1) Zenith Rudder Workshop - This two-day hands-on experience was absolutely essential for the someone with little or no metal working experience. From drilling and deburring to using aviation snips, this workshop provided a quick-start forum for learning the basics. Participating as a Husband/Wife team was something I'm really glad we did since it gave Tammy and I a partnership on this project from the beginning. I can see already that without such a partnership, it would be difficult to balance the airplane and family. Other great aspects of the workshop were: meeting other builders (See Gary's Site), working with the Zenith team, and of course the demo rides in the CH-801!
2) Used/Low-Cost Tools - Although most of the tools required for the CH-801 are standard hardware store type items that most people have lying around, there are a few sheet metal aircraft tools needed that don't show up at the Home Depot. If you don't mind a few scuff marks, Used Tools provide a good value, especially if you're not sure if you're going to stick with it. A Web Search on "Used Aircraft Tools" provided a number of sources. Schools that teach aviation technology or metal working may be another source to buy or borrow some tools. Here are some of my sources:
BEUCO Inc. ==> A local (St. Charles, MO) aviation supply store. So far we've used them for Zn-Chromate primer and numbered drill bits.
The Yard ==> Found this one on the web. Ordered Used Clecos and Cleco Pliers
HDC ==> A discount tool store in Lafayette, IN. Purchased a Pneumatic Rivet puller for $25. Bought modified nose pieces from Zenith to produce "domed" rivet heads. Same specs as similar tools for much more. Has worked great to date. One year replacement guarantee, no questions asked.
Other Airplane Nuts ==> Find friends or EAA members who might loan you some tools until you can get your own. A friend from church and long-time airplane nut who teaches aviation mechanics got me started with misc. tools, FAA books, and metal working process papers. Along with clecos, cleco pliers, and aviation snips, the best thing my friend loaned me that I had not thought of was two 4' long straight edges. One is stiffened and the other is flexible. These have been invaluable in laying out rivet lines along the skin.
Gift Lists ==> Make sure you're very specific when you write your letter to Santa. I tried to convince my relatives to each purchase a different kit section of the plane, but they opted for some of the more affordable shop tools that I specified on our list.
3) Organized Workshop - After the Rudder Workshop and before picking up our first kit section, we set up our future airplane workshop in our basement. Our plan is to build as many of the components in our basement as possible and then do major subassemblies in the garage prior to moving to an airstrip for final assembly. A solid work table was the first essential. We used 4x8' 3/4" particle board framed with 2x6s and mounted to saw horses. Two additional 4x4' sections will be added when we move to the wings. Did you know that you can get at least 30% off the cost of sheets of particle board if you ask for the pieces with some damage (i.e. corners or edges chipped)? Metal storage shelves serve as our parts and tool crib. Having a place for everything helps to keep us organized.
4) Family Support - Get the kids involved. Rachel loved going for a demo ride during our last hardware pick-up at ZAC. Becky enjoys being in the shop even if she's working on another project. |
