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When I started this project, I was under the impression
that it would fly two years and about 1,000 hours of work later...
Duh! That was at the beginning of March 1999 (actually, I cut the
first piece of aluminum on February 26th).
If my skills in estimating and managing IT projects would have been
that bad, I would have fired myself a few times...Well, no, I don't like
to fire people as I prefer to try to make them better... but at least, I
would have given myself a bad review and no bonus! ;-) I
postponed my schedule a few times, thinking that it was not a two-year,
but a three year project... Then, after 3.75 years, I thought I had only a
month or so of work left to do. Good thing happened! I
suddenly got a lot of "free time" (not because of project
estimation and management skills; a major company reorg. resulted in
change of structure, management and location of IT management). So,
after nine months of additional work on the plane, it was still not ready!
 
On June 8th 2004, I obtained the Restricted Special Certificate of Airworthiness.
And on June 24 (after noticing a "bug" with my engine mount that
removed the smile off my face for a week or so), I declared the plane as
being "serviceable" for the second time.
Follow those links for construction details:
I spent 2785 hours working on the project either in my garage, backyard
or at the airport. Except for a few things like the canopy bubble,
the welding of parts, the reduction drive and propeller, I made most
if not all parts myself. The long duration can be attributed to my
limited skills and knowledge, my persistence to pursue things that don't
make sense and the approach I took for the engine (complete custom
installation that prevented me from using a manufactured cowling and
engine mount).
Would I do it again? Yes! But with some changes:
 | I'd go with specified landing gear (lighter, cheaper and faster to
build) |
| Simpler instrument panel (shock mounts not really needed and... do I
need an Autopilot?) |
| Simpler electrical system (Bob's stuff is nice, but try to write the
checklists and see if it makes sense). That simpler system would
weight less and be installed more rapidly. One thing I don't
think is needed is that "Essential Bus". |
| Standard engine and engine package. While I'd definitively
keep the EIS (like that thing!), I'd go with an engine recommended by
the kit manufacturer, buy the engine mount and the cowling and just
bolt on the engine (almost as simple as that!). I lost two
months (full time) on that cowling and I HATE fiberglass now. |
Things I'd keep:
| Reinforcing some parts such as the fuselage fairings (as per Fred
Hulen's design) |
| Radio with integrated VOX Intercom |
| Forward tilting canopy (but I'd make sure to install it at the right
location--mine is too much forward by 2"). |
| Gizmos such as the Whelen lights (I like lights---must be from that
cave diving experience I have) |
| Building from plans. Making parts does not take that
long. If it took me 2785 hours, it is not due to that. I
think that If I'd do the project again (with the changes mentioned
above), I could do it within 1500 hours. |
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