On this page you will find a lot of Information on how to tackle a task or New Ideas for your Zodiac.
Click on picture for the latest on the Sport Pilot Update ~ Finally approved!!
Installing Your Canopy ~ This is a great format for trimming and installing a canopy on the 601 Series aircraft. ~ by Eric Tingley
Weight & Balance - Excel format
Bending the 12 foot Nose Skin ~ Brought to you by Mark & David
Bending Main Gear Leaf and Nose gear fork
Drilling your Spars ~ Debo Cox
3 Point Harness ~ Updated PDF of Zenith 601XL Harness Installation from Neil Hulin
601 XL Rib Template Drawings in 3 formats Files are stored in zip format, choose the one you can use. either .dwg .pdf .dxf The drawings were done in inches, so when you plot them you will have an idea where to start. You can make a set of formers for the #1 and #6 ribs, then after the ribs are done you can reshape the forms to #2 and #7 and so on. This will save a lot of material. Don't forget that #8 and #9 have a smaller hole at the trailing edge. Be sure to check your plots against the Zenith drawings to be sure they are correct ! Remember the disclaimer on the first page! they are YOUR wings
Zodiac 601XL Rear Spar Splice
Zodiac 601XL Spar Cap in two pieces.
Materials List / Cutting Layout in Excel Format in Adobe pdf / Format in CAD dwg ~ I recommend the PDF or DWG for an easy to follow layout this is for the older version of 601XL using .016 skins not the new .025 skinned XL Thanks go to Herb Heaton
NEW CH601 XL VERSION LAYOUT SHEETS ~ due to the changes in the 601XL's plans this file needed to be updated. Thanks to Dino Bortolin for stepping up to update this utility. All files are in Zip compression choose eht file extension you can use. 601XL.DWG 601XL.DXF 601XL.PDF
601XL Hardware materials list MS Doc Format, HTML
601HD Hardware materials list in .pdf Format
Fitting Fuel Pumps between nose ribs 2 and 3 601XL ~ a neat way to install the pumps in your wings. ~from Joe Motis
Zodiac Kit ~ Here is a couple of pictures of what you get in your Zodiac 601 kit
Removable Fuel Tanks
Alternate Part Sources
Buiders Assistance Centers
These folks are the best in the Business, each offers a builders assistance package geared towards getting you in the air as soon as possible.
Can-Zac Aviation Ltd.
Canada ~ Kitplane Builders
South ~ Flight Crafters
West ~ Quality Sport Planes
Matco brake rework ~a very nice way to increase your brakes usefulness.
Alternate Toe Brake Pedal Design for the XL - By David Barth
Inside Steps ~ by Jack Russell
801 nose wheel forks (for 6.00X6 wheels)
Dual Sticks for HD/HDS 3+meg zip file
Aluminum Spring Gear For the 601HD/HDS
Flour Bomb bay door ~ Bob Miller
Brake Pedal Geometry - Min. Mechanical Advantage according to Matco.
Brake Master Cylinder and System Assembly drawings - Also by Matco
Mod to remove Stabilizer at a later date
Behind the Panel Access
New Throttles Quadrants
Dave’s Aircraft Instrument Panel Stencils For Microsoft Visio
Homemade Tow Bar
Nuvite's polishing procedures
Installing Wheel Pants and Towbar
Installing a VOR Antenna on Zenith’s Flying Rudder ~ PowerPoint presentation 1 meg by Bill Bartlett
Rudder Fairing with Acrylic
Foam Seat Construction
Line Drawings for the CH601XL with a Corvair conversion
Painting your plane
Tail Position Light
Fiberglass Parts ~ Some I bet you never thought of.
How to Make Stabilizer Tips ~ by Scott Laughlin
How to Make Fiberglass Wheel Pants
Making a Composite Prop - It's a great idea for your test stand
Composite Fuel Tank Construction
How to Make a
Cowl From Mike Sinclair's 701 Project
Side-Small-Top-601XL paint scheme plans
Heating/Cooling system for your Zodie
Easy Heating system for your 601
Fitting Fuel Filler Fix"
Retracting Steps for your 601
601HD/HDS Landing Light & Gear Box Fairing
Wing Root Fairing
Hinge Idea for Wing Lockers
Center Channel tube run
Balls holding an aileron
Design your instrument Panel ~ Here is a handy online panel designer for your Zodiac, it can save you both Time and Money
Zenith Panel Design
Center Console Fuel Selector
Make your own AOA Lift Reserve indicator
Lift Reserve faces ~ By Dino
Installing (and flying) the Lift Reserve Indicator
TRUE AIRSPEED CALCULATOR
Plumbing your Pitot-Static System
Low Cost Instrument Panel Lighting System.
Aircraft Engravers ~ Specialize in doing work for the home built aircraft market making such products as placards, circuit breaker and switch overlays, vinyl N-numbers, rocker switch and aluminum fuel cap engraving also data plate labeling.
