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The underlying philosophy behind the ZODIAC kit is
to provide the builder with everything needed to complete the airframe - without the need
for special skills or tools. The complete ZODIAC airframe kit requires about one year (or about 400
hours) to build.
All you need to
get started is a level workbench and basic hand tools. The detailed DRAWINGS & MANUALS
guide the builder through the kit assembly process. The Drawings and Manuals supplied with
the complete kit are not just instructions (as with most kits) but are detailed blueprints
of the complete aircraft.
[View AutoCAD Drawing
Samples] [Sample Drawings]
Actually, a ZODIAC builder is really assembling the kit from quality
parts and components supplied in the kit. All components, parts and hardware are supplied
- labeled and numbered for easy identification. Every bolt, fastener, and rivet is
supplied; from the propeller spinner right down to the rear fuselage tie-down bracket.
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Click here for an animated drawing of
the wing assembly
The airframe kit takes an average time of just 400 hours of
straight-forward and basic assembly work to put together using only simple tools, such as
an electric hand drill, a hand rivet puller, 'Cleco' temporary fasteners, a set of
wrenches, a few hand files, sheet-metal snips, etc.
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Importantly, virtually no jigs and fixtures are needed in the
building process, as all sections are built up from the flat workbench. A bending brake,
shear or other machinery is not needed, and assembly is easily done in a single car garage
or basement workshop.
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- BASIC HAND TOOLS: Tape Measure, Electric Hand
Drill, Hand Rivet Puller, Cleco Temporary Fasteners, Sheet Metal Snips, Hand Files, etc.
- Related Topic: Required Tools
& Workshop
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While previous aircraft building experience and sheet-metal skills are always
an asset, the kits and assembly instructions have been developed specifically for the
inexperienced novice builder. In fact, an overwhelming number of ZODIAC builders are
building their very first aircraft ! The simplicity of construction, quality of parts and
components, and the completeness of the kit translates into low build-times and a very
high kit completion ratio, even for novice builders.
The ZODIAC kits meet the requirements for amateur-built
(experimental) categories in the United States and Canada, as well as in most countries
around the world. In the United States, the Federal Aviation Administration (FAA) has
determined that ZODIAC kits meet FAR section 21.191(g), making them eligible for
amateur-built registration.
"A tour of the factory
demonstrates the work which goes into producing a kit. Using state-of-the-art fabrication
techniques, the skilled staff produces all kit parts with special attention to detail. All
parts supplied in the kit are ready-to-assemble." - CANADIAN
FLIGHT |
In the kit, all
the wing ribs and fuselage bulkheads are supplied pre-formed. For example, the internal
wing ribs are first press-formed, with lightening holes cut and flanged, and then hand
finished at the factory for a perfect ready-to-install fit. The strong wing spars comes
complete with all solid (bucked) rivets already set by factory professionals.
Surface skins - wings, ailerons, elevator, rudder, and fuselage - are ready for fitting,
and many flat skins are supplied pre-drilled to minimize construction time.
Pre-assembled parts (such as the wing spar) are factory-treated with
zinc-chromate primer for maximum corrosion resistance. Welded parts, such as the engine
mount, control assemblies, and fuel tank, come factory welded and ready to install.
Zenith Aircraft's kits are complete: landing gear, wheels,
fiberglass wing tips, control systems, welded aluminum fuel tank, etc., are standard
equipment in the complete airframe kit. Every part, component and sub-assembly is made
only from quality materials, passed through a strict quality control program before being
shipped to the customer. With the addition of the 'firewall-forward' Rotax powerplant and
instruments package, the builder gets everything needed to build and fly the ZODIAC. The
only items not included in the kit are the exterior paint, cabin upholstery, and battery.
A
ZODIAC builder can start assembly right away after taking delivery of the kit. Working
from a flat table, the builder can immediately begin to build the wings - simply by
measuring, drilling and riveting, and thus progress through the whole airframe section by
section, aided by the detailed blue prints, step-by-step manual and visual photo guide
supplied with the kit. Building an all-metal ZODIAC kit is straight forward, requiring no
complex jigs, and no messy (and hazardous) doping or epoxy work is involved. With the
proven and simple all-metal construction technique, the ZODIAC builder does not have to
worry about having a temperature controlled dust-free workshop environment, and does not
have to mix compounds and wait for parts to cure.
Parts Manufacturing at the Zenith Aircraft factory:
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Zenith's
new 12-ft x 4-ft CNC router table allows for more prefabrication and
pre-drilling of kit parts.
Click
here to view a video clip of parts manufacturing with the CNC
router (3 min. / 5.75 mb).
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Rib Stamping
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Shearing wing skins to
size
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Riveting the factory-built
wing spars |
Welding the aluminum wing
tanks |
ZODIAC builders are buying more than a box full of
aircraft kit parts: We take customer support seriously, and take pride in the reputation
we've developed over the last twenty years. Our relationship with the customer only begins
when the kit is delivered. Direct factory support is always available - just a phone call,
fax or email message away, which is promptly answered by the same professionals who build
the kits. Whether building from plans-only, component kits, or from the complete kit,
direct technical support is available to every ZODIAC builder. The exclusive online builder resources and the
ZENITH.AERO
online community are other
forms of continuous builder support, providing ongoing updates, building tips and news
from other builders. Also, there are already hundreds of active ZODIAC builders around the
world, happy to help other local builders complete their projects.
Workshops at the factory allow first-time builders to gain
hands-on experience in building their own aircraft with the guidance and help of
experienced factory professionals.
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Compare the value and quality of the ZODIAC kit to the
competition for completeness, pre-manufactured parts and components, standard equipment,
low build time, building ease and required skills. The high kit completion ratio for the
ZODIAC aircraft speaks for the quality of the kit and the level of available customer
support.
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