Answers to Common Questions about the ZODIAC
If you have a question that's not covered below,
email us for a quick response. Continue checking this page, as
we'll be adding new common Q&A's as they're received.
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here for information about the Sport Pilot category
DESIGN
Why should I build an all-metal aircraft?
What engines besides the Rotax 912 can I use?
Can the ZODIAC be equipped for IFR?
Can the wings be removed?
What about cabin size and baggage area?
Is the ZODIAC suitable for aerobatics?
What kind of fuel tanks are available?
What about cabin ventilation?
KIT
How long will it really take me to build my ZODIAC?
What tools and skills will I need to build the ZODIAC?
What kind of workshop is required?
What's the most difficult part about building the ZODIAC kit?
What's NOT included in the kit?
Is the ZODIAC aircraft FAA-approved?
COST
How much does the kit cost?
If I build from scratch (plans-only), how much will it cost me?
What's the resale value of a ZODIAC?
Why should I build an all-metal aircraft?
- Metal construction is the most prevalent aircraft construction
material by all measures, used extensively from jetliners to light aircraft and homebuilts
over the past five decades. Metal construction is best described as "aluminum-alloy,
semi-monocoque, stressed skin construction."
All-metal construction has many inherent advantages that are unique to aluminum alloys:
- Metal construction is certainly proven, with vast existing
documentation on its properties.
- Low weight / high strength
- Corrosion resistance of new modern alloys
- Proven durability and resistance to sun and moisture
- Low cost and widespread availability
- Easy to work with: requires simple tools and skills
- No messy doping, mixing compounds, toxins, etc. in building an
all-metal aircraft
- Easy to inspect, due to "open" construction
- Simple to repair and maintain
While it's true that all-metal aircraft construction can be complex
and time-consuming (most are!), it's equally true that all-metal aircraft can be
quick and easy to build. The ZODIAC design takes the inherent advantages of metal
construction, while making it very simple and quick to build - using single curvature
sheet metal, modern 6061-T6 aluminum alloys, and Textron's Avex blind rivets, which are as
easy to set as 'pop' rivets.
In the kit, all parts and components that require special skills or tools are done at the
factory, so that a builder is really just 'assembling' an aircraft: lining up the parts,
drilling, and riveting. It's really that simple.
Virtually all aircraft use some sheet metal construction, whether an instrument panel on a
composite plane, or a firewall on a tube and fabric design, therefore all builders of all
aircraft types need basic sheet-metal tools and skills. With the ZODIAC, that's all the
tools and skills you'll need to build and complete the entire airframe. As such, the
ZODIAC kit is probably one of the easiest and quickest kit aircraft to build on the market
today. Once the aircraft is completed, an owner is assured of a long airframe life with
minimal maintenance:
- Suitability for continuous outdoor storage
- Easy to inspect thoroughly
- Easy maintenance & repair (you or any mechanic can do this).
Zenith Aircraft has extensive experience working exclusively with all-metal construction, and has developed and
perfected a construction technique that not only provides strong and efficient designs,
but that makes them quick and easy to build, while maintaining all the advantages of an
all-metal aircraft.
- SEE ALSO: All-Metal Construction Made Easy
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What engines, besides the Rotax 912, can I use?
- The ZODIAC is one of the few kit planes not designed 'around' an
engine, making it suitable for different engine installations. In fact, the first ZODIAC
prototype first flew with a VW conversion back in 1984.
We provide the Rotax 912
/ 912S engine because we believe it is currently the best powerplant
choice for this particular design, providing good power to weight (ratio), reliability,
and performance. Rotax engines are also readily available around the world, and parts and
servicing is also readily available. The Rotax powerplant packages we supply are provided
as full "firewall-forward" packages that are ready to install, making engine
installation quick and easy.
However, this does not limit the builders' choice to Rotax engines only. We now also
supply a firewall-forward package for the EA-81 Subaru conversion
from Stratus Inc. The ZODIAC airframe is designed to accommodate powerplants ranging
from 65 to 115 HP, with a max. installed weight of 265 lbs. Other engines that have or are
being customer installed include:
- Continental (C65 to O-200)
- Subaru EA-81 conversions (supplied by Stratus, Formula Power, and others)
- Volkswagen (VW) conversion
- Jabiru 3300
...and more.
The new ZODIAC XL is designed to accommodate
slightly larger engines than the previous ZODIAC models.
