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Cozy MK IV

The process of building an Experimental Airplane

  • About Cozy MK IV (and me)
  • Specifications
  • Useful links
  • Project Pages
    • Chapter 3 – Education / Composite Techniques
    • Chapter 4 – Fuselage bulkheads
    • Chapter 5 – Fuselage sides
      • Step 1. Cutting the jigs and laminating the top longerons
      • Step 2. Building the forms for the fuselage sides and preparing the sides for contouring
      • Step 3. Contouring the insides
      • Step 4. Inside layup and installing the upper longerons
      • Step 5. Installation of lower triangular longerons
      • Step 6. Completion of the fuselage sides
    • Chapter 6 – Fuselage assembly
      • Step 1. Assembly of the fuselage sides
      • Step 2. Center keel and seatback brace
      • Step 3. Contouring and installing the fuselage bottom
    • Chapter 7 – Fuselage exterior
      • Step 1. Building the NACA-scoop
      • Step 2. Contouring the bottom
      • Step 3. Glassing the bottom
      • Step 4. Contouring the sides
      • Step 5. Glassing the sides
    • Chapter 8 – Head rests, heat duct, seat belts and step
      • Step 1. Carving the foam pieces
      • Step 2. Glassing the inside surface for wet layup
      • Step 3. Glassing the outside of the shoulder support
      • Step 4. Glassing & Installing the headrests
      • Step 5. Installing shoulder harness attachments
      • Step 6. Installing the outside seatbelt attachments & external step
      • Step 7. Center seat belt attach
    • Chapter 9 – Main landing gear and landing brake
      • Step 1 – Landing gear bulkhead reinforcements
      • Step 2 – Preparing the strut for installation
      • Step 3 – Attach-tabs and installation
      • Step 4 – Landing gear cover
      • Step 5 – Installing axles, brakes and brakelines
      • Step 6 – Constructing the landing brake
    • Chapter 10 – The Canard
      • Step 1: Trimming the foam-blocks and cutting the cores
      • Step 2: Making lift tabs, Inserts, Jigging cores, Laying up the shear web and installing lift tabs
      • Step 3: Jigging and bonding the canard sections together
      • Step 4: Spar Cap Layup
      • Step 5: Applying the bottom skin
      • Step 6: Installing hard foam blocks for elevator hinges, the upper spar cap, and the upper skin
    • Chapter 11 – Elevators
      • Step 1: Cutting foam cores and bonding to the torque tubes
      • Step 2: Installation of the bottom skin
      • Step 3: Installation of the top-skin
      • Step 4: Installing the NC-6 inserts and the NC-3 hinges in the canard
      • Step 5: Checking elevator travel and installing tip fairings
      • Step 6: Installing the pitch trim belcrank and the elevator mass balance weights
    • Chapter 12 – Canard Installation
      • Step 1: Fitting the alignment pins
      • Step 2: Aligning the canard
      • Step 3: Fitting elevators & torque tube to fuselage
    • Chapter 13 – Nose, Nose Gear, Pitot, Rudder Pedals and Brake Master Cylinders
      • Step 1: Reinforcing the Fiberglass Nosewheel Strut
      • Step 2: Fabrication of the NG-30s
      • Step 3: Installing the Jack Wilhelmson Electric Nosewheel Assembly
      • Step 4: Installation of the NG-30 Box Assembly on the Fuselage
      • Step 5: Nose Floor and Sides
      • Step 6: Installing the Rudder Pedals
      • Step 7: Installing the Master Brake Cylinders
      • Step 8: Completion of the Nosegear
      • Step 9: Piping the Pitot & Static System
      • Step 10: Closing the Top and Carving & Glassing the Outside
      • Step 11: Nose Door
      • Step 12: Skid plate
    • Chapter 14 – Central Section Spar
      • Step 1 – Centersection Jig
      • Step 2 – Assembly of foam parts
      • Step 3 – Interior Layups
      • Step 4 – Install the forward face
      • Step 5 – Outside hard points
      • Step 6 – Spar Cap Layup
      • Step 7 – Shoulder Harness Blocks and Outside Layups
      • Step 8 – Hardpoint Reinforcement
      • Step 9 – Access For Wing Attach And End Layup
    • Chapter 16 – Control System
    • Chapter 19 – Wings and Ailerons
      • Step 1: Building the wing jigs (and wing templates)
      • Step 2: Setting up the jigs
      • Step 3: Cutting foam cores
      • Step 4: Assembly of foam cores and lay up of shear web
      • Step 5: Bottom spar cap
      • Step 6. Bottom skin
      • Step 7. Top spar cap
      • Step 8. Top skin
      • Step 9. Wing ribs
      • Step 10. Ailerons
      • Step 11. Controls
      • Step 12: Attachment, wing to center section spar
    • Chapter 20 – Winglets and Rudders
      • Step 1: Cutting the cores
      • Step 2: Glassing the skins
      • Step 3: Jigging upper winglet to wing
      • Step 4: Inside layups (Right wing)
      • Step 4: Inside layups (Left wing)
      • Step 5: Outside layers (Right wing)
      • Step 5: Outside layers (Left wing)
      • Step 6: Lower Winglet Attach (Right wing)
      • Step 6: Lower Winglet Attach (Left Wing)
      • Step 7: Rudder (Right wing)
      • Step 7: Rudder (Left wing)
  • PPL-A
    • PPL-A Teori
    • PPL-A – Blokk A
    • PPL-A – Blokk B
    • PPL-A – Blokk C
    • PPL-A – Blokk D
    • PPL-A – Mørkeutsjekk
    • PPL-A – Utgått sertifikat!
    • PPL-A – Radiobruk
    • PPL-A – Simulatortrening
    • PPL-A – Pooleys CRP-1
Cozy MK IV

