the pitch control effect of moving the control bar is reversed. Pulling the bar in, which would be a nose-down input at positive lift, gives a nose-up (in vehicle axes) moment, and more impor- tantly, pushing out, which will raise the nose and increase angle of attack at positive lift, causes the nose to drop and decreases angle of attack further. This is potentially quite dangerous since the pilot will likely not be aware of the control reversal. There have been Unlike conventional aircraft, trikes have no aerodynamic control surfaces. They are several hang glider accidents during controlled by tilting the wing relative to the cart by pushing or pulling on a control bar attempted aerobatics where the glider attached to the wing.

Photos and illustrations: Barnaby Wainfan KITPLANES December 2016 99 Stability attack. The machine will be more stable As the bar is pulled in, notice that the As we saw last month, the pitching at high angles of attack and less stable at level of speed stability (the slope of pitch- moment of a well-designed conven- lower angles of attack. ing moment with airspeed) decreases. tional airplane varies linearly, or nearly Turning our attention once again to The faster the trike is trimmed to fly, the so, with angle of attack. The airplane’s the figures, we can see this effect. Notice less stable it is. This reduction in stability stability is the same over its entire pre- in Figure 1 that at all three bar angles, the at higher speeds can contribute to the stall range of angle of attack. slope of the pitching moment curve is kind of tuck-under loss of control we just This is not the case for trikes because of negative (stable) at the trim point where discussed since the aircraft will have less the large vertical offset between the cen- the pitching moment is zero. Also note natural tendency to stay at its trimmed ter of gravity and the aerodynamic cen- that for each bar angle, there is another airspeed. It will also respond more rap- ter of the wing. The pod of a trike, which lower angle of attack where the aircraft idly to a disturbance or pitch input comprises a majority of the mass of the becomes unstable. because it is less stable. Our example machine, is suspended well below the Figure 2 shows how this effect varies aircraft can still be flown safely, at least wing by the mast. Since moving the CG with trimmed airspeed. When the bar is up to the 85 knot speed represented by fore and aft by swinging the pod relative pushed out to trim at lower speed (45 the lowest curve in Figure 2, because of to the wing is how the trike is controlled knots in this case), the aircraft is very the pitching moment characteristic of in pitch, this vertical offset is necessary to speed stable around its trim point. Slow- the wing discussed earlier. With a differ- provide control authority. ing down produces a large nose-down ent, poorer, combination of mast height The vertical offset also causes rela- moment, and speeding up produces a and wing design, it would be possible to tive movement of the CG and the aero- large nose-up moment. If the bar is held end up with a machine that flies com- dynamic center when the bar is held at fixed, the vehicle becomes unstable fortable and stably at lower airspeed, a constant angle. If the vehicle pitches at speeds above 65 knots. This is not and becomes dangerously unstable at up, the CG moves forward relative to the inherently unsafe because the pitching higher speeds. aircraft, and if the vehicle pitches down, moment at higher speeds is still strongly We will discuss the effects of various the CG moves aft. This effect causes the positive, so the machine will tend to go design parameters on the stability and stability of the trike to vary with angle of back to its trimmed speed. safety of trikes next month. J Kitplanes subscriber alert! several of our Kitplanes subscribers have received what appear to be “renewal notices” or “automatic renewal notices” from a company known as preMier subscriptiOn serVice, 5star subscriptiOns, rapiD MaGaZine cOllectiOn, MaGaZine billinG serVices, publisHer’s billinG serVices, circulatiOn billinG center or other similar names. Addresses for these firms include Dallas, tX; lincoln, ne; Omaha, ne; san luis Obispo, ca; salt lake city, ut; White city, Or and prescott, Fl. These firms have nOt been authorized by us to sell subscriptions or renewals for Kitplanes and we cannOt Guarantee that any order or payment sent to them will be forwarded to us. Kitplanes does nOt offer a subscription term of more than 2 years, nor do we retain your bank account information. if you see an offer for 3 or more years or if you receive a notice that references your subscription anD your banking information, it is nOt an authorized offer. We urge you to report these notices to us, as well as to your state’s attorney General and better business bureau. any offer you receive that does not bear our company logo or corporate/customer service address or 800 numbers should not be considered approved by us. the only autHOriZeD inFOrMatiOn for Kitplanes is: toll free via telephone 1-800-622-1065, Dial america renewal telemarketing, or www.kitplanes.com/cs Our texas customer service center: 1-800-622-1065, pO box 8535, big sandy tX 75755 Or our corporate offices at: belvoir Media Group, llc. aviation publishing Group 535 connecticut ave norwalk ct 06854 should you have any questions at all about mail that you receive, please contact us at our web site: www.kitplanes.com/cs or call us toll free to speak to customer service.