Recommended power for the ZODIAC XL is 100 to 125 hp, up to 300 lbs.
installed weight, including the Lycoming
O-235 (116-hp) engine.
Our specification and performance figures are based on the Rotax 912 installation. Other
engines affect these performance and spec figures.
Quite often, more power does not necessarily equate to better performance: important
considerations include weight (power to weight ratio), fuel consumption, torque, etc.
An engine is only as good as its installation in a particular aircraft, and a proper
installation requires significant testing and time. First-time builders are urged to
install proven firewall-forward packages - minimizing time and headaches.
ZODIAC builders don't need to decide ahead of time what engine to install when they start
the kit. Most builders buy their engine later when ready for installation.
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Can the ZODIAC be equipped for IFR?
- Yes, the ZODIAC can be equipped for IFR (instrument flight), and in
fact many builders have installed custom IFR panels. However, light aircraft like the
ZODIAC don't make ideal IFR platforms, and the cost of IFR avionics can add a lot to the
cost of the aircraft. Most ZODIAC builders equip their aircraft for VFR only, and install
custom avionics as needed. A hand-held COM radio and hand-held GPS are often the only
avionics used, keeping the price affordable and installation simple.
See the Photo Gallery for sample panels.
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Can the wings be removed?
- YES, the wings are easy to remove for storage or towing. The wings
are detachable at the fuselage center section (where the wing dihedral starts). Two screws
remove a sheet-metal cover, which gives access to the spars. Four main spar bolts, one
rear spar channel bolt, and an aileron bolt hold each wing in place. Once the wings are
removed, the fuselage sits on the aircraft's gear, making it easy to store or trailer.
[ZODIAC XL: The new ZODIAC XL model does not have a center
wing section, but the wing are equally easy to remove].
Trailering an aircraft on a regular basis is not very practical for most,
regardless of how easy the wings are to fold or remove. One of the main advantages to
owning your own aircraft is the freedom to fly when you want to. Having to first
trailer and attach wings uses up time that you would otherwise use flying.
With its all-metal airframe, many owners keep their aircraft tied-down outdoors, saving
the cost of hangering the aircraft. Thanks to its rugged gear, many owners operate
out of private grass strips, where tie-down fees are usually very affordable.
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What about cabin size and baggage area?
- The ZODIAC cabin and baggage areas provide plently of space,
especially when compared to other light aircraft in its size class. See ZODIAC CABIN for complete details on the cabin and
baggage areas.
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Can I fly aerobatics with the ZODIAC?
- The ZODIAC is not designed as an aerobatic airplane - it's designed
more for stability than for aerobatic maneuverability. However, the design is stressed a
full +/- 6 g's and the controls are quite responsive. Of course, any aerobatics require
proper training and equipment.
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What kind of fuel tanks are available?
- The ZODIAC has a standard 16 US gallon header tank, located between
the firewall and instrument panel. Wing tanks (2 x 7.5 gal.) are also available for the
wing baggage lockers, to supplement the header tank.
A smaller header tank is also available (8 gal), providing increased depth behind the
panel for avionics. Also, wing tanks only may be installed, instead of the header
tank, using new wing leading edge fuel tanks. CG
considerations (i.e. weight of engine) may affect the choice of fuel systems.
- The new ZODIAC
XL uses dual wing leading edge tanks (12 US gallons each) as the
standard fuel system.
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What about cabin ventilation and heat?
- The ZODIAC features a tinted bubble canopy to provide outstanding
unobstructed 360-degree visibility. While it can get hot on the inside (on the ground with
the prop stopped), a standard fresh air vent (through the firewall) provides a steady
stream of fresh air into the cabin as soon as the prop is spinning. For cold weather
operation, a muffler heat shroud provides cabin heat via the fresh air vent. Additional
ventilation can be added with "naca" vents on the cabin sides or fresh air
scoops in the canopy.
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How long will it really take me to build my
ZODIAC?
- Only you can really answer that question, as we can't tell you how
well you work, how experienced and skilled you are, or what your work habits are. However,
average build times for the airframe and standard Rotax engine installation average about
one year, or about 400 hours. This figure (400 hours) is the actual building time, and not
the time you may spend cleaning your workshop, polishing parts, or 'thinking' about
working.
If you can spend a few hours every few evenings and maybe a full day on the weekend, the
project shouldn't take longer than a year to complete. Working on the project consistently
will help you make progress quickly. Any custom modifications, such as a custom engine
installation, always seems to add quite a bit of time.