Ch.3 Education / Composite Techniques

Antolovich, Bruce
Baker, Chad
Balderston, Dan
Barnes, Dave-n-Lynn
Basol, John
Bennett, Andrew
Berenholtz, Dave
Blevins, Jason
Cozy Girrrls
DeFord, Brian
Dembs, Jon
Dillion, Daniel
Dove, Kevin
Fennell, Aaron
Fish, Scott
Furnweger, Charles
Hall, Rick
Irwin, Rick
Khu, Remi
Kissick, David
Maddy, Rick
Moen, Erlend
Rippeto, George
Satchell, Mike
Schilder, David
Silvester, Phil
Siu, Bernard
Speers, d’Armond
Walters, Douglas
Wilhelm, Chad

Project status:

The project has currently  been paused.

If someone is interested in purchasing the project, please contact me.

March 20, 2021:

Working on Chapter 16 – Control System

Last update: Step 4: Installation of Pitch and Roll Assembly

Accumulated hours so far: 1040 (since April, 2009)

Recent Comments

  • ErlendM on Useful links
  • David Schilder on Useful links
  • James Boswell on Useful links
  • Izzy on Canard Calendar 2020
  • ErlendM on Canard Calendar 2020

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  • About Cozy MK IV (and me)
  • Specifications
  • Useful links
  • Project Pages
    • Chapter 3 – Education / Composite Techniques
    • Chapter 4 – Fuselage bulkheads
    • Chapter 5 – Fuselage sides
      • Step 1. Cutting the jigs and laminating the top longerons
      • Step 2. Building the forms for the fuselage sides and preparing the sides for contouring
      • Step 3. Contouring the insides
      • Step 4. Inside layup and installing the upper longerons
      • Step 5. Installation of lower triangular longerons
      • Step 6. Completion of the fuselage sides
    • Chapter 6 – Fuselage assembly
      • Step 1. Assembly of the fuselage sides
      • Step 2. Center keel and seatback brace
      • Step 3. Contouring and installing the fuselage bottom
    • Chapter 7 – Fuselage exterior
      • Step 1. Building the NACA-scoop
      • Step 2. Contouring the bottom
      • Step 3. Glassing the bottom
      • Step 4. Contouring the sides
      • Step 5. Glassing the sides
    • Chapter 8 – Head rests, heat duct, seat belts and step
      • Step 1. Carving the foam pieces
      • Step 2. Glassing the inside surface for wet layup
      • Step 3. Glassing the outside of the shoulder support
      • Step 4. Glassing & Installing the headrests
      • Step 5. Installing shoulder harness attachments
      • Step 6. Installing the outside seatbelt attachments & external step
      • Step 7. Center seat belt attach
    • Chapter 9 – Main landing gear and landing brake
      • Step 1 – Landing gear bulkhead reinforcements
      • Step 2 – Preparing the strut for installation
      • Step 3 – Attach-tabs and installation
      • Step 4 – Landing gear cover
      • Step 5 – Installing axles, brakes and brakelines
      • Step 6 – Constructing the landing brake
    • Chapter 10 – The Canard
      • Step 1: Trimming the foam-blocks and cutting the cores
      • Step 2: Making lift tabs, Inserts, Jigging cores, Laying up the shear web and installing lift tabs
      • Step 3: Jigging and bonding the canard sections together
      • Step 4: Spar Cap Layup
      • Step 5: Applying the bottom skin
