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Plans-Built 4 seat Canard Aircraft SHAREWARE AGREEMENT This electronic document is one of the documents, which together constitute the instructions to build an AeroCanard Aircraft. You are free to copy and distribute this document provided that you do not charge a fee for its distribution, you do not modify it in any way, and you include this shareware agreement with the distributed copy. You may download a complete set of documents representing all the chapters of the AeroCanard plans from http://aerocad2.com. If you received this document from another source it is advisable to check this web site for updates before commencing work on the project. The chapter documents contain all the instructions required to build either an AeroCanard or AeroCanard SB including a complete bill of materials, training in the methods and techniques needed, and detailed step-by-step descriptions of each stage of the construction. Reading these documents will give you a very good idea of the complexity and size of the project you are getting into. If you decide to proceed and build one of these beautiful high-speed 4 seat aircraft you will need the hardcopy drawings and templates, which are NOT shareware. The drawings and templates showing the exact dimensions and precise curves for the various parts may be purchased from http://aerocad2.com A common statement made by those who have completed and are now flying their own canard plans-built airplane is: “The only thing I regret is not starting sooner” What is an AeroCanard? The AeroCanard is a 4 seat canard type aircraft with a Lycoming LIO360 engine. It has a 1000-mile range and typically cruises at over 200 mph on less than 10 gallons per hour. The AeroCanard SB has a smaller body width at the rear seats. The plans include instructions for building either aircraft. There are literally thousands of canard aircraft similar to the AeroCanard flying all over world, and thousands more under construction. You can meet some of the people flying and building canards at http://canardaviationforum.dmt.net/ or at the many fly-in meetings held around the world. This highly efficient, fast, composite airplane can be built by one person in a garage or small workshop in as little as 18 months. All the training needed to master the techniques required is included in the instructions. What Does It Cost? The plans are free. You need the hard copy drawings and templates from http://aerocad2.com which, at the time of writing, are $199. This fee may change. While it is possible to save money with bulk purchases and some used parts, the costs to build are typically: Airframe: $15,000 Engine: $15,000 Avionics: $15,000 TOTAL: $45,000 Costs can be spread over the building period purchasing materials and parts to suit your own cash flow. Many builders construct canard airplanes in evenings and weekends over four or five years purchasing the inexpensive foam, fiberglass and epoxy materials as needed. Spread over five years the cost to own an AeroCanard can be as little as $750/month plus your labor. As the basic materials begin to take the form of an airplane, and confidence of success grows, additional funds are invested to obtain an engine and instruments. Where Can I Get Support? There is a free forum for the Canard Community at http://canardaviationforum.dmt.net/ which covers many of the questions and concerns of canard aircraft builders. A section of this forum is dedicated to discussions between AeroCanard builders. The designer of the AeroCanard, Jeff Russell, visits this forum regularly and will answer your building questions whenever possible. Direct one-on-one support may be purchased from http://aerocad2.com Where Do I Get the Materials? A complete bill of materials is included with the plans. A list of recommended suppliers can be found at http://AeroCad2.com. Can I get a Formal License to Build an AeroCanard? Absolutely. You will receive an official license to build and your unique serial number when you purchase the drawings and templates. You are not authorized to build an AeroCanard without obtaining a license. These shareware files are offered simply to let you discover what is involved in the project before you invest in it. Can I get a printed copy of the plans? Yes. Printed copies are available from HTTP://Aerocad2.com. You can also obtain a CD containing all the documents which constitute the AeroCanard and AeroCanard SB plans.

Can I Really Do This? You bet you’re assumptions you can. Canard builders include carpenters, dentists, astronauts, nurses and even lawyers. You don ’t have to be a rocket scientist, but we do have one in case you need his advice. No special skills are required other than an unstoppable dete rmination to learn and complete the project. The reaction of most builders is that building an airplane isn’t as complex as they thought it would be. It is, in fact, a fun, extremely satisfying and life changing experience. For many, a most rewarding aspect of the experience is the new friends gained as a member of the canard community. Disclaimer of Warranty THESE PLANS ARE SUPPLIED “AS IS” AND WITHOUT WARRANTIES AS TO PERFORMANCE OF MERCHANTABILITY OR ANY OTHER WARRANTIES WHETHER EXPRESSED OR IMPLIED. Because of the various capabilities of different builders, NO WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS OFFERED. The user assumes the entire risk of using these plans.

