10 Day Wonder

Volunteers Build Complete Airplane in 10 days

August 22 - September 2, 1996

St. Paul, MN - Over 1.7 million people had a unique opportunity to be exposed recently to the simple and affordable pleasures of recreational aviation. Sponsored by the Minnesota DOT - Office of Aeronautics, a sleek 6-seat, all-composite floatplane was assembled by a small group of volunteers at the Minnesota State Fair. Known as the "Comp Air 6", and assembled from a "quick-build" kit manufactured by Aerocomp, Inc. of Merritt Island, FL, this airplane was used to introduce aviation to thousands of people who might otherwise never visit an airport.

A dedicated group of 5 to 10 volunteers (some with no previous aviation experience, and others from the local Experimental Aircraft Association Chapter) worked alongside four factory representatives during the 10-day State Fair, and successfully completed the assembly of the entire airplane while fair-goers observed and asked questions about flying. Steve Young, president of Aerocomp, Inc. said, "It took a lot of hard work, but it was all worthwhile as we listened to the comments of hundreds of visitors. Many of them told us that they had always thought flying is exclusively a 'rich man's' sport -- they were fascinated to learn that airplanes can be built, owned, and flown by average working-class people with no special talents or skills."

This was the first time in the history of the Minnesota State Fair that an airplane had been completely assembled by volunteer labor during the show. A set of pre-assembled floats were trucked in from Florida, ready to install on the completed airplane, but space limitations in the booth prevented their installation on the last day of the show. Instead, at the conclusion of the show, the finished airplane was sent to the factory in Florida, where it received a set of beautiful blue paint stripes, the floats were installed, and the airplane was registered, inspected, and test-flown.

Day 1

With a video camera rolling, the first task to be completed was setup of the work area. A tent and worktable were supplied by MN/DOT, with Aerocomp bringing the Comp Air 6 kit, tools, and miscellaneous supplies. Building a wooden floor, setting up the tent and equipment, and introducing the volunteers to the kit components occupied the first day.

Day 2

Starting with the Comp Air 6 "Quick-Build Kit" just the way it is delivered to customers, the volunteers successfully joined the two molded fuselage halves together, installed the header tank and glareshield, glassed in a few cabin reinforcements, and began preparing the wings for assembly.

Day 3

As a couple of the volunteers installed wiring for wingtip lighting and built the wing fuel tanks, several others installed seat reinforcements, spar pickup reinforcements, routed control cables in the wings, and began assembly of the ailerons and flaps. By the end of the third day, one wing was ready for the top skin to be installed.

Day 4

As the people began arriving in the morning for the Fair, the dedicated crew got busy assembling the tail components (elevators, horizontal stabilizers, rudder, etc.). Meanwhile, the wing leading edges were installed and the early evening hours were spent "closing" the first wing by completing the top wing skin installation.

Day 5

Work on the project was progressing well. Everyone was glad to see the horizontal stabilizers (built the day before) installed on the airplane. Straws were drawn to see who would be the unlucky person to crawl into the back of the airplane to install the rear fuselage bulkheads. The honor went to Aerocomp partner Ron Lueck, who argued (unsuccessfully) that it was a job for a skinny person. As he finished his task, the elevators were installed, the second wing was "closed up" with a top wing skin, and the wing drag spars were secured.

Day 6

Time to start thinking about an engine! The brand new 220 hp Franklin aircraft engine sitting in a box, ready for installation, provided the motivation needed to start working on installing engine mount reinforcements. As that was being done, floor reinforcements were finished, wing spar fittings were installed on the airframe, and the first aileron and flap assemblies were mounted on a wing.

Day 7

No airplane is complete without a set of shiny new wingtips, so two volunteers installed a set of Whelen nav lights/strobes and mounted molded fiberglass wingtips on both wings. Meanwhile, the firewall was completed, the engine mount was fitted to the engine, and ailerons/flaps were installed on the second wing.

Day 8

August 29 was a big day for the hardworking crew. Finally, the wings were hoisted overhead (everyone pitched in with THAT job) and mounted onto the airframe. The remainder of the day was devoted to attaching the engine to the airplane, installing the seats themselves (supports had been installed earlier), and starting work on the cowling installation. By evening, the brand new Comp Air 6 (six-seater) airplane was really taking shape. In only 8 days, the crew had created a machine that "looked" like an airplane.

Day 9

"Looking like an airplane" didn't satisfy this crew however. If it was going to be an airplane, it still needed to have engine fuel lines routed, throttle and carburetor heat cables installed, instruments, battery, and wiring completed, and of course -- a set of controls for the pilot. It took all day, but by evening the ailerons, elevators, and rudder were operational, and the instrument panel was wired (no radio yet).

Day 10

Just enough time to finish the project! Before the airplane could be "finished", the cowling installation had to be completed and a propeller needed to be installed. Everyone celebrated as the engine roared to life for its initial start-up. They'd done it! 10 days, working together as a team, a crew of volunteers (many with no similar experience) had successfully displayed their ability to assemble an entire airplane.

UPDATE

After sitting in Florida for several months, the airplane was painted with a custom paint scheme (designed by long-time Aerocomp employee Gordon Milliord "see Meet Gordon Milliord"), the set of "Super Floats" (also manufactured by Aerocomp) were installed, and the airplane was registered and inspected. On December 5, 1996, it made it's maiden flight with pilot Ron Lueck at the controls. He says, "The airplane flies fantastic! It gets off the water quickly, climbs great, and cruises comfortably at 120 mph. It's a super floatplane -- everyone did a really great job."

Built with Pride in the USA. God Bless America.

900 Airport Road. -- Merritt Island, FL 32952 USA .
Phone: (321) 452-7168, (321) 453-6641 -- Fax (321) 452-1880 -- Web: www.compairinc.com
Email: info@compairinc.com