Zenair's Airframe Kits...
In its mission to make it easier and quicker for individuals to build and finish their own aircraft, Zenair has, since its beginnings offered airframe kits for its many different aircraft designs. While the quality and level of finish continues to evolve and standard kits have greatly improved over the years thanks in large part to more modern and innovative manufacturing processes, Zenair has also introduced new levels of "pre-assembled components" in most of its popular airframe kits. Zenair kits of all levels contain the same parts; it is the amount of factory pre-assembly that changes from one level of kit to another, setting Standard or Quick-Build Kits apart.
In its mission to make it easier and quicker for individuals to build and finish their own aircraft, Zenair has, since its beginnings offered airframe kits for its many different aircraft designs. While the quality and level of finish continues to evolve and standard kits have greatly improved over the years thanks in large part to more modern and innovative manufacturing processes, Zenair has also introduced new levels of "pre-assembled components" in most of its popular airframe kits. Zenair kits of all levels contain the same parts; it is the amount of factory pre-assembly that changes from one level of kit to another, setting Standard or Quick-Build Kits apart.
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Our Standard and Quick-Build Kits (QBK) continue to meet traditional 51% rules that apply to amateur-built aircraft in most countries. Builders who choose to build from a QBK typically just want to reduce the assembly time for their kitplane project. To achieve this, builders may order their QBK directly from Zenair, or they can independently contract with a local mechanic or "Builder Assistance Provider" for assistance with the assembly and/or finishing of their kit aircraft.
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Before ordering a kit, it is important to know in which category you plan to register and operate your aircraft. For example, if you plan to register your aircraft in Canada as an Advanced Ultralight (AULA), you will have to follow the step-by-step instructions provided here. Contact your local CAA to know what conditions or restrictions apply in your country regarding kit aircraft. For more information on pricing, available options and delivery schedules, please contact Zenair.
1) QUICK-BUILD KITS (QBK) for the CH 650 and CH 750 series (STOL, CRUZER and SUPER-DUTY)
A few years ago, Zenair still offered Quick-Build Kits for the wings and tail-sections of its airframe kits (pictures of such kits can still be found on the internet). Since the 2021 jump in both kit-demand and with kit delivery times, however, the Quick-Build section of our QBK (for the CH 650 and CH 750 series) only applies to the fuselage section of the airframe. To complete the fuselage, a builder will still need to install the gear system, brake system, control system, canopy system/doors and fuel system (all provided with the kit, but not installed). Note: the controls (stick, pedals, brakes, flap actuators, etc.) and even the landing gear can be factory-installed into custom-made QBK Fuselage kits for an extra fee.
A few years ago, Zenair still offered Quick-Build Kits for the wings and tail-sections of its airframe kits (pictures of such kits can still be found on the internet). Since the 2021 jump in both kit-demand and with kit delivery times, however, the Quick-Build section of our QBK (for the CH 650 and CH 750 series) only applies to the fuselage section of the airframe. To complete the fuselage, a builder will still need to install the gear system, brake system, control system, canopy system/doors and fuel system (all provided with the kit, but not installed). Note: the controls (stick, pedals, brakes, flap actuators, etc.) and even the landing gear can be factory-installed into custom-made QBK Fuselage kits for an extra fee.
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For illustration purposes, below are a couple of video tours of the Zenair Quick Build Kit for the CH 650:
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Whether it is a standard airframe kit or the Quick Build Fuselage Kit, both are composed of the same quality parts. The difference between a standard and a Quick-Build kit is the level of assembly. Assembly time with a Quick-Build fuselage Kit is projected to be 50% less than with the standard fuselage kit!
2) "ADVANCED" Airframes Kits (AAK): No longer offered by Zenair at this time.
(contact a Build-Center for custom assembly)...
ADVANCED Airframe Kits (AAK) from Zenair are even more complete than QBK. Below is a sample description of the "Advanced" kit for a STOL CH 750. Similar kits are available for all CH models listed below. Where applicable (i.e. with the CH 650 and CH 750), Advanced Airframe Kits include all the individual parts from a basic airframe kit as well as its related finishing kit; it's just that most of the parts have now been professionally-assembled.
Wing area
- Wing main skins installed to ribs and spars. Slat and flaperon brackets installed. Wing trailing edge installed. Strut fittings installed.
- Left and right wing top skin tack riveted. Fuel tank and fuel system installed in wings. No electrical wires installed
- Wing tips and root fairings installed
- Wing electrical wires installed. Wing tip strobe/light installed if ordered (option). Pitot static lines installed in wing, but no pitot static head on outside of wing installed. Fuel gauge not installed but cut-out in top of wing and fuel tank completed for gauge.
- Slats assembled and fitted to wings. Plastic end tips installed.
- Flaperons assembled. Plastic tip ends installed. Fitted together and fitted to wings.
