Certification and Operation of Amateur-Built Aircraft

9/30/2009 AC 20-27G Appendix 8 APPENDIX 8. AMATEUR-BUILT AIRCRAFT FABRICATION AND ASSEMBLY CHECKLIST (2009) (FIXED-WING)

Amateur-Built Aircraft Fabrication and Assembly Checklist (2009)

(Fixed-wing)

NOTE: This checklist is applicable only to fixed-wing Name(s):………………………………………… aircraft. Evaluation of other types of aircraft (that is, rotorcraft, balloons, lighter than air) will not be Address:………………………………………....

accomplished with this form.

Aircraft Model:………………………………….

Date:……………………………………………..

NOTE: This checklist is invalid for and will not be used to evaluate an altered or modified type-certificated aircraft Remarks:………………………………………… with the intent to issue an Experimental Amateur-Built Airworthiness Certificate. Such action violates FAA policy …………………………………………………...

and DOES NOT meet the intent of 14 CFR § 21.191(g).

Note : Enter “N/A” in any box where a listed task is not applicable to the particular aircraft being evaluated.

Use the “Add item” boxes at the end of each section to add applicable unlisted tasks and award credit.

A B C D FABRICATION AND ASSEMBLY TASKS Mfr Kit/Part/ Commercial Am-Builder Am-Builder Component Assistance Assembly Fabrication Task Fuselage — 24 Listed Tasks # F1 Fabricate Longitudinal Members F2 Fabricate Composite Cores or Shells, Skins F3 Fabricate Bulkheads or Cross-members F4 Fabricate Control Yokes/Sticks F5 Assemble Control Yokes/Sticks F6 Fabricate Flt Control Push Pull Tubes/Cables F7 Assemble Flt Control Push Pull Tubes/Cables F8 Assemble Fuselage Basic Structure F9 Fabricate Brackets and Fittings F10 Assemble Brackets and Fittings F11 Fabricate Cables, Wire, and Lines F12 Assemble Cables, Wire, and Lines page 1 of 11 8-1 9/30/2009 AC 20-27G Appendix 8 F13 Fabricate Fuselage Fuel System Components F14 Assemble Fuselage Fuel System Components F15 Fabricate Fuselage Covering or Skin F16 Assemble Fuselage Covering or Skin F17 Fabricate Windshield F18 Assemble Windshield to Fuselage F19 Fabricate Windows F20 Assemble Windows to Fuselage F21 Fabricate Doors/Canopy F22 Assemble Doors/Canopy to Fuselage F23 Fabricate Mast and Strut Assembly F24 Assemble Mast and Strut Assembly Add item: Add item: Add item: Add-item: Total of # Mfr Kit/Part/ Commercial Am-Builder Am-Builder Fuselage Fuselage Subtotal Component Assistance Assembly Fabrication Tasks Fuselage Total Points ► A B C D FABRICATION AND ASSEMBLY TASKS Mfr Kit/Part/ Commercial Am-Builder Am-Builder Component Assistance Assembly Fabrication Task Wings — 51 Listed Tasks # W1 Fabricate Wing Spars W2 Assemble Wing Spars to Wing W3 Fabricate Wing Ribs or Cores W4 Assemble Wing Ribs or Cores to Wing W5 Fabricate Composite Cores W6 Assemble Composite Cores to Wing W7 Fabricate Wing Leading and Trailing Edges W8 Assemble Wing Leading & Trailing Edges to Wing W9 Fabricate Drag/Anti-drag Truss Members W10 Assemble Drag/Anti-drag Truss Members to Wing W11 Fabricate Wing Brackets and Fittings W12 Assemble Wing Brackets and Fittings to Wing W13 Fabricate Wing Tips W14 Assemble Wing Tips to Wings W15 Fabricate Special Tools or Fixtures W16 Fabricate Aileron Spars W17 Fabricate Aileron Ribs or Cores W18 Assemble Aileron Ribs or Cores to Aileron Amateur-Built Aircraft Fabrication and Assembly Checklist (2009) (Fixed-wing) page 2 of 11 8-2 9/30/2009 AC 20-27G Appendix 8 W19 Assemble Aileron Primary Structure W20 Fabricate Aileron Leading and Trailing Edges W21 Assemble Aileron Leading and Trailing Edges W22 Fabricate Aileron Brackets and Fittings W23 Assemble Aileron Brackets & Fittings to Aileron W24 Fabricate Aileron covering or Skin W25 Assemble Aileron Covering or Skin to Aileron W26 Fabricate Aileron Roll Trim W27 Assemble Aileron Trim Tab/Roll Trim to Aileron W28 Assemble Aileron to Wing W29 Fabricate Flap Spars W30 Assemble Flap Spars to Flap W31 Fabricate Flap Ribs or Cores W32 Assemble Flap Ribs or Cores to Flap W33 Assemble Flap Primary Structure W34 Fabricate Flap Leading and Trailing Edges W35 Assemble Flap Brackets and Fittings to Flap W36 Fabricate Flap