Derek Lawless
Well-known member
Had the opportunity this week to tour the factory and repair station in Wisconsin and thought I’d share my learnings…
First, they’re just a nice bunch of folks. It’s a very calm environment for a manufacturing/machine shop, and the people working seem to be serious about the work they do. It’s very much a vertically integrated operation with the exception of interiors, landings gear, wheels, avionics, and engines. They take in the raw materials and fabricate most everything in house. Axles, bushings, frame members, spinner backing plates, ribs, sheet metal, wood parts, panels, and the like are all made in house. When Chad tells you he just put in order for manufacturing he really means he’s requested they make a batch of parts.
They have two paint bays, one curing bay, and are happy to mix up small batches of paint (PPG Delfleet). Newer planes should have paint codes in the documentation. Everything is painted individually (unassembled) and then put back together after curing, not painted as an assembly as I’ve seen other shops do.
They use Superflite fabric and the 3M 30NF glue.
They’ve recently redesigned and outsourced the speed fairings that cover the upper strut attachment point on the wings. The new ones look very solid and look like they won’t have a tendency to come loose as easy as the previous version. If you order ahead they will paint them for you and it’s a quick install.
The new style aileron manufacturing process has been improved recently and has resulted in less tweaking post assembly to get them to fly straight.
They label and build up all the wiring harnesses on layup boards. If you bring your plane to them for major rewiring, rather than mixing and matching old and new they just remove all the old wiring and replace it all as a harness.
They’re experimenting with a left/right/both fuel valve. It’s not available yet but seems promising for those with uneven fuel flow. No commitment on if or when that will be available.
They’re also 3d printing some parts (PTT switch comes to mind) and are prototyping a new fuel vent wind deflector that will be smaller and under the fabric instead of screwed to the outside. No commitment on if or when that will be available but I did see a prototype.
The carbon fiber floorboards are balsa plywood with a layer of carbon fiber on top and then a protective layer on top of that. Prices just went us because balsa continues to go up in price.
Fuel tanks are built on site as well. They’re are pressure tested twice and must not leak for (if I remember code correctly) 24 hours, but don’t quote me on that.
The jig they use to build up the frames is the original. Every single frame has been made in the same jig.
Lastly, there are some spots open in the repair station for those looking to get work done or have their plane annualed by folks who really know the airframe and have access to virtually any part (assuming it’s not been superseded) one might need.
First, they’re just a nice bunch of folks. It’s a very calm environment for a manufacturing/machine shop, and the people working seem to be serious about the work they do. It’s very much a vertically integrated operation with the exception of interiors, landings gear, wheels, avionics, and engines. They take in the raw materials and fabricate most everything in house. Axles, bushings, frame members, spinner backing plates, ribs, sheet metal, wood parts, panels, and the like are all made in house. When Chad tells you he just put in order for manufacturing he really means he’s requested they make a batch of parts.
They have two paint bays, one curing bay, and are happy to mix up small batches of paint (PPG Delfleet). Newer planes should have paint codes in the documentation. Everything is painted individually (unassembled) and then put back together after curing, not painted as an assembly as I’ve seen other shops do.
They use Superflite fabric and the 3M 30NF glue.
They’ve recently redesigned and outsourced the speed fairings that cover the upper strut attachment point on the wings. The new ones look very solid and look like they won’t have a tendency to come loose as easy as the previous version. If you order ahead they will paint them for you and it’s a quick install.
The new style aileron manufacturing process has been improved recently and has resulted in less tweaking post assembly to get them to fly straight.
They label and build up all the wiring harnesses on layup boards. If you bring your plane to them for major rewiring, rather than mixing and matching old and new they just remove all the old wiring and replace it all as a harness.
They’re experimenting with a left/right/both fuel valve. It’s not available yet but seems promising for those with uneven fuel flow. No commitment on if or when that will be available.
They’re also 3d printing some parts (PTT switch comes to mind) and are prototyping a new fuel vent wind deflector that will be smaller and under the fabric instead of screwed to the outside. No commitment on if or when that will be available but I did see a prototype.
The carbon fiber floorboards are balsa plywood with a layer of carbon fiber on top and then a protective layer on top of that. Prices just went us because balsa continues to go up in price.
Fuel tanks are built on site as well. They’re are pressure tested twice and must not leak for (if I remember code correctly) 24 hours, but don’t quote me on that.
The jig they use to build up the frames is the original. Every single frame has been made in the same jig.
Lastly, there are some spots open in the repair station for those looking to get work done or have their plane annualed by folks who really know the airframe and have access to virtually any part (assuming it’s not been superseded) one might need.
