Cozy1200

Dust suggested that I post a few pics from plane day. This is Thane removing the frame that holds the top strake skin in shape.

I got to make Plane Parts!!! Does that make me a builder even if it's not my plane? Wow, what a weekend! I don't think I have had more fun this past weekend talking about airplane since Oshkosh. And Dust is right we sat up and talked from 10 to nearly 3am. What a blast!!! Next time I go up my wife is going to go shopping is Dust's wife. Dust and his wife are incredibly welcoming and made me feel right at home. Anyways, I wanted to post some thoughts on plane day. Plane day is absolutely the best way to build confidence before starting. At one point there was three of us working the layout of strake ribs, while Dust kept up supplied with fiberglass and peel ply. It was just a bunch of great guys making plane parts. I do have to say I came away with more tips and tricks than I expect. Dust's router and template method of cutting parts is incredible.

Steve, Since you work with this everyday, a question pop in my mind. The moldless construction we're used to seems to be fairly time consuming in the finishing process. Is this true for the other things you've worked on and does using a mold affect this. Thanks

We need a spell chekcer on this forum. Maybe something like Yahoo uses for yahoomail.

I just look "Straight line sander" up on ebay. These sanders look like the go relatively cheap. But after spending $200 on the fein, alot more tools look cheap.

That is a good question. What do you do when you want to change ratio of fast and slow harders?

Would you please give us a little more info on this tool. I'm not familiar with it. Thanks

Ok, that makes since. So just a light quick sanding, not the more severe sanding used when no peel-ply is used. Thanks

I was under the impression that a layup was ready for another layer after removing the Dacron peel-ply. So does some sanding still need to be done before proceeding.

Ok, I've been wondering about this for a little while and would like to clarify it. You wrote: "the gloss finish is very easily scuffed up for bond since there is no weave to deal with" So am I understanding it right that parts made with plastic peel ply still need to be sanded? Do you use Dacron where a structural joint will be or is sanding adequate? Thanks

I met Dan and Lori Krugar this year at Rough River. I was amazed that whe he told me he built the entire plane in a small barn. If I remember it was something like 12x24! Dan said he couldn't walk around the plane it was so tight. He moved it to a larger place before finishing it.

I forgot about that part!!!! Time for me to watch it again.

If you're goning to buy a video. Do send Nat $20 for the video he put together. It has about 30 minutes on the cozy. It appears that he was interview by a local news someplace. He talks about all the basic of the cozy and canard designs. Now the cool part. He included the Rutan video on the end of the tape. SWEET!!!

Check this link out. It gives a few details on construction. Also, look elsewhere on the site for how to finish a composite plane. I found it interesting. http://curedcomposites.netfirms.com/fueltank.html

That was also as much fun to read as the 'reasons not to build thread'!!!

I guess that does make since. A few weeks exposed to UV probably did not affect the structure that much.

<<Rutan saved weight on the Voyager by not finishing/painting the bottom surfaces>> So how did he finish it and protect the fiberglass from UV?

Dust This came threw the list a while back. I believe this guy bought the Franklin off Nat. Maybe it can help. http://www.rapidnet.com/~mikejjs/Cozy/Project.html

John, You said you'd could run AvGas and then worry about the plugs later. Can you mix AvGas and Auto gas? I'm guessing you would want to be fairly low on gas before filling up with the different type.

Ok I have a question for you guys that plan to transport auto fuel to the airport. What are you going to do on the flipside of a long trip? Just curious. I haven't figured that out yet.

I guess I should have mentioned that I was thinking of the Cozy not the Long-Ez when typing. Keeping that in mind, I guess it does change the numbers. ChuckTheDog, If you ever want a place to fly, just for the sake of flying. Come up to Portland and Muncie. I'll treat you to supper just for a bull session. I don't see to many canards around here.

Chuck, No offense to anyone, but I've heard similar things a bunch of times. Saying you earn $.50 an hour sounds great, but I'm not buying it. Here's why I think this way. Let say it takes you 10,000 hours to build the plane. That should cover build time, reading, research and all the stress a person can stand. This is still over three times what Nat say it should take. Now I'm going to pull another number out of thin air. You make $30,000 Profit after selling the plane and paying for what you've invested. That could be build for $30k, sell for $60k or build for $50k and sell for $80k. Nat claims you can sell for 2-3 time the build cost. I've never talked to anyone who has sold their plane, so I can say for sure. Now back to the simple math. Under this wild scenario $30k divided by 10k hours is $3/hour. Under a more realistic scenario say you invest 3000 hours and still net $30k. With that you make $10/hour. Not bad for a hobby! I'm sure there have been cases of people putting in less hours and making more on their plane, but this is me talking out of my butt as a non-builder. As for the $3.82 per hour and building for 3000 hours, your That is about a $11 to $12,000 profit. It seems a little hard for me believe that these planes for around $100,000 had $90k invested. Someone please correct me if I'm totally wrong. Now my disclaimer: If I am totally out of line for jumping on someone for simply exaggerating to make a point. I apologize. If what I'm saying is correct, why hasn't someone said something before? OH! I know, those smart people are to busy building while I'm still typing.

Why $3.82?

Dust? Oh Dust? DUST? DUUUUUUUUUUUUUUST!!!!!! Are you OK DUST? Is everything OK? I hope everything is ok. Because most of the time you would have pounced on this poor slave. Sorry Dust. I couldn't resist. Hopefully I'll make it up there in a few more weeks and then I can be your slave. HA HA Drew PS Jack Email Nat and ask for local builders. I did the same and gave me 5 builders in the state. He did ask for an email instead of a call.

Congratulations Dust! Well I'm weekends are starting to slow down. Hopefully I'll be able to be a slave for a day soon. Now for the big announcement. I woke John up by saying I was waiting till next oshkosh to buy the plans. I called my wife from Oshkosh and told her that I was more confindent than ever that the Cozy was what I wanted to build. Not that I didn't like alot of the other planes there, but this plane fit our top three critiria the best. To my complete astonishment, She bought the plans as an anniversy gift. She said my reaction was worth every penny. I hadn't planned to get them until I completed my ticket. I didn't want to get to many irons in the fire. She said after I called her from Oshkosh, she new that was the only gift that would do. (Is that Love or WHAT?) As much as I would LOVE to start right away. I have several other projects to finish. Some large, some small. If things go great, I could be building by Chirstmas, or as late as next summer. I orginally didn't want to work on my license and this at the same time. I think I've changed my mind. It will make each take longer, but hey I'll be having alot of fun. My favorite time to be working in the shop is 10-12pm. You don't learn to fly at that time anyways. We'll see what will happen. I agree with what someone said at Oshkosh. Too many people consider themself a builder just because the bought the plans. So for now, I've changed my signature line from "Cozy Builder Wanna-Be" to "Cozy Builder Soon-To-Be". Boy am I impressed with the plans!!!!