      • Step 6: Installing hard foam blocks for elevator hinges, the upper spar cap, and the upper skin
    • Chapter 11 – Elevators
      • Step 1: Cutting foam cores and bonding to the torque tubes
      • Step 2: Installation of the bottom skin
      • Step 3: Installation of the top-skin
      • Step 4: Installing the NC-6 inserts and the NC-3 hinges in the canard
      • Step 5: Checking elevator travel and installing tip fairings
      • Step 6: Installing the pitch trim belcrank and the elevator mass balance weights
    • Chapter 12 – Canard Installation
      • Step 1: Fitting the alignment pins
      • Step 2: Aligning the canard
      • Step 3: Fitting elevators & torque tube to fuselage
    • Chapter 13 – Nose, Nose Gear, Pitot, Rudder Pedals and Brake Master Cylinders
      • Step 1: Reinforcing the Fiberglass Nosewheel Strut
      • Step 2: Fabrication of the NG-30s
      • Step 3: Installing the Jack Wilhelmson Electric Nosewheel Assembly
      • Step 4: Installation of the NG-30 Box Assembly on the Fuselage
      • Step 5: Nose Floor and Sides
      • Step 6: Installing the Rudder Pedals
      • Step 7: Installing the Master Brake Cylinders
      • Step 8: Completion of the Nosegear
      • Step 9: Piping the Pitot & Static System
      • Step 10: Closing the Top and Carving & Glassing the Outside
      • Step 11: Nose Door
      • Step 12: Skid plate
    • Chapter 14 – Central Section Spar
      • Step 1 – Centersection Jig
      • Step 2 – Assembly of foam parts
      • Step 3 – Interior Layups
      • Step 4 – Install the forward face
      • Step 5 – Outside hard points
      • Step 6 – Spar Cap Layup
      • Step 7 – Shoulder Harness Blocks and Outside Layups
      • Step 8 – Hardpoint Reinforcement
      • Step 9 – Access For Wing Attach And End Layup
    • Chapter 16 – Control System
    • Chapter 19 – Wings and Ailerons
      • Step 1: Building the wing jigs (and wing templates)
      • Step 2: Setting up the jigs
      • Step 3: Cutting foam cores
      • Step 4: Assembly of foam cores and lay up of shear web
      • Step 5: Bottom spar cap
      • Step 6. Bottom skin
      • Step 7. Top spar cap
      • Step 8. Top skin
      • Step 9. Wing ribs
      • Step 10. Ailerons
      • Step 11. Controls
      • Step 12: Attachment, wing to center section spar
    • Chapter 20 – Winglets and Rudders
      • Step 1: Cutting the cores
      • Step 2: Glassing the skins
      • Step 3: Jigging upper winglet to wing
      • Step 4: Inside layups (Right wing)
      • Step 4: Inside layups (Left wing)
      • Step 5: Outside layers (Right wing)
      • Step 5: Outside layers (Left wing)
      • Step 6: Lower Winglet Attach (Right wing)
      • Step 6: Lower Winglet Attach (Left Wing)
      • Step 7: Rudder (Right wing)
      • Step 7: Rudder (Left wing)
  • PPL-A
    • PPL-A Teori
    • PPL-A – Blokk A
    • PPL-A – Blokk B
    • PPL-A – Blokk C
    • PPL-A – Blokk D
    • PPL-A – Mørkeutsjekk
    • PPL-A – Utgått sertifikat!
    • PPL-A – Radiobruk
    • PPL-A – Simulatortrening
    • PPL-A – Pooleys CRP-1
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