Covering or Skin W37 Assemble Flap Covering or Skin to flap W38 Assemble Flaps to Wing W39 Fabricate Wing External Lighting Components W40 Assemble Wing Ext Lighting Components to Wing W41 Assemble Basic Wing Structure W42 Fabricate Wing Fuel System components W43 Assemble Wing Fuel System Components to Wing W44 Fabricate Cables Wires and Lines W45 Assemble Cables Wires and Lines to Wing W46 Fabricate Wing Covering or Skin W47 Assemble Wing Covering or Skin to Wing W48 Fabricate Wing Struts/Wires W49 Fabricate Fuel Tank W50 Assemble Fuel Tank to Wing W51 Calibrate Fuel System Components Add item: Add item: Add item: Add item: Total # of Mfr Kit/Part/ Commercial Am-Builder Am-Builder Wings Wings Subtotal Component Assistance Assembly Fabrication Tasks Wings Total Points ► Amateur-Built Aircraft Fabrication and Assembly Checklist (2009) (Fixed-wing) page 3 of 11 8-3 9/30/2009 AC 20-27G Appendix 8 A B C D FABRICATION AND ASSEMBLY TASKS Mfr Kit/Part/ Commercial Am-Builder Am-Builder Component Assistance Assembly Fabrication Task Empennage — 57 Listed Tasks # E1 Fabricate Horizontal Stabilizer Spars E2 Assemble Horizontal Stabilizer Spars to Stabilizer E3 Fabricate Ribs or Cores E4 Assemble Horizontal Stabilizer Ribs or Cores to Stabilizer E5 Fabricate Horizontal Stabilizer Leading and Trailing Edge E6 Assemble Horizontal Stabilizer Leading and Trailing Edges to Stabilizer E7 Fabricate Horizontal Stabilizer Brackets & Fittings E8 Assemble Horizontal Stabilizer Brackets and Fittings to Stabilizer E9 Assemble Horizontal Stabilizer Structure E10 Fabricate Horizontal Stabilizer Lead/Trailing Edges E11 Assemble Horizontal Stabilizer Lead/Trailing Edges to Stabilizer E12 Fabricate Horizontal Stabilizer Cables, Wires and Lines E13 Assemble Horizontal Stabilizer Cables, Wires and Lines to stabilizer E14 Fabricate Horizontal Stabilizer Empennage Covering or Skin E15 Assemble Horizontal Stabilizer Empennage Covering or Skin to Stabilizer E16 Assemble Horizontal Stabilizer Structure to F uselage E17 Fabricate Elevator Spars E18 Assemble Elevator Spars to Elevator E19 Fabricate Elevator Ribs or Cores E20 Assemble Elevator Ribs or Cores to Elevator E21 Assemble Elevator Structure E22 Fabricate Elevator Leading and Trailing Edge E23 Assemble Elevator Leading and Trailing Edges to Elevator E24 Fabricate Elevator Brackets and Fittings E25 Assemble Elevator Brackets and fittings to Elevator E26 Fabricate Elevator Covering or Skins E27 Assemble Elevator Covering or Skins to Elevator E28 Fabricate Elevator Trim Tab E29 Assemble Elevator Trim Tab to Elevator E30 Fabricate Special Tools or Fixtures Amateur-Built Aircraft Fabrication and Assembly Checklist (2009) (Fixed-wing) page 4 of 11 8-4 9/30/2009 AC 20-27G Appendix 8 E31 Fabricate Vertical Stabilizer Spars E32 Assemble Vertical Stabilizer Spar to the Vertical Stabilizer E33 Fabricate Vertical Stabilizer Ribs or Cores E34 Assemble Ribs or Cores to Vertical Stabilizer E35 Fabricate Vertical Stabilizer Leading/Trailing Edges E36 Assemble Leading and Trailing Edges to Vertical Stabilizer E37 Fabricate Vertical Stabilizer Brackets and Fittings E38 Assemble brackets and Fittings to Vertical Stabilizer E39 Fabricate Vertical Stabilizer Cables, Wires, Lines E40 Assemble Cables, Wires, Lines to Vertical Stabilizer E41 Fabricate Vertical stabilizer Empennage Covering or Skin E42 Assemble Vertical stabilizer Empennage Covering or Skin to Vertical Stabilizer E43 Assemble Vertical Stabilizer Structure to Fuselage E44 Fabricate Rudder Spar E45 Assemble Rudder Spar to Rudder E46 Fabricate Rudder Ribs or Cores E47 Assemble Rudder Ribs or Cores to Rudder E48 Assemble Rudder Structure E49 Fabricate Rudder Leading and Trailing Edge E50 Assemble Rudder Leading and Trailing Edge to Rudder E51 Fabricate Rudder Brackets and Fittings E52 Assemble Rudder Brackets and Fittings to Rudder E53 Fabricate Rudder Covering or Skin E54 Assemble Rudder Covering or Skin to Rudder E55 Fabricate Rudder Trim Tab E56 Assemble Rudder Trim Tab to Rudder E57 Assemble Rudder to Vertical Stabilizer Add item: Add item: Add item: Add item: Total # of Mfr Kit/Part/ Commercial Am-Builder Am-Builder Empennage Empennage Subtotal Component Assistance Assembly Fabrication Tasks Empennage Total Points ► Amateur-Built Aircraft Fabrication and Assembly Checklist (2009) (Fixed-wing) page 5 of 11 8-5 9/30/2009 AC 20-27G Appendix 8 A B C D FABRICATION AND ASSEMBLY TASKS Mfr Kit/Part/ Commercial Am-Builder Am-Builder Component Assistance Assembly Fabrication Task Landing Gear — 12 Listed Tasks # LG1 Fabricate Struts LG2 Fabricate Brake System Components LG3 Fabricate Landing Gear Actuation System Components LG4 Fabricate Landing Gear System Cables, Wires and Lines LG5 Assemble Wheels LG6 Assemble Brakes, Tires LG7 Assemble Landing Gear LG8 Assemble Landing Gear System Components Next Level Structure LG9 Align Landing Gear LG10 Fabricate Landing Gear Fairings/Gear Doors LG11 Assemble Landing Gear Fairings/Gear Doors to Next Level Structure LG12 Perform Landing Gear Operational Check (Normal, Emergency Systems) Add item: Add item: Add item: Add item: Total # of Mfr Kit/Part/ Commercial Am-Builder Am-Builder Land Gear Landing Gear Subtotal Component Assistance Assembly Fabrication Tasks Landing Gear Total Points ► Amateur-Built Aircraft Fabrication and Assembly Checklist (2009) (Fixed-wing) page 6 of 11 8-6 9/30/2009 AC 20-27G Appendix 8 A B C D FABRICATION AND ASSEMBLY TASKS Mfr Kit/Part/ Commercial Am-Builder Am-Builder Component Assistance Assembly Fabrication Task Propulsion — 27 Listed Tasks # P1 Fabricate Engine Mounts(s) P2 Assemble Engine Mount(s) to Next Level Structure P3 Fabricate Engine Cooling System/Baffles P4 Assemble Engine Cooling System Baffles to Engine P5 Fabricate Engine Compartment Overheat/Fire Detection System P6 Assemble Engine Compartment Overheat/Fire Detection System to Engine Compartment P7 Fabricate Induction System P8 Assemble Induction System to Engine P9 Fabricate Exhaust System P10 Assemble Exhaust System to Engine P11 Fabricate Engine Control Installation Brackets P12 Assemble Engine Controls to Next Level Structure P13 Rig and Adjust Engine Controls P14 Fabricate Brackets and Fittings P15 Assemble Brackets and Fittings to Next Level Structure P16 Fabricate Cables, Wires and Lines P17 Assemble Cables, Wires and Lines to next Level Structure P18 Assemble Engine (Likely N/A) P19 Assemble Engine to Engine Mount P20 Fabricate Engine Propeller (Likely N/A) P21 Fabricate Propeller Spinner Components P22 Assemble Propeller to Engine P23 Rig and Track Propeller P24 Fabricate Engine Cowling P25 Assemble Engine Cowling to Airframe P26 Fabricate Engine Fuel System Components P27 Assemble Engine Fuel System Components to Next Level Structure Add item: Add item: Add item: Add item: Total # of Mfr Kit/Part/ Commercial Am-Builder Am-Builder Propulsion Propulsion Subtotal Component Assistance Assembly Fabrication Tasks Propulsion Total Points ► Amateur-Built Aircraft Fabrication and Assembly Checklist (2009) (Fixed-wing) page 7 of 11 8-7 9/30/2009 AC 20-27G Appendix 8 A B C D FABRICATION AND ASSEMBLY TASKS Mfr Kit/Part/ Commercial Am-Builder Am-Builder Component Assistance Assembly Fabrication Task Cockpit Interior — 11 Listed Tasks # C1 Fabricate Instrument Panel C2 Fabricate Instrument Panel Bracket and Fittings C3 Assemble Instrument Panel with Fittings and Brackets C4 Assemble Avionics to Instrument Panel C5 Fabricate Seats C6 Fabricate Seat Brackets and Fittings C7 Assemble Seats to Cockpit C8 Fabricate Seat Belts Fittings and Shoulder Harness Fittings C9 Assemble Seat Belts and Shoulder Harness to Structure C10 Fabricate Electrical Wiring, Controls and Switches C11 Assemble Electrical Systems Controls and Switches to Next Level Structure Add item: Add item: Add item: Add item: Total # of Cockpit Mfr Kit/Part/ Commercial Am-Builder Am-Builder Cockpit Interior Subtotal Component Assistance Assembly Fabrication Interior Tasks Cockpit Interior Total Points ► Total # of Aircraft Tasks ◄ SUM #1 Amateur-Built Aircraft Fabrication and Assembly Checklist (2009) (Fixed-wing) page 8 of 11 8-8 9/30/2009 AC 20-27G Appendix 8