Chapter 4 Page 1 AeroCanard plans version 1.0 Copyright (C) 2000 All Rights Reserved

8 in. and trim the seatback (Fig. Save the scraps. low-density. Cut a rectangular piece of 0. Repeat for both edges. and squeegee it over the side to be glassed. Now flip the seat back front down. angled so they will be horizontal when seatback is installed.75 in. 45 deg. Cut holes where shown (Fig. Now cut the templates (better yet. then the instrument panel. In addition.2 in. and glass with one layer of BID with fibers at 45 deg. sides and bottom edges of the foam. and the firewall is made from 0. 2). so you may wish to work on several bulkheads simultaneously to maximize your progress. STEP 1. and make flox corners everywhere the glass surfaces will meet Squeegee micro over the remaining bare foam. Because it is inclined at approx. You may have to glue 2 pieces together with 5-min. remove the excess. and the holes passing through the bulkhead. From fore to aft in order. After partial cure. 3). and prop the seatback up so glass edges can hang down unobstructed. Align the templates with the top. Don’t leave any excess! Now cut 2 plies of UND and glass over the front side and tapered end (the side you just microed. 5). PVC foam 28. these are F-22 and F-28 (named for their fuselage stations). knife trim flush with the foam edges all around and let cure. 1). There are many short jobs in this chapter with cure times in between.25 in. and lastly. thick. then the forward and aft landing gear bulkheads.75 in. The front seatback is made from 0. thick. tan. trace.25 in. Now taper and round one edge as shown (Fig. thick fir plywood. which mount the canard. thick birch plywood. Scissor trim excess glass. Chapter 4 Page 2 AeroCanard plans version 1. I hope!) (Fig. stiff enough so it just flows. both the top and the bottom edges are angled. thick.CHAPTER 4 OVERVIEW FUSELAGE BULKHEADS In this chapter you will manufacture the seven bulkheads which are installed in your AeroCanard fuselage. Peel ply around edges and trim after cure. blue. F-22. 6). Round the corners to be glassed around. you will need to make a temporary firewall for assembly purposes from 0. (Fig. you can use them later. white. F-28.0 Copyright (C) 2000 All Rights Reserved . 4). the firewall. Approximately 25 hours are required for the bulkheads. epoxy if necessary. medium density PVC foam.25 in.. then the front seatback. x 42 in. high density Last-A-foam. low-density PVC foam. as well as the notches for the longerons. and cut at this angle. Note that the map pocket hole should be cut undersize and trimmed to size after the pocket is installed in Chapter 6. The landing gear bulkheads are made from 0. Mix up some micro. blue. Visualize how the bulkhead will be inclined at 45 deg. and the instrument panel are made from 0. which define how to trim the corners of the seatback for a snug fit to the fuselage sides. FRONT SEATBACK Refer to Chapter 6 to see how the seatback fits in the fuselage. trace them) from large drawings A-1 and A-2. and taper the bottom edge (Fig..

Squeegee micro overall. After part cure. trim or add foam as required. 12). F-22 gets 2 plies BID overall. onto the previously glassed area (Fig. and shape checked against the drawings. knife trim. Chapter 4 Page 3 AeroCanard plans version 1. so cut out pieces and glue together with 5-min. Now. or saw trim after full cure. white. bumps removed. It is suggested you trace these rather than cut them up. These are made from 0. 9). fiber orientation over both F-22 and F-28. FORWARD BULKHEADS Full size patterns for F-22 and F-28 are shown on large drawing M-4. press the doubler in place. one UND horizontal above the leg holes. flip the instrument panel over. Then lay up 1 horizontal ply of UND on F-28 (Fig. 7). After cure. Use peel ply and wax paper so the weights won’t bond to your layups. micro. and glass with 2 plies of BID at 45 deg. and then extra local buildups of 5 UND and 4 BID as shown (Fig. and glass the forward faces. and then 1 ply of UND horizontally above the leg cutouts (same as the aft face). You can do those later. and 1 layer UND horizontally. Peel ply for a smooth finish after cure. After cure. 8). Tracing is easy if you backlight them by taping them to a window. Cut all hole except instrument and avionics holes you are uncertain about. The instrument panel is also made from 0. INSTRUMENT PANEL Full size patterns for the instrument panel are shown on large drawings M-1. thick white. epoxy as indicated by the dashed lines (Fig. While F-22 is still wet. Weight the bulkheads down flat for cure. and one ply of UND horizontally.2 in. remove the excess. and weight down if necessary for a flat cure. squeegee micro on the aft faces of the bulkheads. and M-3. check the bulkheads against the drawings to make sure the shape agrees. and layup 2 plies of BID at 45 deg. After the pieces are glued together. high-density Last-a-foam. After part cure. same as the aft face (Fig. fiber orientation overall. It is suggested that you do not cut out the instrument and avionics holes until after you have decided what you will be installing and actually have them in hand. thick. flip the bulkheads over. micro the aft face of the doubler.0 Copyright (C) 2000 All Rights Reserved . 8). The sheets are not large enough to cut out F-22 in one piece. M-2. prepare the aft face for glassing. 11. STEP 3. remove any bumps of epoxy.2 in. micro. and glass the forward face with 2 plies of BID at 45 deg. F-28 gets 2 layers BID at 45 deg. The thicker buildups can be trimmed after cure with a sabre saw or hack saw blade. fiber orientation overall. If not. and lay up 2 plies of BID at 45 deg. lapping 1 in. and before proceeding. 10). knife trim where possible. high-density Last-afoam and will also have to be pieced together as shown in Fig.STEP 2. Now. and then 1 ply of UND horizontally above the leg cutouts (Fig.