First Flight Checklist
Valuable lessons for everyone to review before their first flight!
Flight Testing Handbook
Terminal Procedures/Airport Diagrams (symbols)
Nearby Airport Locator (HOT)
Entire USA VFR Sectionals Online (HOT)
Flight Route Calculator
AWC Product Overlay
Bend Line Spreadsheet ~ A great tool for figuring out developed length, by Larry Winger
Cutting aluminum on a table saw
Amateur Built Aircraft Reference Material
Surface Preparations for primer and paint
What a Canadian inspector looks for
Riveted Joints ~ a must read for beginners from The Boss
Solid Riveting - Military Specifications (Mil Spec)
Weight & Balance Excel worksheet
Control Cable Basics
CH601 Operating Manual
CH601XL Operating Manual
CH601 HDS Pilot Operating Handbook This manual is from Thilo Kind and is a great basis for making your own manual. ~ Thanks Thilo
Some thoughts on Crimping vs. Soldering vs. Both
Good Soldering Techniques
Airport Information | Airspace Explained | Equipped to Survive | Potts Bush Flying | Ops at Towered Airports | Weather Strategies | See How It Flies | Pilot/Controller Glossary | AIM
Choosing Your Homebuilt: The One You'll Finish And Fly!
Kenneth D. Armstrong, 3rd edition
For many Homebuilders, myself included, deciding what to build is the hardest step. This book can help you decide which plane, or even if you should build at all. It will help you find an aircraft you can build, fly and afford. And it provides perspective on almost every aspect of Homebuilding, from deciding whether to go with a kit or plans, to the paperwork involved.
Composite Construction for Homebuilt Aircraft: The Basic
Handbook of Composite Aircraft Aerodynamics, Construction, Maintenance and .....
Jack Lambie, 2nd edition, 1996
ISBN 0-9387-1626-3, $20
This book is entry level and mostly a summation of various principles. It has an interesting section on the Taylor Paper Glass (TPG) process.
Converting Auto Engines For Experimental Aircraft
Richard Finch, 4th edition, 1998
ISBN 0-9661-4571-2, $16
This book helps reduce the high cost of building your own aircraft.
Aircraft homebuilders usually do so to save money. They should read this book to try to get their mind out of the rut that the outrageously overpriced aircraft engine is a necessity. Many homebuilt aircraft have flown for years with auto engines and Finch explains how others have done it and saved big money engines, maintenance and fuel. This book explains what it takes to do it yourself.
Ronald J. Wanttaja, 2nd edition, 1996
ISBN 0-0706-8161-9, $26
This book is a basic 'primer' covering the basic skills and knowledge necessary to build your own homebuilt aircraft. Chapters cover selecting the right kitplane, engine selection, workshop setup, aircraft-quality workmanship, and specific information on all modes of construction. It doesn't go into such depth that it can be your only guide once you've decided on a plane; if you build a wood plane, you'll need much better guides to carpentry. If you build a composite plane, you'll want to get a good bit more research and practice on laying fibreglass. You'll definitely need separate electronics instruction. Each subject is like that; Wanttaja tells you enough to get you started, but it would take a library to cover in proper detail everything you'll need to know for one plane. What Ronald Wanttaja is mostly doing is giving you as good an idea as possible just what it entails to build your own airplane of one type or another, and helping you decide which, if any, you would have the best chance of completing (Most homebuilt aircraft projects never fly). The first edition won the Aviation/Space Writer's Association 1992 Journalism Award in the Technical/Training books category.
Recommended reading for kit builders, but quite relevant for other builders as well.
The Sportplane Builder: Aircraft Construction Methods
Tony Bingelis, 1992
If you are going to build your own aircraft, you should get this book. I can't put it any simpler than that. In fact, this is the first of a series of books by Tony no homebuilder should be without. For more years than I've been a member, EAA members have opened up their issue of Sport Aviation each month to Tony Bingelis' column "Sportplane Builder" for tips, methods and invaluable advice. This book if full of that and more. In these pages you'll find things you may remember from his monthly column, and many new tips, tricks and techniques. Once you read each chapter you'll wonder why you didn't think of it. Tony builds constantly, boats, bows, furniture, gadgets, and more aircraft than anyone I've ever heard of. I can think of no better person to advise you on building your own aircraft.
Sportplane Construction Techniques: A Builder's Handbook
Second in a series of "you gotta have it if you're a homebuilder" books by Tony Bingelis. In this volume you'll find more Bingelis common sense that isn't so common. For example, you find invaluable tips on how to get set up to build while you're waiting for your plans or kit to arrive. Or you'll read how to deal with fittings, and avoid some potentially dangerous pitfalls.