► TOTAL TASKS AND LINE ITEMS ↓ ↓ ↓ ↓

FABRICATION AND ASSEMBLY SUMMARY A B C D Mfr Kit/Part/ Commercial Am-Builder Am-Builder Component Assistance Assembly Fabrication 1. Total Points for Each Category 2. Total Points for Complete Aircraft Construction (SUM #2) ► (SUM # 2 should equal SUM # 1 above.)

3. Percentage of Each Category as Part of Total Aircraft Construction 4. Total Percentages for Complete Aircraft Construction – Add all percentages in row 3. (Total should equal 100% (+ .5%).)

5. Total Builder Points – Add together points in row 1, columns C and D only.

6. Total Builder Percentage – Add together percentages in row 3, columns C and D only.

Amateur-Built Aircraft Fabrication and Assembly Checklist (2009) (Fixed-wing) page 9 of 11 8-9 9/30/2009 AC 20-27G Appendix 8 Instructions for Completing the Amateur-Built Aircraft Fabrication and Assembly Checklist (2009) 1. Total Points for Each Category (columns A, B, C and D). Each column’s total points are tallied by adding the sum of the points awarded to the tasks in each section (for example, Fuselage, Wings, Empennage). Include points assigned to additional items in each section. Boxes with a N/A (not applicable) have zero points.

2. Total Points for Complete Aircraft Construction .

SUM #1 . To find total points, add up the six “Total # of Tasks” blocks at the bottom left of each fabrication and assembly tasks section.

SUM #2. In the FABRICATION AND ASSEMBLY SUMMARY section, add the four blocks from each column’s category total (columns A+B+C+D).