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What tools and skills will I need to build the
ZODIAC?
- If you're building from the kit, only very basic tools and skills are
required. With the kit, all parts or components that require special skills or tools are
done for you at the factory. You'll need an electric hand drill, a hand 'pop'-type rivet
puller, Clecos temporary fasteners, a tape measure, sheet-metal snips, files, wrenches,
and not much else.
The airframe kit takes straight-forward and basic assembly work to put together using only
simple tools.
Importantly, virtually no jigs and fixtures are needed in the building process, as all
sections are built up from the flat workbench. A bending brake, shear pneumatic rivet
hammer or other machinery is not needed, and assembly is easily done in a single car
garage or basement workshop.
While previous aircraft building experience and sheet-metal skills are always an asset,
the ZODIAC kit and assembly instructions have been developed specifically for the
inexperienced novice builder. In fact, an overwhelming number of ZODIAC builders are
building their very first aircraft. The simplicity of construction, quality of parts and
components, and the completeness of the kit translates into low build-times and a very
high kit completion ratio, even for novice builders.
- SEE ALSO: Required Tools and Workshop
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What kind of workshop is required?
- Only a level work table is required (about 10' x 4'). Most builders
put all the sections together in a single car garage or basement workshop. The assembly
process is 'modular' - each section is built individually, meaning that a large work area
is really not required until the very end, when the wings and tail sections are attached
to the fuselage center section.
The ZODIAC builder can start assembly right away after taking delivery of the kit. Working
from a flat table, the builder can immediately begin to build the wings - simply by
measuring, drilling and riveting, and thus progress through the whole airframe section by
section, aided by the detailed blue prints, step-by-step manual and visual photo guides
supplied with the kit. Building the all-metal ZODIAC is straight forward, requiring no
complex jigs, and no messy (and hazardous) doping or epoxy work is involved. With the
proven and simple all-metal construction technique, the ZODIAC builder does not have to
worry about having a temperature controlled dust-free workshop environment, and does not
have to mix compounds and wait for parts to cure.
- SEE ALSO: Required Tools and Workshop
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What's the most difficult part about
building the ZODIAC kit?
- You'll find it most difficult getting started on the project.
While you won't need special skills or tools, knowing how and where to start is probably
the biggest challenge you'll face with a kit project, and you'll likely be overwhelmed by
the scope of the project at first.
However, once you've drilled that first hole and realized that you're only working on a
small section of the aircraft, you'll find that everything is starting to come together -
literally.
The following is an actual quote from a first-time ZODIAC builder who had a hard time
getting started:
"Finally got past the jitters and have started construction. What a great
project!!!"
To help bypass initial "getting started" difficulty, we recommend that
first-time builders attend a factory workshop - where they'll gain hands-on building
experience, and pick up a lot of building tips and hints. If you can't attend a
workshop, expect to have difficulty getting started with the project. However, don't
despair - the above quote is very typical.
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What's NOT included in the kit?
- The ZODIAC kit is complete: landing gear, wheels, hydraulic brake
system, fiberglass wing tips, control systems, welded aluminum fuel tank, etc., are
standard equipment in the complete airframe kit. Every part, component and sub-assembly is
made only from quality materials, passed through a strict quality control program before
being shipped to the customer. With the addition of the 'firewall-forward' Rotax
powerplant and instruments package, the builder gets everything needed to build and fly
the ZODIAC aircraft.
Items not included in the kit are the exterior paint, cabin upholstery, and battery.
In the kit, all the wing ribs and fuselage bulkheads are supplied pre-formed. For example,
the internal wing ribs are first press-formed, with lightening holes cut and flanged, and
then hand finished at the factory for a perfect ready-to-install fit. The heavy-duty wing
spar comes complete with all solid (bucked) rivets already set by factory professionals.
Even the spar's wing dihedral has been set to minimize the builder's need for jig
fixtures. Surface skins - wings, ailerons, elevator, rudder, and fuselage - are ready for
fitting, and many flat skins are supplied pre-drilled to minimize construction time.
Pre-assembled parts (such as the wing spar) are factory-treated with zinc-chromate primer
for maximum corrosion resistance. Welded parts, such as the engine mount, control
assemblies, and fuel tank, come factory welded and ready to install.
- SEE ALSO: Kit
Features and Equipment List
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Is the ZODIAC aircraft FAA-approved?