100 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes Multimeter musings. Now that we’ve pretty well thrashed around 10 Megohms (10 MΩ) as the load. out how people make multimeters, This is a ratio of 33:1 or 3%. let’s do some practical uses for our little Even more important is when you meter. As I said when I started this thread, are working on a piece of equipment in please buy one of those cheap $6 Harbor a fairly high-impedance electronic cir- Freight multimeters to start. When you cuit. Let’s take a simple transistor ampli- smoke one or two of them, it isn’t like fier with a collector load of 100kΩ. Let’s you tossed away half an AMU (1/2 Aviation also operate the transistor from a 10-volt Monetary Unit = $500) or so. Later on you supply and adjust the current through can buy one of the really nice meters. the transistor for 5 volts on the collec- Actually, Harbor Freight was giving tor. Now if I measure what should be 5 away multimeters this last weekend volts on the collector with the pointer with any purchase. That’s about the least meter, we have a voltage divider that expensive multimeter you will ever get. reads 3.8 volts, a whopping 1.2-volt error. Not only that, but you could print out The same measurement with the digital another one of the coupons and your meter shows 4.95 volts, or a more reason- significant other or junior birdman could able 0.05 volt error. have gotten a second one. Now admittedly, the really cheapo Before we start, let me give you a Harbor Freight meter is only a 1-MΩ repeat of what I said in the first part of meter, but even so, the measurement on this series: You measure voltage and this amplifier would read 4.5 volts, which resistance across a part and current in is a moderately reasonable 0.5 volt error. series with the part. Keep this golden rule So, reading voltages seems to be in mind and you ought to have multime- rather straightforward. In a relatively ter happiness. An analog multimeter on the bottom, the low-impedance world like batteries, Now, why did we get away from cheap Harbor Freight $6 multimeter on light bulbs, and devices that draw mod- using the old “pointer” style meters in the top left, and a very good $50 digital erate currents (say, 100 milliamps or favor of the digital readouts? Price, for multimeter on the top right. more), the cheap HF meters are roughly one. Expensive moving pointer meters pointer meters required a relatively large as accurate as the expensive meters. required a magnet, a precisely wound amount of this power, while the digital When you start playing around with the coil of wire, a set of hardened (sometimes meters require somewhere around 5% innards of radios and such, you need to jeweled) pivots, a case, and other hard- of the best pointer meter’s consumption. understand the limitations of an analog ware. Cheap digital readouts are some Let me give you an example. Let’s meter with an input impedance less electronic liquid “goop” sandwiched in simply measure the voltage of a 12-volt than a megohm (1 MΩ). between two pieces of plastic. aircraft battery (12.6 volts fully charged). On to current meters. Once again, Even more so, all electronic meters A moderate-quality pointer meter on the the meter is going to rob the circuit of require that we rob the circuit we are 15-volt scale puts around 300 Kilohms a tiny bit of power to operate. This time, working on from a tiny bit of power to (300kΩ) as a load onto the battery. A though, instead of the voltmeter rob- move the meter or change the digits. The relatively inexpensive digital meter puts bing current, the current meter is robbing

is the chief avioniker at RST Engineering. He answers avionics questions in the internet news- group www.pilotsofamerica.com–Maintenance. His technical advisor, Cyndi Weir, got her Masters degree in English and Journalism and keeps Jim on the straight and narrow. Check Jim Weir out their web site at www.rst-engr.com/kitplanes for previous articles and supplements.

