STOL CH 801 - Sport Utility Kit Aircraft

 
STOL CH 801

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ASSEMBLY MANUALS
This Page Last Updated July 06, 2012

Following are online assembly manuals for the STOL CH 801 kit assembly and construction.  These online manuals are presented in the Adobe Acrobat file format for online viewing.  If you do not have the free Adobe Reader 6.0 software installed on your system, click here to download a copy.

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NOTICE: These manuals contain copyrighted information and are presented for educational purposes only. THE FOLLOWING MANUALS ARE NOT FOR DUPLICATION OR DISTRIBUTION.
See the Zenith Aircraft Builder Pages for additional updates.  Zenith.Aero: The exclusive online community for Zenith builders and owners. 

STOL CH 801 ASSEMBLY MANUALS Revision Posted
801-assembly Basic view of the STOL CH 801 airframe assembly  sketch 7/12/00
801-assembly1 Enhanced views of the STOL CH 801 airframe assembly  sketch 12/28/01
RUDDER TAIL SECTION - KIT ASSEMBLY
introduction Introduction to building - 18 pages 10/02 11/6/02
CS Construction Standards Draft 3/11
8XR-1 Rudder Exploded View
Parts 8R1-1 to 8R3-4
dwg
3/1/02
8/26/02
8RU-01 1 of 3: 
Rudder Assembly Drawing 1 - internal assembly
dwg
2/25/02
8/26/02
8RU-02 2 of 3:
Rudder Assembly Drawing 2 - installing the skins
dwg
2/25/02
8/26/02
8RU-03 3 of 3:
Rudder Assembly Drawing 3 - tail light & rudder hinge
dwg
2/25/02
8/26/02
rudder0 Title Page / Table of Contents 2/03 2/20/03
rudder1 1 of 5: 
Building the Sub-Assemblies: Spar and Skeleton
3.0
8/02
8/26/02
rudder2 2 of 5: 
Building the Sub-Assemblies: Spar and Skeleton
3.0
2/03
2/20/03
rudder3 3 of 5: 
Installing the Rudder Skins
3.0
8/02
8/26/02
rudder4 4 of 5: 
Installing the Rudder Skins
3.0
8/02
8/26/02
rudder5 5 of 5: 
Installing the Rudder Fairings
3.0
8/02
8/26/02
HORIZONTAL TAIL SECTION - KIT ASSEMBLY
tail part list Horizontal Tail Part Number List 5/18/04 5/18/04
8XH-1 Horizontal Tail - Exploded View (1 of 3) dwg
5/14/14
5/04
8XH-2 Horizontal Tail - Exploded View (2 of 3) dwg
5/14/14
5/04
8HA-1 Horizontal Tail - Skeleton Layout (3 of 3) dwg
5/14/14
5/04
elev1 ELEVATOR SKELETON ASSEMBLY 4.1 6/18/04
elev2 POSITIONING THE ELEVATOR SKINS 4.1 6/18/04
elev3 INSTALLING THE ELEVATOR HORN AND HINGE PLATES 4.0 05/14/04
elev4 ELEVATOR TRIM TAB 4.0 05/14/04
horizt1 HORIZONTAL TAIL SKELETON ASSEMBLY 4.1 06/18/04
horizt2 INSTALLING THE HORIZONTAL TAIL SKINS 4.0 05/14/04
horizt3 FITTING THE ELEVATOR HINGES 4.0 05/14/04
horizt4 INSTALLING THE FIBERGLASS TIPS 4.0 05/14/04
LEADING-EDGE WING SLATS SECTION - KIT ASSEMBLY
8XS-1 Slats Assembly - Exploded View
Parts 8S1-1 to 8S2-1
dwg
3/1/02
3/1/02
slats1of3 Introduction / Parts List
INSTALLING THE RIBS
3.1 12/02
slats2of3 POSITIONING THE SKIN 3.1 12/02
slats3of3 POSITIONING AND INSTALLATION OF THE SLATS TO THE WING 3.1 12/02
FLAPERONS SECTION - KIT ASSEMBLY
8XA-1 Flaperons Assembly - Exploded View dwg
12/02
12/02
flaperons1 REAR SKINS AND NOSE RIBS ASSEMBLY 3.0 9/02
flaperon2of3 INSTALLING THE LEADING EDGE SKIN AND THE SPLICE PLATES 3.0 5/5/99
flaperon3of3a 1 of 2: POSITIONING THE FLAPERON TO THE WING AND FUSELAGE 4.0 9/27/00
flaperon3of3b 2 of 2: POSITIONING THE FLAPERON TO THE WING AND FUSELAGE 4.0 9/27/00
fr3-6 Flaperon Control Horn 8A2-5 dwg 9/19/00
WING SECTIONS - KIT ASSEMBLY
8XW-1 Wing Assembly - Exploded View
Illustrated Parts List 
dwg 01/02/02
8XW-2 Wing Assembly - Exploded View
Wings Struts / Fuel Tank
dwg 01/02/02
wings-section1 Parts List
FLAPERON BRACKET AND REAR RIB SUB ASSEMBLY
3.0 8/12/99
wings-section2 SLAT BRACKET AND NOSE RIB SUB ASSEMBLY 3.0 8/12/99
wings-section REAR WING SPAR SUB ASSEMBLY 3.0 8/16/99
wings-section4 MOUNTING RIBS TO MAIN SPAR 3.0 8/16/99
wings-section5 INSTALLING THE REAR SPAR 3.0 8/16/99
wings-section6 INSTALLING BOTTOM REAR WING SKIN 3.0 8/18/99
wings-section7 INSTALLING THE BOTTOM SECTION OF THE LEADING EDGE SKIN 3.0 8/18/99
wings-section8 INSTALLING THE FORWARD STRUT ATTACH DOUBLER 3.0 8/18/99
wings-section9 FITTING THE REAR SKIN 3.0 8/18/99
wings-section10 INSTALLING THE TOP PORTION OF THE LEADING EDGE SKIN 3.0 8/18/99
wings-section11 INSTALLING THE FLAPERON AND SLAT BRACKETS 3.0 8/18/99
wings-section12 TRAILING EDGE INSTALLATION 3.0 8/18/99
8-wt FUEL TANK INSTALLATION
DRAWINGS - 9 Pages
3.0
(8/02)
8/14/02
wings-section13 FUEL TANKS INSTALLATION 3.0 8/18/99
wings-section14 INSTALLING THE INBOARD WING TIP 3.0 8/18/99
wings-section15 FLAP ATTACH STIFFENER 3.0 8/18/99
FUSELAGE ASSEMBLIES

