Online Community of Zenith Builders and Flyers
Sorry Scott, I did not notice you were building an HD. I did not even know it was still offered.
I had very few problems at all with documentation. Any confusion was cleared immediately by calling Roger. Call rather than email.
Have you been to the Builder Resources section online? http://www.zenithair.net/Builder-Secure/ Each section has a full color step by step process. e.g., Wing has several subsections: 6-W-1 is flaps, 6-W-2 is Ailerons, 6-W-3 is outboard wing, etc,
The HomebuiltHELP are an excellent resource. However, some of those have some errors I believe. e.g., how they tell to install camlocs, in my opinion, eliminate the benefit of the camloc; may as well use screws.
My build order on the airframe was (1) Rudder, (2) Remainder of Tail, (3) Wings, (4) Fuselage.
Also consider the demonstrated lead time of engines/parts for whatever engine you're going with. Knowing that up front can help you avoid delays when you're close to the finish line, or if you need parts after you've been flying for a while.
Wait on instruments/electronics until the last moment.
Do as much as you possibly can in the comfort of your own garage. As soon as you move stuff to a distant airport (even if it's only a mile away), progress on that stuff will become more difficult, and you'll end up needing a second set of "hangar tools".