Last Update: 11/13/05
This is neither the official cozy site nor even the unofficial cozy site. This web page simply describes my personal experience of a cozy Mk IV construction project as it progressed from a pile of parts and materials to an airplane that flys at over 200 mph. The text is mainly written for those who follow. Note that the text is chronologically organized by chapter so don't do the work as you follow along with me, or you'll repeat all my mistakes. I highly recommend that you read to the end of each chapter and each related chapter, both here and in a couple of the other builder's pages, and read the flight testing pages, before starting the work.
As you can see from the above picture, my cozy looks a lot likeNat Puffer's plane. It flies like it too. Maybe even a little faster and smoother. This web site served as my builder's log for the FAA certification. Rather than simply repeat the plans text I concentrated on things that didn't go according to plan and how I got around them. I visited other builder's sites at least four or five times in each chapter, just to see how things looked in they're pictures and read about the obstacles they hit. Hopefully this will help those who follow me but, remember the immortal words of Dennis Miller:
This is just my opinion. I could be wrong. Building things out of glass and foam is easy. Introduction
Making the bits into an operational flying machine takes a lot of work.
Breakdown by Chapter
Tips & Tricks
Glossary of terms
Canard Aviator's Mail list Censorship - is this what members want?
Changing times at AC Spruce?
Credits & Acknowledgements
about the author
List of things to be done (now closed)
cozy IV parts spreadsheets
Register you're own building or flying status (wasnt working. Now works)
A daily log as I progressed toward first flight
Building things out of glass and foam is easy.
IntroductionHow I came to start the project, some of the factors which affected the decision on type of plane, how I chose my suppliers, and my overall impression so far.
Current statusThe hours listed are very rough estimates of time spent actually working on the project. This doesn't include research, preparation or cleanup. Keeping a precise hourly time sheet seems a bit meaningless and I don't want to be that regimented. Elapsed time is a much more useful and meaningful measurement to me. Initial progress was beyond all my expectations. I went from first foam cut to sitting on wheels in less than 12 weeks. After 18 months, the airframe was complete and in primer. I was then distracted by annoying things (like having to earn a living). I had over 14 months where my productivity went down to almost nothing. The airplane flew after 5 years, one month. I'm working very slowly through Phase 1 flight testing. In early July, after just 8.3 flying hours, the stock Mazda turbo gave up and the airplane was grounded for almost 3 months while I waited for a refurbished and modified turbo to come from Australia. In the meantime I got on with a few minor jobs and installed an engine monitor. Then I discovered that the turbo ate a seal and one of the housings on its way out, and the plane stayed grounded while the engine was removed and rebuilt. After 4 months delay for one thing and other the airplane is finally flying again and I'm gradually building the hours.
|Chapter||Start Date||End Date||Hrs.|
|Chap 4 - Bulkheads||3/6/99||3/22/99||60|
|Chap 5 - Fuselage Sides||3/22/99||3/31/99||50|
|Chap 6 - Fuselage Assembly||3/31/99||4/9/99||80|
|Chap 7 - Fuselage Exterior||4/9/99||4/28/99||65|
|Chap 8 - Head rests, Seat Belts, Heat duct||4/19/99||5/1/99||48|
|Chap 9 - Landing Gear & landing brake||5/1/99||5/28/99||135|
|Chap 10 - Canard||5/29/99||6/20/99||92|
|Chap 11 - Elevators||6/5/99||9/16/99||45|
|Chap 12 - Canard Installation||6/21/99||9/16/99||20|
|Chap 13 - Nose, Nose Gear, Rudders||6/23/99||12/28/00||97|
|Chap 14 - Centersection Spar||7/29/99||8/29/99||90|
|Chap 15 - Firewall||6/20/00||7/14/00||24|
|Chap 16 - Control System||4/07/00||4/30/00||45|
|Chap 17 - Trim System / center console||8/15/99||05/05/00||79|
|Chap 18 - Canopy||12/16/99||10/12/00||153|
|Chap 19 - Wings, Ailerons||9/22/99||12/14/99||173|
|Chap 20 - Winglets & Rudders||10/02/99||12/14/99||50|
|Chap 21 - Strakes, Fuel Tanks||12/21/99||02/11/00||300|
|Chap 22 - Electrical||5/5/99||3/10/04||348|
|Chap 23 - Engine||3/18/00||3/10/04||600|
|Chap 24 - Covers & Fairings||6/29/99||7/31/01||340|
|Chap 25 - Finishing||4/3/99||6/5/02||720|
|Chap 26 - Upholstery||8/1/00||9/3/03||60|
|Chap 27 - Preflight||6/23/03||3/10/04||267|
|Chap 28 - First Flight||4/1/04||4/9/04||59|
|Chap 29 - Phase 1 flight testing||4/10/04||7/4/05||NA|
|Flight Stories and Trip Reports|
Tips and tricksA few tips and tricks I learned along the way.
LinksLinks to suppliers, builders sites and other places of interest.
I used to publish my email address here, but the webcrawlers and search engines were grabbing it, and plugging it into every junk mail circulation list on the internet. To contact me, join the Canard Aviation Forum and send me an email from the membership list there, or send email to jslade at canardaviation dot com.