Chapter Log

Step 1 - Deciding to Build, Selecting a Plane
Status: Completed 
Est Time: 20.00, Actual: 20.00
Est Cost: $ 10.00, Actual: $ 10.00
Date Completed: 00/00/0000

I didn't track my time here but I'm estimating it was at least 200 hours. No kidding, this happened over several months. There is so much material available on the Internet that I was fascinated by everything I found.

I have wanted to fly for some time, and as my budget allowed I had planned on taking lessons and working towards my Private Pilot ticket. However, being a dreamer and planner I spent a lot of time thinking about the future and what that certificate would do for me.

Money was a big problem. Buying an aircraft today can be painful even with a very old plane and a long-term mortgage. Between purchase costs, taxes, maintenance costs, and so forth, buying a plane can cost as much as buying a house. Finally, who wants to go through all of that hassle for a plane that is happy topping a little over 110kts? The Cessna is a great little plane, but I had my heart set on something a little more interesting and a little less expensive.

Bulding is not a panacea, but it suits my needs perfectly. Once I started investigating the option, I realized there are even more building choices than there are buying choices. There are perhaps 6 reasonably priced certificated aircraft if you count out antiques. But for kitplanes and plans-built aircraft, I was up to over forty options before I stopped counting. I love choice, but I can understand why some find even this first step daunting.

There are three main options: kit planes, kit planes with quick build options, and plans-built aircraft. I chose plans-built because I love to do things, and want to get into every little detail during the build process. Also, plans-built aircraft have the lowest overall cost despite the high build times.

After quite a bit of reading, I chose the Cozy for several reasons:

• First and foremost, the up-front costs are minimal. The plans were $500, and materials may be purchased whenever funds allow. Most kits incur a high up-front cost as a non-refundable investment. With the Cozy, the only big expenses are the engine and avionics, which come at the end of the process, so you can save up for them if you budget carefully.
• This plane can cruise at upwards of 200kts for a total investment of approximately $25,000 - you do the math! (That's $125 per knot. Compare that to $233 for a 1960s Cessna or $720 for a 1990s Cessna.)
• The Cozy has a big following, and there are many good Web sites with other builders sharing information and experiences. There is also a newsletter that is very helpful. Finally, Nat Puffer himself is a very helpful resource to builders.
• Modifications are somewhat frowned upon but not entirely outlawed. Don't like the plans fuel sight gauges? An LED-lit replacement with a very visible floating ball is available as a replacement. The list of just the "common" modifications is still extensive.
• The plane seats four (although the back is best suited for children). Since my primary passengers will be my wife, son, and future child if we're blessed with one, this is ideal for us.

Step 1 - Deciding to Build, Selecting a Plane
Status: Completed 
Est Time: 20.00, Actual: 20.00
Est Cost: $ 10.00, Actual: $ 10.00
Date Completed: 00/00/0000

I didn't track my time here but I'm estimating it was at least 200 hours. No kidding, this happened over several months. There is so much material available on the Internet that I was fascinated by everything I found.

I have wanted to fly for some time, and as my budget allowed I had planned on taking lessons and working towards my Private Pilot ticket. However, being a dreamer and planner I spent a lot of time thinking about the future and what that certificate would do for me.

Money was a big problem. Buying an aircraft today can be painful even with a very old plane and a long-term mortgage. Between purchase costs, taxes, maintenance costs, and so forth, buying a plane can cost as much as buying a house. Finally, who wants to go through all of that hassle for a plane that is happy topping a little over 110kts? The Cessna is a great little plane, but I had my heart set on something a little more interesting and a little less expensive.

Bulding is not a panacea, but it suits my needs perfectly. Once I started investigating the option, I realized there are even more building choices than there are buying choices. There are perhaps 6 reasonably priced certificated aircraft if you count out antiques. But for kitplanes and plans-built aircraft, I was up to over forty options before I stopped counting. I love choice, but I can understand why some find even this first step daunting.

There are three main options: kit planes, kit planes with quick build options, and plans-built aircraft. I chose plans-built because I love to do things, and want to get into every little detail during the build process. Also, plans-built aircraft have the lowest overall cost despite the high build times.

After quite a bit of reading, I chose the Cozy for several reasons:

• First and foremost, the up-front costs are minimal. The plans were $500, and materials may be purchased whenever funds allow. Most kits incur a high up-front cost as a non-refundable investment. With the Cozy, the only big expenses are the engine and avionics, which come at the end of the process, so you can save up for them if you budget carefully.
• This plane can cruise at upwards of 200kts for a total investment of approximately $25,000 - you do the math! (That's $125 per knot. Compare that to $233 for a 1960s Cessna or $720 for a 1990s Cessna.)
• The Cozy has a big following, and there are many good Web sites with other builders sharing information and experiences. There is also a newsletter that is very helpful. Finally, Nat Puffer himself is a very helpful resource to builders.
• Modifications are somewhat frowned upon but not entirely outlawed. Don't like the plans fuel sight gauges? An LED-lit replacement with a very visible floating ball is available as a replacement. The list of just the "common" modifications is still extensive.
• The plane seats four (although the back is best suited for children). Since my primary passengers will be my wife, son, and future child if we're blessed with one, this is ideal for us.

Step 2 - Order Plans
Status: Completed 
Est Time: 1.00, Actual: 1.00
Est Cost: $ 500.00, Actual: $ 500.00
Date Completed: 00/00/0000

I ordered the plans while away on business, and couldn't wait to get home when my wife called to tell me they had arrived. I also ordered the free catalogs from both Wicks and Aircraft Spruce. I've heard a number of stories about the quality of service from these two vendors, so I'll try both and see what happens.

The Robinsons are officially building Cozy MKIV Serial #1147!

I like the sound of that: 1147... 747... Get it?

Step 3 - Plans Introduction
Status: Completed 
Est Time: 1.00, Actual: 1.00
Est Cost: $ 0.00, Actual: $ 0.00
Date Completed: 00/00/0000

I have a tendency to rush things, so this project will in part be a test of my patience. I have decided to carefully read every word of the plans several times before beginning each step, and I'm not about to skimp on the introduction. It looks to me like I need to get some post-it notes and go through the newsletters to identify areas where the plans need to be updated.

Update: No worries about patience. There is so much wait time between steps while things cure that I'm automatically prevented from rushing things.

Step 4 - Update plans
Status: Completed 
Est Time: 4.00, Actual: 5.00
Est Cost: $ 0.00, Actual: $ 4.50
Date Completed: 00/00/0000

The Cozy plans are not the end-all answer to building this plane. There is also a newsletter, and changes to the plans for safety and other reasons are published there. It is therefore necessary to go through the plans to update them. To that end, I've purchased a glue stick, a pad of airmail paper (which is very thin) and a few pads of Post-It notes, and will make my modifications that way. The cost listed for this step went to those supplies.