- No. Kit aircraft are registered as "experimental" aircraft,
and as such are not FAA 'approved' or certified.
The ZODIAC kit meets the requirements for amateur-built (experimental) categories in the
United States and Canada, as well as in most countries around the world. In the United
States, the FAA (Federal Aviation Administration) has inspected and determined that the
ZODIAC kits meet FAR section 21.191(g) known as the '51% rule,' making it eligible for
amateur-built registration.
In many countries, the ZODIAC CH 601 UL is an approved "advanced ultralight" or
has been certified to as a "primary" category aircraft. Rules vary by
country: Check with your local civil aviation authority and/or amateur-builder
organization.
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How much does the kit cost?
- The actual kit price varies depending on which model you build. The
kit includes everything for the airframe, but does not include powerplant (firewall
forward) and instruments. See the Price Information for current
price details. Of course, you can "finance" the kit price by buying the
component kits as you build. The ZODIAC "Starter Kit" costs just $375 for the
rudder tail kit - this is an introductory kit to introduce you to the assembly and
building technique for the ZODIAC while actually starting to build.
- Click here
for ZODIAC XL pricing information.
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How much will it cost me by the time my ZODIAC
is completed and ready to fly?
- This varies a lot with the installed powerplant and instruments /
avionics. The 'standard' ZODIAC CH 601 HD (with a factory-new Rotax 912 and basic
instruments) will cost about $25,000, plus a paint job and basic upholstery. Other engines
will change this price, of course. Most Zodiacs flying today have between $20,000 and
$30,000 invested in them. (Not bad for a brand-new all-metal aircraft!).
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If I build from scratch (plans-only), how much
will it cost me?
- If you have more time than money available, scratch building is an
attractive alternative to purchasing the kit. The cost depends primarily on the tools and
skills you have. If you have access to a bending brake and 8-ft shear, and have the skills
to make forming blocks, buck-riveting, and welding (aluminum and 4140 steel tube), you
won't have any difficulty scratch-building. Typically, the cost of materials is about 40%
to 50% of the airframe kit (though this varies greatly on your source for raw materials).
If you don't have the tools and/or skills, it may cost you significantly more if you have
to buy the tooling or get some of your parts custom made locally.
If you decide to scratch build, any individual part, component or section kit can be
purchased separately from the factory, such as the wing spars, fiberglass fairings,
rivets, etc.
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What's the resale value of a ZODIAC?
- Resale value of kit (experimental) aircraft varies on a number of
different factors. It is thus difficult, if not impossible, to forecast resale value for a
particular kit aircraft.
However, a number of factors strongly influence resale value of a kit aircraft:
- Reputation And Popularity Of Design;
- Operation / Service History;
- Aircraft Type: Utility, Ease Of Flying, Configuration, etc.;
- Workmanship And Aircraft Finish By Builder;
- Operating Costs & Maintenance Requirements;
- Market Conditions: Number Of Aircraft On The Market, Resale History.
Historically, Zenith Aircraft designs have maintained excellent resale values. This can be
attributed to:
Excellent Reputation / Service History Of Aircraft;
Durability - All-Metal Construction (used aircraft are often in 'like-new' condition);
Ease Of Inspection - Metal Construction Can Easily Be Inspected By Any Mechanic For
Structural Integrity / Workmanship (vs. composites);
Low Operating Costs / Efficiency;
Ease Of Flying / Good Characteristics / Capabilities;
Market Demand - Very Few Used Ones Available;
Availability of Manufacturer / Designer Support and Spare Parts;
High Level Of Owner Satisfaction.
- Used Zodiacs are hard to come by on the used market - their owners
usually keep them for many years. Often, when one is sold, it's sold privately to a friend
or locally - without being advertised. Used values vary from the cost of the kit and
engine / equipment (low end) to premiums $5,000(or easily more) above the actual cost. If
buying a used completed kit, it is your responsibility to make sure that the aircraft was
constructed and maintained well by the original builder. Have the aircraft thoroughly
inspected by a licensed mechanic, and make sure you get a proper check-out in the type
before your first flight. As a builder, it's thus important to keep a detailed
construction log and accurate maintenance records.
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SEE ALSO:
If you have a question that's not covered here,
click here to email us for a quick response.
Note: The answers provided above are
opinions only, and may not represent the opinion of the designer of the
aircraft.
Prices, availability and equipment are subject to change without
notice. |