Note: Flaperons assembled. Finished and fitted to wings. Removed for shipping, Wings fitted to fuselage with struts and jury struts. removed for shipping
Tail area
- Elevator 100% finished with electrical wires for trim motor. Motor not installed.
- Elevator trim tab 100% finished and installed to Stabilizer
- Stabilizer 100% finished
- Elevator and Stabilizer assembled together and fitted to fuselage. Removed for shipping
- Rudder assembled and fitted to fuselage
- Rudder and elevator control cables installed and fitted to cabin controls, rigged for deflections.
Fuselage area
- Rear & forward fuselage are riveted together with steel cabin frame.
- Main landing gear, wheels and brakes installed. Removed for shipping
- Nose gear leg installed with bungee system. Nose wheel fork and wheel installed but removed for shipping.
- Cabin seat area and baggage area is tack riveted
- Fuselage side windows are riveted to fuselage
- Seat frames included. No upholstery
- Domed bubble doors fitted, door handle with key installed
- Instrument panel installed. No cutouts
- Engine mount (shown in above picture) can be installed to firewall but must be purchased separately.
Available engine mounts for: Continental 0-200, Rotax 912ULS, ULPower, etc.
- Fuel system lines installed rear of firewall with 1 fuel value installed on center console. Gascolator and other fuel plumbing installed rear of firewall. Electric Fuel senders not installed into wing tanks. All wing tank plumbing installed. Larger tanks installed if ordered (optional)
- Rudder pedals installed and rods to nose gear installed. Toe brakes installed for pilot and co-pilot, brake lines not installed.
- Control center torque tube installed with rest of flight controls.
- All steel parts installed are painted gray & all mating surfaces primed.
- Windshield or top window not installed. We recommend installation after painting of the aircraft.
- Other items not installed: All electrics, instruments, firewall forward, paint, landing gear brake system lines, seatbelts (seatbelt brackets installed) and other items not mentioned above.
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3) "CUSTOM" Airframes: "Custom" airframes are NO LONGER OFFERED by Zenair at this time.
(contact a Build-Center for custom assemblies)...
Zenair Ltd. is able to ship custom-prepared airframe kits worldwide. In some places, FAA restrictions applicable to US kitplanes do not apply. Zenair will deliver custom-built advanced airframe kits for any CH design upon request; please contact Zenair to discuss your specific needs, special conditions, and/or for a custom quote.
Custom Airframe Price: ..........................................................................Will vary based on custom requirements.
(contact a Build-Center for custom assemblies)...
Zenair Ltd. is able to ship custom-prepared airframe kits worldwide. In some places, FAA restrictions applicable to US kitplanes do not apply. Zenair will deliver custom-built advanced airframe kits for any CH design upon request; please contact Zenair to discuss your specific needs, special conditions, and/or for a custom quote.
Custom Airframe Price: ..........................................................................Will vary based on custom requirements.
4) TWO-WEEK WONDER Factory-Assist Program.................................. for the STOL CH 750, CH 750 Cruzer and CH 650
Orders for "Two-Week-Wonder" programs are NOT BEING ACCEPTED by Zenair at this time. Contact a Build-Center for custom assembly)...
In just two weeks, participants in our Two-Week Wonder program could complete their aircraft at the Zenair factory in Midland, Ontario, Canada. During the two-weeks, participants would:
Orders for "Two-Week-Wonder" programs are NOT BEING ACCEPTED by Zenair at this time. Contact a Build-Center for custom assembly)...
In just two weeks, participants in our Two-Week Wonder program could complete their aircraft at the Zenair factory in Midland, Ontario, Canada. During the two-weeks, participants would:
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Zenair provided a fully equipped shop with everything needed to complete the project, and experienced technicians worked with the program’s participants 10 hours a day, five days a week for two weeks. Day seven of each week was reserved as a catch-up days if necessary.
Visit the Two-Week Wonder pages for additional information.
Again, no Two-Week-Wonder programs are being scheduled at this time (01/23).
Visit the Two-Week Wonder pages for additional information.
Again, no Two-Week-Wonder programs are being scheduled at this time (01/23).
5) "FINISHED" Aircraft ("RTF"):
Ready-to-Fly (RTF) Zenair designs are only available from regional Builder-Assistance Centers in the USA, from "Build Centers" in Canada, or from Regional Representatives in other international locations.
Ready-to-Fly (RTF) Zenair designs are only available from regional Builder-Assistance Centers in the USA, from "Build Centers" in Canada, or from Regional Representatives in other international locations.
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Contact your nearest Builder-Assistance Center, Build Center or Regional Representative for prices and availability.
Firewall Forward (FWF) packages for the above kits are available from Zenair. Components from the FWF Package can be custom-installed on advanced kits (FWF and labor additional). Zenair can also arrange to have engines shipped (un-installed) with advanced airframe kits. Call Zenair for quotes and availability. New engines available through Zenair include:
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