holes. holes through the hardpoints as shown on drawing A-5. You will need to make this material from 22 layers of BID and allow it to cure before cutting the hardpoints to shape.0 Copyright (C) 2000 All Rights Reserved . Tape a piece of saran wrap over the rectangle. drill 3/16 in. medium density PVC foam. After cure. They will be drilled after fuselage assembly in Chapter 6. Fuselage Assembly. and cut them out with your sabre saw. It is suggested that you trace these rather than cut them up. After the aft face has cured and trimmed. Again. inserts shown A-7 before glassing. it is suggested that you trace them. squeegeeing all air out as you go (Fig. Then cut out the 4 piece permanent firewall from the 0. vacuum the foam. thick fir plywood (Fig. and then 5-min. Do not cut the holes for the longerons until later.25 in. In the meantime. You may learn from the temporary firewall that the holes may have to be adjusted slightly. The forward f3ce gets 2 plies of BID at 45 deg. You have accomplished a lot in this chapter. overall.25 in. The aft bulkhead should be prepared in a similar way for glassing. make the same layups on the aft face (2 BID and 1 UND). LANDING GEAR BULKHEADS Full size patterns for the landing gear bulkheads are shown on large drawings A-5 and A-6. tan. 14). STEP 4. 13). FIREWALL Full size patterns for the firewall are shown on large drawings A-7.2 in. Trace the location of these screws on the respective firewall parts. and mark a rectangle 8 in. 2 plies UND horizontally. do not drill the 0. Glass per detail. orientation. flip them over. Save the plywood scraps. and countersink the forward face (not glassed yet). The permanent firewall is made up of 4 pieces. and then cut 22 pieces of BID cloth at a 45 deg. The aft bulkhead is made in one piece. Now glass the forward face of all the parts. flat area of your worktable. and 5-min epoxy the hard points in place. sand the forward face locally with 36 grit to remove the shine. and then 3 plies of UND at an angle from vertical as shown.25 in. one at a time. Remove any bumps after installing the hard points. Tape a newspaper over a smooth. Both bulkheads are made from 0. The forward bulkhead (2 pieces) gets 2 plies of BID at 45 deg. Make sure they are weighted flat for cure.13-and large drawing A-1). thick birch plywood included in your materials kit (Fig. and that the two pieces of firewall aft of the centersection spar each have 3 blind MS24694-S54 screws installed. grind a flat on each of the 14 screws (so they won’t turn) and install them in the holes with flox. holes shown on the drawing. with a felt tipped pen. it is desirable to use a temporary firewall. epoxy the 0. Glass the aft side of the permanent firewall pieces with 1 ply of BID at 45 deg. The forward bulkhead is made in two pieces which are not joined together until Chapter 6. Cut out and install four 1” x 2” x ¼” Alum. and then micro the forward surfaces. After cure. Now. and one ply of UND horizontally on the front face and. overall. Now proceed to wet out the 22 layers. you can make many excellent sabre saw blades from one broken band saw blade. and are now ready to start Chapter 5. Now. Then cover with a piece of saran wrap. x 12 in. and then 8 plies of UND at an angle from vertical as shown. trace the hard points on the layup. and weight down a flat board on top and allow to cure. The additional UND layups shown on the drawing are installed later.25 in. trace the fiberglass hard points on the foam bulkheads. Incidentally. After cure.25 in. The ribs also serve as channels for electrical wires. trim.25 in. strips of foam where and as shown Fig. all in one piece for assembly operations. cut out the foam with a razor blade. thick solid fiberglass. Chapter 4 Page 4 AeroCanard plans version 1. Fuselage Sides. sand away the shine on the hardpoints (36 grit) and any roughness on the foam (120 grit). 16). in Chapter 6. 2 plies of UND horizontally.For added stiffness. fiber orientation. drill the 0. After cure. You will note that both bulkheads have hard points for the landing gear attach of 0. 15). Note that the bottom piece has 4 blind MS24694-S54 screws installed both left and right. STEP 5. and support on blocks if the flox has not yet cured. The aft face of the aft bulkhead gets 2 plies of BID at 45 deg. Make a one-piece temporary firewall from 0. after cure. First. x 1 in. you will need them later. two horizontal and two vertical ribs are added to the forward face of the instrument panel (Fig. which are installed separately in subsequent chapters.

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