Click here for Third Edition Fuselage Assembly Manuals

8XF-1 Fuselage Exploded View (rear)
Parts 8F1-1 to 8F5-11
dwg 12/02
8XF-2 Fuselage Exploded View (fwd)
Parts 8F7-1 to 8F8-7
dwg 01/16/02
8XF-3 Fuselage Exploded View (cabin)
Parts 8F9-SA to 8F11-16
dwg 9/14/01
8XF-4 Fuselage Exploded View (cabin)
Parts 8F14-1 to 8F18-1
dwg 12/02
8XF-5 Fuselage Exploded View (cabin)
Parts 8F19-2 - 8F22-9 (doors & seats)
dwg 12/02
fuselage-view Overview of the full fuselage assembly with gear sketch 7/12/00
fuselage Overview of the full fuselage assembly (drawing) sketch 5/00
F5-3Z Top Channel "Zee" Reinforcement Dated 10/2001 10/15/01
FUSELAGE ASSEMBLY

Click here for Third Edition Fuselage Assembly Manuals

CONTROL SYSTEM ASSEMBLY

Click here for Third Edition Control System Assembly Manuals

FINAL ASSEMBLY
top-view Top View of Aircraft Assembly dwg 11/30/01
8XC-1 Control System: Exploded View
Parts 8C1-1 to 8C6-9
dwg 12/02
8CX-2 Control System: Exploded View
Parts 8C8-1A - 8C9-5
dwg 01/25/02
8XL-1 Landing Gear Exploded View: Parts 8L1-1 to 8L2-4 dwg 12/02
8LS-1 Drawing: Main Landing Gear Spring Assembly - drawing. dwg 1/15/01
gear-s1 1 of 3
Nose Gear to Fuselage
2.0
2/14/03
6/03
gear-s2 2 of 3
Nose Gear Bungee
2.0
2/14/03
6/03
Nosewheel Bungee Installation Tool allows you to install or replace nose gear bungee easily in minutes.
gear-s3 3 of 3
Main Gear Spring
2.0
2/14/03
6/03
final-assy-s4-a 1 of 3
Assembly of the Cabin Doors
3.2 11/03
final-assy-s4-b 2 of 3
Assembly of the Cabin Doors
3.2 11/03
final-assy-s4-c 3 of 3
Door Stop / Opening Latch
3.2 11/03
final-assy-s5 Installing the Fin to the Fuselage / Stabilizer 3.0 5/5/00
AIRCRAFT FINISHING
8VV0 Slat Position Detail dwg 12/22/00
8SO-1 Slat Position Template dwg 4/16/01
front-seat Assembly of the Front Seat draft 11/10/00
windows Installation of the Windows & Windshield 3.1 8/22/00
Web link LP Aero Plastics' online documentation on handling, drilling, trimming and cleaning the acrylic windshield.
finish1of3-stab-attach Installing the horizontal tail to the fuselage draft 9/15/00
finish2of3-rudder-attach Installing the rudder to the fuselage draft 9/15/00
finish3of3-wings-attach Installing the wings to the fuselage draft 9/19/00
brake-lines Installing brake lines 1.0 2/12/02
LYCOMING 0-360 Engine Installation
thrust-line Lycoming Thrust Line Position dwg
8/26/02
8/26/02
cowl-a1 Lycoming O-360 - Section A1 - Installation of the engine cowl 1.0 01/10/02
baffles-1a Lycoming O-360 - Section 1a - Installation of the engine baffles 1.0 11/30/01
baffles-1b Lycoming O-360 - Section 1b - Installation of the engine baffles 1.0 11/30/01
oil-cooler-2 Lycoming O-360 - Section 2 - Installation of the Oil Cooler 1.0 11/30/01
fuel lines-3 Lycoming O-360 - Section 3 - Installation of the Fuel Lines 1.0 11/30/01
carb-heat-4 Lycoming O-360 - Section 4 - Installation of the Carb Heat Box 1.0 11/30/01
