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My Airplane Project

Cozy IV - Nat Puffer's This section of stealthTURTLE.com contains the detailed build process, step by step as I go through the process of building an experimental aircraft in my garage. The build process is broken into chapters that cover major components of the build process and most of the time, these chapters have many major steps that are required to complete this section or part of the aircraft.

Before you think to yourself... "This can't be a real airplane. I mean one that you get in and fly around in and go places right?"

Yes it is. This is a real aircraft with four (4) seats and a sizable useful load that I intend to use quite frequently once it is complete.

Enjoy the site as I enjoy the build process.... and the flying.

  • Building my Own Airplane F.A.Q.   ( 8 Articles )

    PreviewThe answers commonly asked of a person building their own airplane to fly around in, take on vacation and just generally have fun. They're answered here.

     

  • The Building Blog   ( 67 Articles )

    IMG_1985.JPGThis is where you will find general ramblings about the build process. There isn't really any rhyme or reason to it.... just whatever happens to be on my mind. Sometimes about where to buy stuff that I need, sometimes where I have really cheesed something up (screwed up) and other times it's about what I think my wife thinks is going on. Sure that's alot of thinking... but if you're married, you know what I am talking about.

     

  • Getting the Aircraft Plans   ( 1 Articles )

    mishmash1_046.jpgCOMPLETE
    Getting ready to start building an airplane in your garage is a project in and of itself. This area show all the things that I had to do to get started... can you say... new deck, new hot-tub, new out-building....... you get the idea!

     

     

     

  • Cozy IV - Getting Ready to Build   ( 1 Articles )

    IMG_0083.JPGCOMPLETE
    Now that the things that were in the way of building are done, we can actually start building the Jig table, epoxy cabinet and other things that enable the build process.

     

  • Cozy IV - Chapter 3   ( 1 Articles )

    COMPLETE
    The educational chapter
    teaches you to be comfortable with all of the needed skills required to build this baby.

     

  • Cozy IV - Chapter 4   ( 6 Articles )

    Picture_018.jpgCOMPLETE
    Building the bulkheads -
    You start the build with some of the less "Flight Critical" sections of the aircraft. These are big, flat parts that help you get even more comfortable with the composite build process.

     

  • Cozy IV - Chapter 5   ( 1 Articles )

    IMG_1498.JPGCOMPLETE
    Building the fuselage sides -
    This is a really fun chapter! You get to start seeing this thing take shape. At the end of this and the next couple chapters you'll have a darn fancy "bathtub" that you can set in and make "Vrooom" sounds in.

     

  • Cozy IV - Chapter 6   ( 3 Articles )

    IMG_2065.JPGCOMPLETE
    The Fuselage Assembly -
    Here you get to assemble the fuselage sides with the bulkheads. You will also create a couple heat ducts and seat back keel and marry these into what you are doing at this point.

     

  • Cozy IV - Chapter 7   ( 5 Articles )

    IMG_3096.JPGCOMPLETE
    The Fuselage Exterior
    - Up to this point I have the sides done and married to the bulkheads. Here we create the bottom, shape the exterior and glass the outside of the fuselage. At the end I have a "Fancy Bathtub". Bring on the "VROOOOM" noises!!!

     

  • Cozy IV - Chapter 8   ( 7 Articles )

    IN PROGRESS
    Headrests, Seat belts, Headrests, Etc.
    - Back to making some of the smaller parts. This is a fun chapter with some detailed work to accomplish.

     

  • Cozy IV - Chapter 9   ( 6 Articles )

    IN PROGRESS
    Landing Gear, Axles, Brakes & Air Brake
    - This is a sort of mish-mash chapter that seems to scare many builders. You have to marry the landing gear strut with the fuselage. But to do this you have to create attach tabs and do some interesting layups.

     

  • Cozy IV - Chapter 10   ( 1 Articles )

    100_1227.JPGCOMPLETE
    The Canard
    - The canard is the front flying surface of this aircraft. This is the first "flying" surface that you build on the aircraft.

     

  • Cozy IV - Chapter 11   ( 1 Articles )

    100_1231.JPGCOMPLETE
    The Elevators
    - On a canard aircraft the elevators are in the front attached to the canard. This is a building block from the last chapter. You have to build the elevators and attach them to the canard.

     

  • Cozy IV - Chapter 13   ( 1 Articles )

    IN PROGRESS
    The Nose of the Aircraft, the nose-gear and the rudders/Brakes pedals.

    This section includes the buildout of the nose of the aircraft. Up to this point we have had a fancy, composite boat with a ton of holes in the front. After this we will have a streamlined boat with headlights, brakes, master cylinders and a variety of other components.

     

  • Cozy IV - Chapter 14   ( 1 Articles )

    100_5911.JPGIn Progress
    Centersection Spar
    - This is the chapter where you manufacture the centersection spar. The spar is the part of the aircraft where the wings attach to the body. It is one of the strongest parts of the aircraft.

     

  • Cozy IV - Chapter 18   ( 1 Articles )

    On Hold
    The Canopy / Turtleback
    - Finally the whole lid of the passenger compartment will be finished. When this section is complete, I'll be able to get in, shut the canopy and take a nap in my fully enclosed Cozy IV.

     

  • Cozy IV - Chapter 19   ( 1 Articles )

    Cozy Mark IV - Wings, Winglets and AileronsCompleted
    Wings and Ailerons -  In this chapter we finally begin to work on the wings of the aircraft. After we have completed this work we will have wings and ailerons but still need to build the winglets and rudders that are attached to the ends of the wings.

     

  • Cozy IV - Chapter 20   ( 1 Articles )

    Cozy IV Winglets and Rudders - Nate Wolfe's Cozy IV projectCompleted
    Winglets and Rudders - On the Cozy IV, we have a 'non-traditional' configuration and this places the rudders out on the ends of each wing on 'winglets'. We build these things here as a first step to creating the wings.

     

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