Jon Matcho

The AeroCanard plans are adding a total of 5 1/4" to the total width of the landing gear bulkheads to the upper longerons as far as I can tell. Not sure where the 3.5" of increased rear seat width comes from. It seems it should be closer to 5" to me. Any AeroCanard builders out there who can confirm this? I'm waiting on a mail back from Jeff.

My wife gets me now and again by saying, "I'm not sure about this airplane stuff." I immediately panic, then look at her to find I'd just been had. I credit Dewey Davis' Web site as perhaps THE source of inspiration for me pushing me over the edge. There I found he had built a Cozy and was flying his wife and 2 kids all over the place on family vacations! "I need to do that!", I thought. I'm not sure if me showing her Dewey's site helped her through whatever process she needed to go through, but I'm sure it didn't hurt.

Don't think that you're the "greenest" one out there . Chad Robinson has you beat. He bought plans in the same state as you, but without ever having seen a Cozy in person. He has a great Web site w/Cozy info. at www.lucubration.com.

Looking at the AeroCad back seat dimensions here, and after speaking w/Jeff, I'm off on this 7" figure. I'll measure and post the correct dimension when I can.

Per the FAQ at www.cozybuilders.org, some have purchased G10 "plastic" instead of fabricating the hardpoint material. Curious, I looked up 2 vendors: Polymer Plastics Corp would sell me a custom-cut sheet for $59. American Micro Industries would sell me a 3' x 4' sheet for $534, where I would have an extra 11 AeroCanard-sized plates or 16 Cozy-sized sheets left over. Perhaps an enterprising individual could add 'Cozy Hardpoints' to their product line, and buy the AeroCanard molds while they're at it.

The difference widens the back by a full 7", moving the longerons out, which is enough of a change for Nat to want the plane NOT to be called a Cozy (based on what I read in the Cozy Mail List archives). However, considering the entire set of plans, the AeroCanard plans are essentially Cozy plans (AeroCanard SB) with an AeroCanard FG option written in here and there. I never understood, and now completely don't, what motivated Jeff to put "New (lower cost) re-formatted "Cozy MKIV plans are now offered for sale by AeroCad" on his Web site. Jerry, I'm still waiting for you and the Florida crew to take over the AeroCad business. How's that coming? Seriously, I hope "starting offers are at $48K" means that the builders that have been making parts intend to take it over. Time will tell us the answer...

This timing is interesting, as I just decided to build my landing gear bulkheads and rear firewall per AeroCanard FG plans. From what I understand from reading the archives, I'm now supposed to call my plane an AeroCanard. I don't want to do that, so maybe I'll make another major mod and create an entirely new name for it... let's see, these are taken: Limo EZ Stagger EZ King Kozy I'll likely still call it a Cozy, but don't tell Nat.

After ordering my Fein and level, I went on vacation, which seemed to take some momentum away from me (gotta blame something). Anyway, back in action now building the landing gear bulkheads, although with some major modifications. I did the 22-BID hardpoint layups over 2 days, totalling what seemed to be 5+ hours. At the end, I had a very hard 8.5" x 16.25" plate of glass. I marveled at it, wondering what someone would pay for it. Didn't matter, as it seemed worth too much to part with.

Posted by request of Robert Holgate: Feel free to reply here, but don't forget to write to Robert directly.

Ron, I second Chris' congratulations. Hoo rah!!! I have been giving serious thought to door concepts, and am going to decide after final assembly of my "tub". Unless, of course, you have a better idea...

The following was posted by Jeff Russell on the COZY mail list: Thoughts anyone?

Maybe not, but he does fly it close to the sun.

I am a non-flying builder. It has been my experience that when you ask the question "Should I get my certificate before I start building?", you will typically get a knee-jerk reaction of "Yes, you should", but without much real justification. I have since phrased the question as, "What do you think about me building a Cozy before getting my license, and getting a license within 2 years of finishing?" Answers to that question have been agreeable, perhaps because I am acknowledging that I'm not going to take off from the local school yard. Reading your post, your biggest hurdle may not be whether you are to be a capable builder or flyer... Not sure what I can offer here, but you really need to connect with her on this. Have you tried having a specific and sincere conversation about what YOU want to do? She may also benefit from some education with regard to homebuilt aircraft. Apparently you have been cleared to take lessons, and fly in a plane built by who-knows-who, that's been maintained by that person's neighbor, and one that neither you nor your spouse really have any idea for the shape it's really in. By building your own plane, you'll know ever piece and part of the plane. Composite aircraft are more durable and weather resistant in many areas than their "spam can" counterparts. This doesn't actually need to become an official worry until you finish the plane (years from now). Hope just some of that helped...

There's no shortage of words from many about this great wonder, and I just had to link a picture here from www.space.com. My wife asked me, "You're not going to switch to building a space ship, are you?" The White Knight mothership is designated as an Expermimental aircraft.