mixture-ctrl-5a Lycoming O-360 - Section 5a - Installation of the Mixture Control Cable 1.0 11/30/01
mixture-ctrl-5b Lycoming O-360 - Section 5b - Installation of the Mixture Control Cable 1.0 11/30/01
muffler-6 Lycoming O-360 - Section 6 - Installation of the Muffler 1.0 11/30/01
oil-pressure-7 Lycoming O-360 - Section 7 - Installation of the Oil Pressure Sender 1.0 11/30/01
spinner-9 Lycoming O-360 - Section 9 - Installation of the Propeller Spinner 1.0 1/19/04
OTHER
parts-list Parts List - Complete kit
Indexed by Part Number (14 pages)
Part List
rev. 12/20/02
12/02
panel Instrument panel blank dwg 2/27/02
manual updates Assembly Manuals Update
(32 pages)
text 12/20/02
VCI-373 Cortec 373 Corrosion Protection brochure
   - Material Safety Data Sheet
brochure 10/2003
pneu-riveter Using the pneumatic rivet puller   12/18/01
801-w&b STOL CH 801 Weight & Balance Worksheet: Form FWB-801 6/25/02 6/25/02
801-cg STOL CH 801 Center of Gravity Limits: Form FCG-801 8/2002 8/6/02
8XE-1 Fuel System (standard, firewall mounted gascolator)  dwg 10/18/01
8XE-2 Fuel System (auxiliary wing tanks)  dwg 10/18/01
8XE-3 Fuel System (standard, under cabin mounted gascolator)  dwg 10/18/01
8FE-1 Fuel Line Trim Around Door  dwg 2/13/01
8FE-1.1 Fuel Line Routing Around Door 
- standard fuel system.
dwg 2/13/01
8FE-2 Fuel Line Trim Around Door
- dual wing tanks
dwg 2/13/01
8FE-2.1 Fuel Line Routing Around Door
- dual wing tanks
dwg 2/13/01
flap-circuit-fig1-2 Electric Flap Circuit Drawing dwg 3/3/00
8ZV-01 Pitot Tube, Airspeed Markings and Wing Tie-Down Rings dwg 6/29/01
8ZZ-1 Rear Tunnel Assembly and Center Seat Belt dwg
12/15/02
12/15/02
8CN-01 Elevator / Rudder Control Cables dwg
8/16/02
8/02
8CN-02 Flaperon & Elevator Control System (hardware). Two Pages dwg 12/4/00
8CN-3.1 Control Deflections: Flaperon, Elevator and Rudder  dwg 09/22/04
8CN-3.2 Elevator and Flaperon Deflection Templates dwg 9/15/00
8ZE-1 Fuel Pump Assembly and Air Box Location dwg 11/19/01
wing-dihedral Setting the Wing Dihedral Drawing dwg
12/20/02
12/02
strut fairing Installing the Wing Strut Fairing Option 1.0
1/02
6/03
CONSTRUCTION PHOTOS - Click here for directory listings

Additional useful resources:

These manuals contain copyrighted information and are presented for educational purposes only. THESE ONLINE MANUALS ARE NOT FOR CONSTRUCTION, DUPLICATION, OR DISTRIBUTION. 

Recommended reading...      Recommended Reading and building and piloting reference materials specifically for builders, from KitplanesBooks.com, including logbooks, EAA's "Amateur-Built Certification Kit" with decals, forms, and more...      "EAA Certification Kit"

 

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Mexico, Missouri, 65265-0650 USA.
Tel: 573-581-9000 (Mon - Fri, 8-5 Central),
Fax: 573-581-0011
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Zenith Aircraft Company: 2012-07-06