Paul Sanders
  • Brawley, CA
  • United States
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Paul Sanders's Discussions

Nylon ties on the engine frame?

Started this discussion. Last reply by Paul Sanders Jun 15. 11 Replies

While doing some study for my inspection I came across this video which the…Continue

Has any one used EkoEtch?

Started this discussion. Last reply by Don Morrisey Dec 15, 2014. 8 Replies

Regular readers of my comments here know that I have some heavily oxidised wing skins from the crates sitting out for too long during the one storm we get a decade.…Continue

Cleaning up water-troubled aluminium

Started this discussion. Last reply by Joe Harrington Mar 16, 2014. 4 Replies

When my wings kit arrived it sat in my back yard for quite a while before I was ready to get the skins out. During that time we had our one day of rain for the year and much later when I needed the…Continue

Heat Resistant Paint on the Firewall?

Started this discussion. Last reply by zihad mahmud Jul 2, 2014. 13 Replies

I'm about done with the firewall but the homebuilthelp video matter of factly mentions painting the firewall with a heat-resistant paint. I'm curious if this is what others have done, and if so, what…Continue


Paul Sanders's Page

Latest Activity

Paul Sanders posted a status
"was planning some extended taxi tests this w/e, but forecast is for 120F and my Rotax manual says don't even try to start it in those temps"
Jun 15
Paul Sanders posted a status
"Great start to my inspection process, DAR pointed out my data plate is wrong. At least this is happening before the inspection, can fix it"
Jun 14
Paul Sanders posted a status
"Engine compression and fuel flow tests done, all inspection paperwork now sent to the DAR. Now to redo all my zip ties lol"
Jun 13
Paul Sanders posted a discussion

Nylon ties on the engine frame?

While doing some study for my inspection I came across this video which the presenter says you should never use nylon ties to attach wires to the engine frame because over time oil mist will loosen the ties and then the vibration will make the tie cut into the frame.Now this guy is a DAR so presumably if he thinks that then anyone he inspects will have to think the same. But I'm…See More
Jun 12
Paul Sanders posted a status
"Curious if people tested their static system before inspection (seems like you must) and if so how. I'd have to fly mine for a pro to do it"
Jun 10
Paul Sanders posted a status
"Here's a truly amauter experimental build"
Jun 6
Paul Sanders posted a status
"Looking over the 154 point inspection checklist from my DAR, wants compression tests, fuel flow test etc - is this usual?"
Jun 5
Paul Sanders posted a video

Taxi with the Cowling on

First taxi as a finished airplane
Jun 3
Paul Sanders posted a blog post

"Final" Stats

Updating all my documents for the inspection, it looks like I have~ 6 years 10 months elapsed time (thanks to location and climate I can only work weekends, and not at all between August and October)~650 hours of build time (60 of which was the vinyl wrapping)~$63,000 of spend on parts (small to big)~10 occasions where I gave up~2 occurrences where I had to be restrained from torching the whole damn thing  (well, I was close to it!!!)What a project. …See More
Jun 2
Paul Sanders posted photos
May 29
Paul Sanders posted a photo

Door trimmed and wrapped

Needs a front latch
May 26
Paul Sanders posted a status
"Plane is finished EXCEPT without some kind of front latch, I don't think the doors will be staying on long in flight... research...."
May 26
Paul Sanders posted a status
"Just the door fit to go and I will actually be done. To that end, can anyine confirm the front door edge is flush with the frame, not on top"
May 20
Paul Sanders posted a status
"Away on business, researching 750 empty weights. Mark Townsend's 750 was 695lbs so maybe my 710 is indeed correct...."
May 15
Paul Sanders posted a status
"Close enough to finishing that I was able to weigh the plane today - 710 lbs, I must have done it wrong?"
May 13
Paul Sanders posted a status
"So while I thought I was close to finishing, I had forgotten that I have who knows how many hours of removing glue from the doors to do :("
May 7

Profile Information

Aircraft Model
Project Status
Nearly done
Building From
Partial kit
Engine installed (or plan to install)
Rotax 912
Your website (about your aircraft...)
Building Experience
No Experience
Flying Experience
Private Pilot
Building and Flying Info / Your Profession / Other Background Info
Software Developer for a large foreign games company by day, instrument-rated private pilot when time and money allows. I'm a dual UK/USA citizen living in the desert east of San Diego; yes it's hot in the summer. Too hot :)
Home Airport (ie. KMYJ)

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Paul Sanders's Blog

"Final" Stats

Posted on June 2, 2017 at 11:30am 6 Comments

Updating all my documents for the inspection, it looks like I have

~ 6 years 10 months elapsed time (thanks to location and climate I can only work weekends, and not at all between August and October)

~650 hours of build time (60 of which was the vinyl wrapping)

~$63,000 of spend on parts (small to big)

~10 occasions where I gave up

~2 occurrences where I had to be restrained from torching the whole damn thing  (well, I was close to…


Six Years In

Posted on July 17, 2016 at 12:01pm 2 Comments

Today is the 6 year anniversary of opening up the rudder box in my living room and drilling the first hole. Even though I only get to work on weekends, and on weekends outside of the summer when it isn't 110+, I had kinda thought I'd be done by now. But if I've learned one thing on this project is to take all estimates and double them: and expect it to take longer than that.

