



Table of Contents
Build a Plane – Are you CRAZY?!!
Introduction
I
guess there is nothing really special about me. I grew up in Western Canada, worked at my father’s engineering
& metal manufacturing company until college. I graduated from LeTourneau University in Texas with an
Engineering degree and then moved to San Jose, California – where I’ve been at
the same company here for 20 years (wow!!).
There was also an 18-year marriage wedged in there somewhere (but I digress). I’m 46, single, and have a great 11 year
old son (Michael), who lives with me during the summer months. I’ve always enjoyed building things and
flying, therefore it made sense that the two hobbies should be merged into a
new PASSION. So, here I am ready to
take some time out for myself and pursue something I have always dreamed
about. Besides - how cool would it be
for Michael and his Dad build a plane together?!
Ok... I’m going to do it… I’m going to build an airplane. Not a small balsa wood model or even a big balsa wood model. Nope! This is going to be a for-real airplane -> 2 place, all metal, “jack-of-all” trades type plane.
It’s
really not as crazy as you would think.
Thousands of people have done it before.
Heck
– My dad build his C-GYRV (Yukon RV). It’s a tandem 2-place kit plane (RV-4) manufactured by Vans Aircraft.

Fig
1-1 Fig
1-2
Even
my mom got into the action and built her C-FBJJ (Built by Jean
& Jack)…. Hers is an RV-9A
(the A signifies a tricycle gear) - a 2 place, side-by-side kit also sold by
Vans Aircraft.

Fig 1-3 Fig
1-4
The
choice of type of plane was really easier than I thought it would be. I wanted something proven, reliable, backed
by a good company – and with a large support group. So it made sense to go with the family tradition and build
something from Vans. Besides I could
always ask Ma or Pa for advice (or more importantly – maybe borrow some
tools….). The problem is not what company – but what MODEL! I originally leaned toward the RV-7 (an
aerobatic tail dragger). I checked out
Van’s Demonstrator RV-7 and purchased the preview plans at Oshkosh in 2002… but
then stalled out for awhile. Later I
flew Dad’s RV-4 and found it a little too “squirrelly” for my taste. Besides, I wanted side-by-side seating. Then, last summer – I tried Mom’s RV-9A
(tricycle gear) and fell in love with it.
So – it’s going to be an RV-9A for me!
Why you ask? Well Mike @ http://www.my9a.com/index.asp put it
better than I ever could:
The -9A is a fast plane that lands nice
and slow. It can carry two big passengers and a mess of baggage. It has a 700
mile range on a tank of gas, and it can cruise at 180 miles per hour. It is
easy to fly and looks great. It is not intended for aerobatics, but is
optimized for smooth cross-country flying. It is a real airplane that can be
built for not a lot of money. It is exactly what I wanted.
Flies Fast
- I want to go three times as fast as a car! The RV-9A will cruise at 180mph.
Wow!
Lands Slow
- The slower a plane can fly without stalling, the better. Typically fast
planes are difficult to land. The RV-9A lands at about the same speed as a Cessna
150.
Two Seats
- I decided that the majority of my flying will be by myself or with only one
passenger.
Large Baggage Area
- In addition to two passengers, there is plenty of room for nearly 100 pounds
of baggage.
700+ Mile Range
- The plane is really optimized for cross-country travel. The fuel tanks hold a
combined 36 gallons of fuel, which will allow me to fly for four hours with
reserves.
Easy To Fly
- The -9A has a specially designed wing that just wants to fly. The extra wing
area means that the glide ratio is extremely generous. It also means that there
is more time to find a suitable landing spot if the engine decides to quit.
Not Aerobatic
- Here is the tradeoff. To get this really great cross country capability, fast
speed, and slow approach speeds, you have to give something up. That thing is
aerobatics. I'm not an aerobatics sort of guy, so this is a tradeoff I'm
willing to make.
Not Expensive
- This is a major issue for me. I am not able to spend a lot of money on a
plane. Furthermore, I didn't have a lot of up-front money to invest.
OK,
now that I’m seriously thinking about doing this do this -> Maybe I should
figure out what it’s really like. And
what better way than to take some classes?
I decided to take both the EAA Sport Air Sheet Metal Basics and RV
Assembly classes (http://www.sportair.org/). Besides, I had an inside scoop – Dad was
teaching them!! It was the best $$ I
could spent!! In addition to gaining
experience and confidence – I even got to walk away with a couple of souvenirs
(AKA class projects).

Fig 1-5 Fig
1-6