I'm having a Fein Father's Day, and am going to have a Fein vacation next week, and then will get back to some Fein building the week following. My wife ordered the single-speed Fein and a Stabila electronic level for me today (she actually just pushed the Order button).

Hennie, the only real reason I was considering air-powered tools was that I was pondering the use of carbon fiber. The problem with that is when the little bits get into your motor and on your hand, you can short your motor as well as give yourself a good shocking. I have since realized that this was a weak premise for equipping myself with another $2,000 worth of tools. I didn't think about oil contamination, which makes me even more in favor of the electric version.

John DiStefano stopped by this weekend with his Fein Multimaster to show me firsthand how it does against 12 layers of glass. After using the tool myself I am dead set on getting one so that I never need to wait for the partial cure stage to trim ever again. Amazon has a special going for Father's Day -- save $50 on a Tools order over $250 -- that I'm going to take advantage of. I'm looking to get the non-variable speed version and a couple HSS blades. I still expect to use the Dremel and my new wheels, just not on cutting the monster layups. Thanks everyone!

I tested the Dremel 542 blade (tungsten carbide) last night as well as the 545 (diamond wheel, see attached). The diamond wheel is slightly better than the carbide wheel, and being thinner throws less dust. However, I found both to be less than desirable for cutting through 12 layers of cured glass. Both were great for 3 layers, but the 12 cumulative on F28 reminded me of using the basic cut-off wheel on 3 layers. Contrary to a prior post I made, both wheels wanted to kick back at times on the thick sections. At this point I am willing to buy the Fein if I can find out how well it will do many layers of cured glass from Jerry or JD. Happy Father's Day!

That's good to know -- I actually prefer, for the time being at least, acquiring the minimum amount of tools I absolutely need. Chris/everyone, I have to cut through 12 layers of cured glass tomorrow. Will the Dremel and the 542 wheel cut it? Or is now a good time to get myself a Rotozip? Here's where I contradict myself -- I will buy whatever tool I need to cut through this stuff straight and fast. If the answer is FEIN, do let me know, but what then should I do in the meantime between now and Father's Day? I suppose I could always start the IP bulkhead.

Paul, this is truly an inspiration and judging from your Web site, you've done an exceptional job! Congratulations on your achievement. Your plane looks fast in the video as it does in your still pics. Looking at your Web site and noticing the doors (again), I can't help but wonder how torsional stiffness is supplied. Is there any sort of spar with the purpose of keeping the canard parallel to the main wing? Or is the airframe stiff enough as-is?

Wil, I decided to proceed through the first real building chapter with a somewhat makeshift table setup: a 3' x 4' piece of 3/4" smooth and flat birch plywood on top of a plain old 8' fold-up table. I have no regrets with this approach as I have become much more in tune with what I actually need and what will work within the space I have available (10-12' x 20'). Looking down the road, I am planning to build a number of small tables similar in design to those recommended by EAA Chapter 1000: http://www.eaa1000.av.org/technicl/worktabl/worktabl.htm I have found suggested table dimensions to be in the range of 36"-44" x 10'-12', and most tending to build one-piece tables. My opinion is just one of many, but I don't think you can go wrong with the plywood and fold-up table approach for starters.

Andrew, I got the Dremel 542 for $15 @ Home Depot -- I didn't shop around at all. It truly is like a knife through butter through 3 cured layers of glass with little-to-zero tendency to want to "attack" the rest of your part. I'll look for more of this once I glass the forward sides of F22 and F28. I wonder if there's really any need now to wait for the "gum" stage to cut with a razor knife? The Fein apparently is the tool to get when you're ready to "graduate" to the next level. For that, I'm still up in the air as to whether to get the single- or variable-speed version, or even the air-powered version. I have time on that one, but... Father's Day is coming up!

Jerry, you're killing me... I want one! Unfortunately I think I need to decide between the Fein and this, as I have a Dremel already -- even though it's quaking in the presence of this thing.

I went out and bought the 542 Dremel Carbide wheel Dan suggested: This turned out to be a major improvement over the Permagrit wheel: Both are coated with Tungsten Carbide, but I think the Permagrit wheel is probably out of balance judging by how the Dremel seems to labor while spinning it. The Dremel Carbide wheel has the tool spinning smoothly again, and cutting the cured glass is like a knife through butter. Thanks Dan! The Permagrit wheel just has a bit too much mass I feel (as well as the Dremel not being a Proxxon). I'll try the smaller Permagrit wheel, but am now wondering why I never looked to Dremel accessories in the first place. Oh, I know, "because I don't know what I'm doing". (yet )

I received AeroCanard plans and the full set of video tapes from AeroCad yesterday. I skimmed through the plans and found them as I expected, give or take. I watched a bit of the first tape and was amazed to see a big U-shaped fuselage, obviously out of a mold. I guess I never realized that was what the AeroCanard Kit consisted of. From what I understand, all parts with the exception of the landing gear are available. For the short term at least, I expect to be Cozy-centric but will be reading the AeroCanard plans step-for-step with the Cozy plans.