Firewall Forward: Engine Installation Methods
Third in a series of "you gotta have it if you're a homebuilder" books by Tony Bingelis. Covering installation of piston engines in homebuilt aircraft, this book is full of information and practices that have proven effective and practical.
SportPlane Resource Guide
James R. Campbell, 2nd edition, 1998
This is the second edition of this resource book on Homebuilt Aircraft. It includes a Comprehensive Powerplant Directory, Specs & Reviews of over 800 SportPlanes, and 60 How-To Chapters.
You Want To Build And Fly A What? Or, How I Learned To Fly, Built A WWI Replica,
And Stayed Married
This is the funniest book in Homebuilt Aviation. This is the story of how Dick Starks got into aviation, and then Homebuilding, and how he and his wife survived/enjoyed the experience. The funniest thing about this story is it's all true! (Just ask his wife.) Dick has a way of looking at any situation that will make you laugh. For a Homebuilder that is a good trait to have. And to top it off it's illustrated by aviation cartoonist, Bob Stevens. You can't help but enjoy this book.
Aerodynamics & Design Books
Understanding Aircraft Composite Construction: Basics of
Materials and Techniques for the Non-Engineer
Zeke Smith, 1996
This book explains, in plain language, without difficult mathematics, how and why composite materials work and how this family of materials achieves high mechanical performance, particularly in small aircraft. The target reader is a builder who is considering an aircraft project but may not have chosen the technology (tube and fabric, wood, aluminum) and needs to learn enough about the principles of composite construction to make an informed choice. This book will be of particular interest to the builder who is considering one of the popular prefab kits like the Glasair, Lancair, or KIS, where most of the structure consists of large, precision-molded sandwich forms. While not a design manual, the book will be of special interest to a builder who wishes to develop his own design and is prepared to do the necessary testing of prototype structures.
Without Tears: A Primer on Aircraft-Stress Analysis Requiring
No Advanced Mathematics
Tom Rhodes, 1994
ISBN 0-7881-1343-7, $40
I've had this book recommended by several persons.
Aircraft Design: A conceptual Approach (Aiaa Education Series)
Daniel P. Raymer, 1989
ISBN 0-9304-0351-7, $67
This book is a college textbook on the subject.
Composite Materials for Aircraft Structures (Aiaa Education Series)
Brian Hoskin, 1986
ISBN 0-9304-0311-8, $55
An introduction to virtually all aspects of the technology of composite materials as used in aeronautical design and structure. This text discusses important differences in the technology of composites from that of metals: intrinsic substantive differences and their implications for manufacturing processes, structural design procedures, and in-service performance of the materials, particularly regarding the cause and nature of damage that may be sustained.
Barnaby Wainfan, 1997
This book is a reprint of a series of articles first published in Kitplanes magazine. This book gives a basic understanding of airfoil geometry and how that geometry affects the aerodynamic characteristics of an airfoil and the characteristics of an airplane using that airfoil.
Aerodynamics of Wings and Bodies
Holt Ashley, 1985
ISBN 0-4866-4899-0, $9
Didn't cost much, so I couldn't resist buying it.
The Illustrated Guide to Aerodynamics
Hubert "Skip" Smith, 1992
This book clearly explains basic aerodynamics without using pretentious technical jargon and dry scientific explanations. It's perfect for pilots, aircraft owners, homebuilders, and airplane mechanics. This book is a perfect text to read prior to reading a university level textbook.
Donald R. Crawford, 1986
This book is a reprint of a series of articles first published in Kitplanes magazine. These articles focus on "bite-sized" pieces of the overall design problem. Many articles are accompanied by computer program code listings.
A Practical Guide to Airplane Performance and Design
Donald R. Crawford, 1979
This book is unusual in that key aerodynamic relationships are clarified with easy to use and easy to understand nomograms. As a result you can immediately make valid performance calculations for a new design, and see the consequences, or benefits, of changing design features.
L.M. Milne-Thomson, 4th edition, 1973
This book is a university text and reference book, and is considered a classic in the field. It covers nearly all aspects of aerodynamics. This is no easy read. It does help to be familiar with the elements of the differential and integral calculus.
Theory of Flight
Richard Von Mises, 1959
A balanced, well written account of fundamental fluid dynamics. It is one of the clearer presentations of uncompressed air flow. It is designed for the college senior or beginning graduate student, and assumes a knowledge of the principles of calculus and some familiarity with general mechanics.
Theory of Wing Sections
Ira H. Abbott & Albert E. Von Doenhoff, 1960
ISBN 0-4866-0586-8, $12
Concise compilation of the subsonic aerodynamic characteristics of modern NASA wing sections together with a description of their geometry and associated theory. Intended to be primarily a reference work for engineers and students, the book devotes over 300 pages to theoretical and experimental considerations. Rather heavy reading (have to brush up on my calculus) and perhaps a little outdated. Interesting section on the effect of flaps and wing slats.