While we are firmly in the 110s, I have managed to sneak some early mornings in this summer in an…


4 Years In

Posted on July 21, 2014 at 3:11pm 4 Comments

This week marked the 4th anniversary of that first snip into the metal of the rudder kit. I now have 340 hours into the project, only managed 53 last year thanks to 10 weeks of airport resurfacing that robbed me of hangar access during the best months of the year. But what I lacked in hours I made up for in dollars, lol - the purchase of the Rotax 912ULS added quite a bit to the rolling total. I think it will be worth it though.

It really is starting to look like I am near the…


First Stab Panel Decision

Posted on April 16, 2013 at 12:26pm 4 Comments

With the firewall finished I now have all the major components assembled and have to work out how, and in what order, to put these things together. Part of the problem to solve is where the non-metal parts go that aren't covered by the instructions but clearly have to be installed before panels get riveted over them.

So that got me thinking about my panel and I think I am fairly comfortable with this as my first "definite" decision; can't help feeling I will make more…


Comment Wall (12 comments)

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At 7:06pm on September 2, 2015, ronald zielke said…

Hi Paul  got my fuel valve today it's the V1 4 way .  the valve body has three holes on the lower end of the valve with no indication of what is supposed to feed what tank or motor,or what  is to go to what hole, tried to email the co but that didn't work to well, that was probably me.   This valve has 4 positions off, both, l, R.  there are no marking on the valve or in the very modest instructions as to how to plumb it?  how did you do yours?    thanks for any advice.  Ron


At 5:32pm on February 23, 2013, David Fitzgerald said…

Paul I feel your pain. I am verry lucky I was able to work on my project almost nonstop for 6 months and finished in that time. I am a total beginner like yourself. After reading some of your posts I can relate. like where or when do you install antennas. You will run into this often. If you call zenith as often as I did they need to be on speed dial. Roger is very halpful, if you get  sent to Kaleb he will make you feel like a fool. I bought the videos and they helped alot, but there were still many ? . I have 55 hrs on my plane since my first flight Jan. 1st.  and all I can say is hang in there. It really is worth the trouble. I am having a ball.

At 4:28pm on May 9, 2012, Blaine Schwartz said…



If you can build the plane, you can build the motor. I built a Corvair for my CH 750 and have a great time doing it. I encourage you to go to a Corvair College; you learn so much. Google CC#22 to check oout some of the pictures.



At 6:40pm on January 17, 2012, Phill Barnes said…

Hi Paul

I use the hole cutter in my cordless drills which have 3/8 chucks so you will be fine.



At 8:33pm on January 16, 2012, Phill Barnes said…

This is the exact one.





At 8:21pm on January 16, 2012, Phill Barnes said…

HI Paul

Regarding you fuel sender hole cutting needs. On one of my visits to the US in 2008, I purchased an adjustable cutter with HSS blade from Sears for 20 bucks. I bought it for the very same job and works well. Be sure to use it slowly with light pressure though. Also fantastic for cutting instrument holes.





At 4:21pm on September 30, 2011, Ian Sowman said…
Gidday Paul. Dual nationality = dual flags. Good idea, been to Osh a couple of times and noted many stars & stipes in various graphics.........generally look good. I'd like to see finished pix. Be careful though as you may not know wether you are coming or going!
At 2:53pm on April 21, 2011, Rod Hatcher said…
Hi Paul, The 3M wrap has an adhesive on one side and is very thin and flexible. It is quite easy to smooth on and position. It easily conforms to rivets. On sharp edges you undercut the vinly and smooth it into place. If you cover a sharp edge it will eventually cut through the film. The film is warranted for 7 years. I am expecting that if you keep the plane hangared it should last at least 10 or 12 years. Good luck on your project. 
At 11:14pm on February 1, 2011, Joe McGough said…
Thanks Paul, for the comment.  Just finished priming tonight,  Hope to get it riveted together tomorrow. I thought my rudder was warped too but when I drilled for the nose skin it seemed  to pull everything together. Thanks, Joe
At 7:43pm on January 5, 2011, Tom Anderson said…

Hi Paul,

My decision to complete the wings before the fuselage is based on work shop location. The wings can be completed in the basement and there is a way to get them out. I will have to move to the garage (which is not heated) to complete the fuselage. So my plan is to do  fuselage construction during spring and summer.


Are you going to paint your plane? I'm leaning towards polished finish with some paint.




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