Compare SUM #1 to SUM #2. SUM #1 should be equal to SUM #2. (Verify the two sums are equal within a deviation of ±0.5). Total points will vary from aircraft to aircraft depending on number of N/As (not applicable), and additional items applied (123 listed task points + additional items - N/As).

3. Percentage of Each Category . To compute percentages, divide each of the point totals in each column (row 1) individually by the number derived in row 2. For example, if the total points of Mfr Kit/Part/Component category (column A) equals 60 and the number in row 2 equals 170, then divide 60 by 170 to equal 35.3 percent. Do this for each category column. Percentages may be rounded to the nearest tenth (for example, 22.86 percent is rounded up to 22.9 percent).

4. Total Percentages for Complete Aircraft Construction as Part of Total Aircraft Construction . Add the percentages of each of the four categories together (columns A+B+C+D). Total must be equal to 100 percent with a deviation limited to ± 0.5 percent. For example, a derived percentage between 99.5 percent and 100.5 percent is acceptable. If this computation falls outside the accepted deviation, then an error has occurred in row 1, 2, or 3.

5. Total Builder Points . Add the two point tallies from column C and column D derived in row 1. Total will vary from aircraft to aircraft depending on number of N/As applied.

6. Total Builder Percentage . Add the two percentage tallies from column C and column D derived in row 3. Total must exceed 50 percent to be eligible for amateur-built status and to meet the major portion requirement under 14 CFR § 21.191(g).

Amateur-Built Aircraft Fabrication and Assembly Checklist (2009) (Fixed-wing) page 10 of 11 8-10 9/30/2009 AC 20-27G Appendix 8 Explanations and Examples ► A point (each task equals 1 point) can be divided over multiple categories (Manufacturer, Commercial Assistance, Amateur-Builder Assembly, and Amateur- Builder Fabrication) into 1/10 fractions. A manufacturer may be a kit manufacturer, a component manufacturer, or a part(s) manufacturer. Commercial assistance (for hire or compensation) may include assistance provided by kit manufacturers, commercial assistance centers, individuals (for example, A&P mechanics or avionics technicians).

► For example, 0.5 point can be assigned to the manufacturer, 0.3 point as commercial assistance, and 0.2 point to the amateur builder as fabrication, for a total of 1 point.

► All points are added at the end of the form in the FABRICATION AND ASSEMBLY SUMMARY section under their respective categories. The point total is comprised of all the credits awarded for primary delineated tasks plus any credits given for additional items.

► Additional items may be assigned points the same as primary listed tasks if work or parts not reflected in the main entries need to be credited.

► The applicants’ completion of tasks can be documented in a number of ways and may include the following:  Comprehensive builder’s logs, to include photographs of all the steps included in each of the listed tasks in the Amateur-Builder Aircraft Fabrication and Assembly Checklist (2009), materials and techniques used in construction, as well as dates, locations, and detailed descriptions,  Photographs/video/DVD,  Drawings and engineering specifications,  Kit manufacturer data when necessary,  Relevant documentation (for example, plans) and references (for example, handbooks) used,  Documentation concerning any commercial assistance used,  Documentation concerning any non-commercial assistance used,  Part inventories and histories,  Receipts and Catalogs, and  Logbook entries.

In addition to using this checklist, the builder should document the entire fabrication and assembly process. To issue an airworthiness certificate, the FAA must make a major portion determination (the major portion of an aircraft was fabricated and assembled by an amateur builder(s)). Making this finding requires sufficient, credible, and adequate documentation.

Amateur-Built Aircraft Fabrication and Assembly Checklist (2009) (Fixed-wing) page 11 of 11 8-11

9/30/2009 AC 20-27G Appendix 9 APPENDIX 9. SAMPLE AERONAUTICAL CENTER FORM 8050-88, AFFIDAVIT OF OWNERSHIP FOR AMATEUR-BUILT AIRCRAFT 9-1

9/30/2009 AC 20-27G Appendix 10 APPENDIX 10. SAMPLE AERONAUTICAL CENTER FORM 8050-2, AIRCRAFT BILL OF SALE 10-1 9/30/2009 AC 20-27G Appendix 11 APPENDIX 11. SAMPLE LETTER FOR REQUESTING AN AIRCRAFT REGISTRATION NUMBER UNDER 14 CFR § 47.15 [Insert Date] Federal Aviation Administration Aircraft Registration Branch, AFS-750 P.O. Box 25504 Oklahoma City, OK 73125-0504 Sir/Madam: This is a request for a U.S. identification number assignment for my amateur-built aircraft.

