For some, building an airplane can be an important and very satisfying experience. In most countries, building your own airplane is legal - this is definitely an incentive for anyone who wants to get involved. The results are extremely rewarding, both for you and for your family.
Steps
Step 1. Make sure building a plane is legal in your country
In the United States, building a plane is absolutely legal, even before you have obtained your private pilot license.
Step 2. Obtaining a pilot license is recommended
You should know what kind of plane you want to build. In this regard, it is advisable to try flying various types of aircraft before making this decision. Reading the specs may only give you some information, but experiencing what these specs mean in real life is completely different, especially to check how the airplane you want fits your body.
Step 3. Decide if you want to build an aircraft that has already been built or if you want to design one
If you want to get up and running faster, it's best to use an existing design.
Step 4. Decide if you want to build the plane using a kit or a blueprint
A well-structured kit will make the process faster, while only with the project can occasionally encounter obstacles.
Step 5. Decide how you want to build it
There are three main types of building materials: fabric, aluminum and the composite (mixed structure materials).
- A lot of maintenance and a slower speed are required if you are using fabric, but it is the lightest type of aircraft, and for some it may be the least difficult to build.
- Using aluminum is more difficult, but it is virtually maintenance-free and aircraft built with this material are very fast.
- Composite is the most difficult to use due to the sanding process required for finishing, but it generally produces the fastest planes.
Step 6. Take a look at different projects and define your priorities:
minimize expense, good performance, functionality, etc. Take note: simple designs that produce aircraft with good functionality are the most popular, and can be the best choice for achieving a good result.
Step 7. Attend an event organized by a flying sport association
Here you will find the most popular aircraft mounting kits. You should spend most of your time talking to the aircraft owners about their building experience, and trying to fly the aircraft you are interested in, rather than talking to the manufacturers.
Step 8. Call an aviation insurance agent and see if it is possible to obtain insurance with your current flying experience, and with what you estimate to have achieved once the project is completed
Some aircraft are not of sufficient value to insure their intrinsic value, but you should still ask for a liability quote. The amount they ask to pay is their way of assessing the safety of the aircraft.
Step 9. Take a ride with the type of plane you would like to build to see if you like it more than others
Some manufacturers allow test flights. Joining a sports flying association in your area could put you in touch with someone who owns the plane you want to build.
Step 10. Find someone in your area who is building the aircraft you would like to build
It doesn't have to be quite the same type of aircraft, but it should use the same type of build procedure, and possibly material from the same manufacturer as well, so that you can learn the build techniques and check the quality of the kit. Don't be pushy, as good builders are usually short on time and won't want you around if you waste it. When you decide to build your plane you can avoid many of the mistakes that many builders usually make, because you will know what to do from the beginning.
Step 11. Find a place to build your plane after making a design decision
A garage on your property or a large space to work within your home are the best options. Make sure you can keep the temperature above 10 degrees: you can't work well with your hands if it's too cold.
Step 12. Get the tools
Now that you've found your ideal workspace, it's time to get the tools. Gear can usually be procured through your local sports flying association, from those who have recently finished building their aircraft. If not, the manufacturer's kit can point you in the right direction.
Step 13. Get the blueprints and start building
Most kits will get you started with the "feathered" or more formally "fletching" tail. Building the flange will give you a general idea of the project, without having to bear the full cost of it. This is a bit of a bankruptcy insurance for those who don't have a chance to get help from a more experienced builder before starting construction. You can consider getting yourself a good fletching by consulting the classifieds, and buying it from a builder who got lost along the way during the project.
Step 14. Follow the instructions carefully
Don't improvise, unless you already have some building experience. Detours cost time, money and sometimes life. It is generally best to start with the tail (as shown in step 13), but always refer to the instructions.
Step 15. Request the collaboration of a technical consultant to check the project and verify your work
This can also save you money on insurance.
Step 16. Pay attention to how long it took others to make the same project as you in order to track your progress
Some parts have lead times that could get in the way of your schedule. Flight experience for your insurance, engines, propellers and hangar may come to mind. Find out the delivery times for each of them and make sure you have everything ready when you need it; 3-6 months before you plan to start using your aircraft, you need to register it.
Step 17. Keep the plane at your home for as long as humanly possible
It is much easier to find 30 minutes to work while dinner is on the fire, when to go to your workshop you only have to walk 3 seconds; on top of that, hangars cost a lot of money. This of course depends on the space you have available, but try to do most of the work at home: assembly of the engine and powertrain, complete wiring and possibly even the paint job. Some, however, prefer to paint the aircraft only after the test flight has been carried out, to keep the investment low and have a last chance to eliminate cracks in the composite structures, if there were any.
Step 18. Take the plane to the airport for final assembly
Step 19. Verify that there is sufficient fuel flow to support the system
Step 20. Complete the necessary registration procedure
Step 21. Fly for a few hours - preferably with a similar type of aircraft
Chances are you've spent so much time building that you neglected your flying skills - not a good strategy. Take a few hours of flight, without rushing. Do some unusual maneuvers and with the engine off; unusual maneuvers are useful since the pilots who built the plane often get distracted in flight, playing with some gadgets they have installed (forgetting that they are flying they find themselves having to do unusual maneuvers); also, you are never good enough to land an airplane with the engine off.
Step 22. Get help from a consultant to plan your first flight and test period
Step 23. Bring your insurance slip
Advice
- Designing aircraft is difficult; ask for advice from someone who knows, both professionals and amateurs with experience.
- Don't let difficulties deter you from building the plane of your dreams, but understand that being the first to build and fly a project is difficult. Each step is a new challenge, because what you do may never have been done before.
- Consider joining EAA.org.
- You can find a builder register here.
