Building an airplane My name is Ben Hallert, and I've decided to build an airplane.  After a lot of research, I've chosen the Cozy Mk IV, a four seat variant of the Long-EZ designed by Burt Rutan (designer of the first private manned spacecraft).  The FAA requires an experimental aircraft builder to keep a builders log to prove that they built the plane.  This webpage will be that log, as well as a way to show my friends how I'm progressing.

Current status
4/23/06 - Like sands through the hourglass....  finally did my first big glass layup.  The seat back bulkhead is curing, we'll see how badly I messed it up in the morning.  I've insulated my garage door and put a heater out there, it seems to be doing ok at keeping the temp up in the curing area.  We'll see what happens, I'll add more details later.
3/19/06 - With the kids asleep, managed to finish microing the seatback.  Oh yeah, this baby will be flying in no time. 
3/11/06 - Continued work on front seat, spent an hour on it.  During that hour, I cut out a corner that I messed up on 3/7 and micro'd some replacement foam into it.  Once that cures, I'll be able to contour it into good shape.  Gotta love composite construction!  After that, I started micro'ing the surface in preparation for putting down my first layers of glass.  I didn't have enough time/confidence to do that today, but I'll get to it soon.  I got the surface maybe 75% covered before I had to stop.  If I had just mixed one bi batch and done it in one or two shots, I'd be done, but I underestimated the amount of micro that the foam surface would eat, so I kept mixing one or two ounce batches.  I'm an idjut!  A note for the future, I can probably mix bigger batches of micro since I'm using the slow hardener.  Glargh!  Well, at least I'm building.  At this rate, I should be just about ready to fly for the 100th anniversary of the first Cozy test flight.
3/7/2006 - Life is starting to get back to normal, or at least as normal as can be.  It's been a month since I got my supplies, it's time to start building!  Today, I cut out the front seat!  I cut and smoothed one edge as shown in the plans, but managed to really pooch it up by making it kinda rough.  I don't know how hard it will be to fix, probably something I can fix with dry micro.  During one cut, I broke off a corner (I epoxied it back, no harm, it's setting now).  An inauspicious start, but...  it's a start! - 1 hour.
3/2/2006 - Crikey, now my wife's grandmother has died.
2/12/2006 - My wife's parents were killed in a fire, the project is on hold.  Much more important things to worry about right now.
2/7/2006 - Got my first shipment of supplies!  Plans, epoxy, hardener, ratio pump, etc.
1/31/2006 - Finally received my serial number and word that the materials are shipping.  I am the proud owner of Cozy MK IV plans serial #1432, which is funny, as that used to be the combination to get in at Santa Monica Airport when I received my pilots certificate.
1/25/2006 - Made my order!  NOW I'm a builder, right?  Enroute via UPS is:
  - One set of plans $500
  - One gallon MGS 285 Epoxy $86
  - One quart slow hardener for the above $24
  - One ratio pump for the epoxy/hardender $250
  - The materials for Chapter 4 of the plans $460.
1/22/2006 - Making the first order this week for plans and materials for Chapters 1-4, plus an epoxy pump. Added Panel Ideas page.
1/8/2006 - Received information packet.  It's official, I've spent money on it.  Am I a builder yet?

Choices and rationale
The decision process - How I came to choose the Cozy.
Which engine to use - What's going to burn off all that extra gasoline I buy?
Variations from plans - What will I do/have I done differently from the plans, and why?
Misc notes & data - Stuff that doesn't go anywhere else.
Running cost tally - How much have I spent so far, and where?
Paint schemes - It can't fly unless it looks pretty, right?
Panel ideas - This is the last stuff you buy, but it's fun to dream

External links
Cozy/EZ specific -
Cozy Development - The official Cozy page
Cozy Builders - The unofficial Cozy page
Brian Deford's Blonde Streak - One of the many great Cozy's out there, along with a great build writeup.
The Cozy Girrrls - Home of some exciting modifications, including the Cozy Girrrl's strakes that I'll be doing.
The Canard Zone - Great forum for getting data and advice from other builders.  I'm there as 'Chairboy'.
EZ Squadron - A place to read about canard aircraft
Bulent Aliev - Another nice rotary powered Cozy

Experimental related -
Blue Mountain Avionics - I'll be watching these guys during the build for sure, some very exciting avionics.
Aircraft Spruce - The place I'll be getting my plans and building materials from.  They are now the official owners of the design.
Atkins Rotary - An engine vendor that specializes in aircraft conversions of 13Bs.
Barnstormers - Aircraft classifieds.  Might be a place to get inexpensive gauges for basic VFR until I can get the money for that IFR panel together.
Rotary Engines - The Mazda Wankel Rotary Engines for Aircraft website
Conversion Concepts - A manufacturer of engine mounts for rotary engines
Homebuilt internal dimensions - A comprehensive list of cockpit sizes
EAA 31 - The EAA chapter I'm a member of