Aircraft Description : Make/Builder : Early A. Builder Type (airplane, rotorcraft, glider, or balloon): Airplane Model : VAN’S RV-6 Serial Number : 1001 This aircraft has not previously been registered anywhere (reference 14 CFR § 47.15(a)(1)).

X Normal Request ($5); fee attached (check or money order) Special Registration Number Request ($10); fee attached (check or X money order) Choices st 1 130EA nd 2 130JR rd 3 130FE th 4 130JJ th 5 130TX Sincerely,

Early A. Builder

Early A. Builder Owner 11-1

9/30/2009 AC 20-27G Appendix 12 APPENDIX 12. SAMPLE FAA FORM 8130-12, ELIGIBILITY STATEMENT, AMATEUR-BUILT AIRCRAFT 12-1

9/30/2009 AC 20-27G Appendix 13 APPENDIX 13. SAMPLE PROGRAM LETTER TO ACCOMPANY APPLICATION FOR AIRWORTHINESS CERTIFICATE [Insert local FAA office or DAR] Date: [Insert date] TO: In accordance with 14 CFR § 21.193, I request a Special Airworthiness Certificate for my aircraft for the purpose of operating amateur-built aircraft. The aircraft description is as follows: Builder : Early A. Builder Registration No. : N130EA Model : VAN’S RV-6 Serial No. : 1001 No. of Engines : 1 No. of Seats : 2 Design Criteria : my own design built from plans built from a kit X The aircraft is complete and the following items have been accomplished: Yes No I enclose FAA Form 8130-6 with Sections I, II, and III complete.

I enclose FAA Form 8130-12 with Sections I, II, and III complete and Yes No notarized in Section IV.

Yes No I possess Aeronautical Center Form 8050-3.

Yes No I enclose a three-view drawing or photographs of the aircraft.

I have weighed the aircraft to determine that the most forward and aft center of gravity positions are within established limits. The weight and Yes No balance report is available at the aircraft, and a copy is submitted with this application.

I have maintained a construction log for the project, including photographs showing methods of construction and workmanship during Yes No the construction. Log entries describe all inspections conducted during construction.

The marking requirements of part 45 have been complied with, including permanent attachment of a fireproof identification (data) plate, Yes No permanent application of appropriate registration marks, and the word “experimental” displayed near each entrance to the cabin or cockpit.

The following placard is displayed in the cockpit in full view of all occupants (not required for single-place aircraft).

“PASSENGER WARNING—THIS AIRCRAFT IS Yes No AMATEUR-BUILT AND DOES NOT COMPLY WITH FEDERAL SAFETY REGULATIONS FOR STANDARD AIRCRAFT.” 13-1

9/30/2009 AC 20-27G Appendix 13 APPENDIX 13. SAMPLE PROGRAM LETTER TO ACCOMPANY APPLICATION FOR AIRWORTHINESS CERTIFICATE (CONTINUED) The aircraft will be available for inspection at this location, and directions are as follows: Grayson County Airport Hangar No. 3 4701 Airport Dr.

Sherman, TX 75020 I request airworthiness certification and operation limitations be issued permitting me to operate the aircraft within the following geographical area for flight testing. Initial flights will determine engine reliability and flight control characteristics. A flight test plan has been developed using the guidance in AC 90-89 and is available for review. After Phase I flight test completion, I plan to operate the aircraft under VFR conditions only.

25-statute mile radius of Grayson County Airport Latitude, 33-43 N; Longitude, 096-40W Dallas-Ft. Worth Sectional (L13) My residential telephone number is (903) 555-1212.

My daytime business number is (214) 555-1212.

Early A. Builder

Early A. Builder Owner/Builder 13-2 9/30/2009 AC 20-27G Appendix 14 APPENDIX 14. SAMPLE FAA FORM 8610-2, AIRMAN CERTIFICATE AND/OR RATING APPLICATION 14-1