From: BOBPAS26@aol.com
Message-ID: <31.94451fe.26d60036@aol.com>
Date: Thu, 24 Aug 2000 00:36:06 EDT
Subject: Lancair IV Kit Quality
To: lancair.list@olsusa.com
Reply-To: lancair.list@olsusa.com
Mime-Version: 1.0

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In a message dated 8/23/00 1:19:47 AM Eastern Daylight Time, 
winterland@rkymtnhi.com (Andy) writes:

<< Regarding (Lancair IV/IV-P) kit quality:  Can someone assess the overall 
qualities of what is
 delivered from the factory. It seems like I've been reading a lot of
 "doesn't fit" problems. These are things I became accustomed too with my
 $15,000 RV and most were easily rectified. However with a $120,000 Lancair,
 I'd like to expect more, especially in an airframe which requires such
 higher tolerances.  >>

Andy,
Three of us shook hands to build three Lancair IV-Ps together as a team in 
the fall of 1998. We took delivery last year (one in the spring and two in 
September) and are approximately 20-25% complete. Percent of completion is 
very difficult to estimate at this time, but progress is steady and very 
personally rewarding. None of us have built an airplane before, so the 
following assessment comes only from a career as a USAF aviator, a study of 
alternative kits/plans-built planes and hands-on experience with three 
Lancair kits.

The IV-P kit components are absolutely top quality. Workmanship on completed 
sub assemblies and components, both composite structural parts and other 
fabricated components (e.g. the nose and main gear assemblies) is as good as 
I've seen in any commercial/military aircraft facility. Having said that, 
this is not a swing set with "some assembly required" but a complex, 
pressurized, turbocharged, aircraft that definitely is not "simply bolt 
together and go fly." I chose to answer your question about kit quality 
because I have recently passed on information via this forum to alert and 
assist other builders to specific problems I encountered during construction. 
These would not have been problems for more experienced or careful 
builders--I followed instructions without checking or understanding the 
consequences--and therefore failed to recognize that component improvements 
had been made that required minor deviations from the extensive construction 
manuals/plans. One should expect accurate and concise assembly instructions, 
but I believe that Lancair has done an impressive job in this area, and when 
I put the minor "deviations" in the context of the overall kit and 
instruction set, they are insignificant. You'll need to go through the 
manuals yourself to form your own opinion--a $600 investment I made before 
deciding to buy the kit that I'd recommend to you if you have any questions 
here!

As to tolerances, a general observation is that the kit requires measurement 
and assembly to the nearest 1/8th inch for most general airframe (composite) 
work, and much better for some components. The component parts provided meet 
or exceed the required tolerances; installing them where and how specified is 
a significant challenge in some cases; it is definitely not a case of 
unwrapping and bolting in place! That for us has been one of the true 
challenges and rewards of building a Lancair. Specifically, without altering 
the structure or basic design, there are many opportunities to improvise 
better components. This has also been a source of great satisfaction and 
pride of accomplishment.

Lastly, none of us have build a metal airplane, but from watching others (we 
have an RV-8 being built in our shop) errors and fit problems are more easily 
corrected in a composite plane than an aluminum one. To be sure, it is 
possible to render even the best built components useless (did you hear about 
the builder who over-pressurized his wing tanks while testing them?), and 
some errors require simple replacement, composite assembly is generally far 
more forgiving and capable of rebuild/repair.

This is longer than I intended, but I think you get the message that we are 
very happy with our decisions to build IV-P (at least to date) and would only 
wish for a more reliable engine option! As we don't need them for a couple of 
years, we worketh like hell while we waiteth. Glad to talk to you directly if 
desired. Call me in Arlington, VA

Robert R (Bob) Pastusek
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LML website:   http://www.olsusa.com/Users/Mkaye/maillist.html
LML Builders' Bookstore:   http://www.buildersbooks.com/lancair

Please send your photos and drawings to marvkaye@olsusa.com.
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