Photos and diagrams: Jim Weir KITPLANES December 2016 101 You measure current in series with the circuit to be measured and the The digital meter loads the battery very little, while the voltage in parallel with the circuit to be measured. analog meter loads the battery many times more. voltage. There will be a tiny little voltage • If you are measuring a capacitor to the master switch relay and the starter (about 0.1 volts) subtracted from the see if it is shorted or leaking, be sure solenoid). Measure the length of the wire power supply voltage in order to mea- to discharge it by shorting across it and then translate that into a resistance sure the current. In general, unless we before you make the measurement. If at the wire table calculator on http:// are making laboratory measurements, the capacitor is particularly large (say, tinyurl.com/heydk82. Once you have the we don’t worry about this so-called “bur- over 1000 microfarads) or particularly resistance of your battery-starter wire, den voltage.” high voltage (say, over 100 volts or you can crank over the engine while And the last one of our trio is the so) then short the capacitor, wait ten measuring the voltage drop across the ohmmeter, or resistance meter. Here is minutes, and then short it again. Some wire. One quick Ohm’s law calculation (I the secret of this little gem…you have to capacitors have what is called “dielec- = E / R) and you have the starter current. have at least one of the contacts on the tric absorption” where the charged Here is an example: device you are measuring completely electrons hide inside of the insulating • You have a 10-foot run of AWG 2 wire out of the circuit. I can’t tell you how dielectric and then sneak out slowly to from battery to starter, which has a many people measure a resistor in the bite you during the measurement. resistance of 0.0016 ohms according circuit and say, “Ah-ha, I’ve found the • Measure diodes with an ohmmeter by to the spreadsheet calculator. If you problem,” only to replace the suppos- measuring in one direction, and then measure a voltage drop from one end edly defective resistor, then find that it reversing the leads and measuring in of the wire to the other of 0.39 volts wasn’t bad after all. Here are some other the other direction. There should be during engine start, then your starter “gotchas” to watch out for: at least a 100x difference in the two current is 244 amps. Please note that it • An incandescent light bulb will be resistances, more like 1000x+ for a does not matter how long the leads are somewhere around 50 to 90% lower normal diode. from the multimeter to the two ends resistance than you expect. Light bulbs Here is a trick for measuring very large of the #2 battery wire. A quick calcula- go up in resistance when they get hot, currents (like starter currents). You have tion shows that you could have (if you so the cold resistance is far below what to know the AWG gauge of the wire wanted to) not quite a thousand miles you might expect. between the battery and the starter (or of #24 wire connecting the multimeter

Measuring very heavy currents (like a starter motor) is easy by simply measuring the voltage across the battery to starter wire.

102 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes Odd-Size SHOP Transfer Punch TIPS By David Paule

Using an analog voltmeter to measure a sensitive circuit gives false readings, while This homemade transfer punch a digital high-impedance meter gives very worked for me for drilling a panel close to the actual voltage. to match the mounting plate of an instrument. The plate already had nutplates attached to it. to the battery wire for less than a 1% My matched-hole punches are in fractional sizes, so they didn’t fit. However, I error in measurement. found a number drill bit that was a very good fit. I sent the panel’s owner out to the Back in August ’15, I gave you an ele- hardware store to buy me a replacement bit, and I cut the flutes off my bit with a mentary checker to be sure that your Dremel cutoff disk. This left me with a short smooth stub, about an inch long. That multimeter was telling you the truth. I’ve went into the drill press, and I put a shallow point on it. improved on that design a little and am Presto! A custom match-drill punch. re-presenting it to you as an indispens- Since I used a very small tap hammer to make the punch marks (the owner had able little tool for your multimeter bag. I the instrument in place while I made the marks, and I didn’t want to jar it with a increased the voltage source from 1.5 to larger hammer), I had to go over these rather shallow punch marks with a deeper 9 volts, which also increased the current punch, but that was no big deal. Then with the locations very well defined, the from 1.5 mA to 9 mA to take advantage of owner drilled the holes. the 10-volt range on a lot of the available The mounting plate fit perfectly.J multimeters. The current set remains the same at 1.0 kΩ, so you can test the voltmeter part, the current meter part, and the ohmmeter part. While at Oshkosh this year, somehow I managed to lose the rubber duckie antenna from my aircraft band hand- held. I think I’ll make a replacement antenna out of Romex cable for a total cost (including connector) of somewhere around $5. After I get done with that, I’ll write up a couple of things I talked about at my Oshkosh forum and then maybe do a little bit of work on a nifty new cheap airplane whirligig with solar lighting. It’s going to be a good year. Stick around… stay tuned. J

The cheap meter checker. Measuring from A to B gives 9 volts on the voltmeter. Measuring from A to C gives 9 milliamps on the current meter. Measuring from B to C gives 1.0K on the ohmmeter.

KITPLANES December 2016 103 By Robrucha

104 KITPLANES December 2016 www.kitplanes.com & www.facebook.com/kitplanes