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Builders Page for the Zenith STOL CH801

Following are the latest STOL CH 801 photo assembly guides. The following is published to supplement (and not replace) the drawings. If a discrepancy arises between these photo assembly guides and the Drawings, the Drawings always take precedence. These documents are presented in the Adobe Acrobat file format for online viewing and easy printing. The photos are presented in low-resolution for quicker downloads.

NOTICE: These documents contain copyrighted information and are NOT FOR DUPLICATION OR DISTRIBUTION.

Zenith CH 801 Assembly Manuals
Documents Description Revision Last Update
801-assembly Basic view of the STOL CH 801 airframe assembly sketch 7/12/00
801-assembly1 Enhanced views of the STOL CH 801 airframe assembly sketch 12/28/01
RUDDER TAIL SECTION - KIT ASSEMBLY
Documents Description Revision Last Update
introduction Introduction to building – 18 pages 10/02 11/6/02
CS Construction Standards Draft 3/11
8XR-1 Rudder Exploded View Parts 8R1-1 to 8R3-4 dwg 3/1/02 8/26/02
8RU-01 1 of 3: Rudder Assembly Drawing 1 – internal assembly dwg 2/25/02 8/26/02
8RU-02 2 of 3: Rudder Assembly Drawing 2 – installing the skins dwg 2/25/02 8/26/02
8RU-03 3 of 3: Rudder Assembly Drawing 3 – tail light & rudder hinge dwg 2/25/02 8/26/02
rudder0 Title Page / Table of Contents 2/03 2/20/03
rudder1 1 of 5: Building the Sub-Assemblies: Spar and Skeleton 3.0 8/02 8/26/02
rudder2 2 of 5: Building the Sub-Assemblies: Spar and Skeleton 3.0 2/03 2/20/03
rudder3 3 of 5: Installing the Rudder Skins 3.0 8/02 8/26/02
rudder4 4 of 5: Installing the Rudder Skins 3.0 8/02 8/26/02
rudder5 5 of 5: Installing the Rudder Fairings 3.0 8/02 8/26/02
HORIZONTAL TAIL SECTION - KIT ASSEMBLY
Documents Description Revision Last Update
tail part list Horizontal Tail Part Number List 5/18/04 5/18/04
8XH-1 Horizontal Tail – Exploded View (1 of 3) dwg 5/14/14 5/04
8XH-2 Horizontal Tail – Exploded View (2 of 3) dwg 5/14/14 5/04
8HA-1 Horizontal Tail – Skeleton Layout (3 of 3) dwg 5/14/14 5/04
elev1 ELEVATOR SKELETON ASSEMBLY 4.1 6/18/04
elev2 POSITIONING THE ELEVATOR SKINS 4.1 6/18/04
elev3 INSTALLING THE ELEVATOR HORN AND HINGE PLATES 4.0 05/14/04
elev4 ELEVATOR TRIM TAB 4.0 05/14/04
horizt1 HORIZONTAL TAIL SKELETON ASSEMBLY 4.1 06/18/04
horizt2 INSTALLING THE HORIZONTAL TAIL SKINS 4.0 05/14/04
horizt3 FITTING THE ELEVATOR HINGES 4.0 05/14/04
horizt4 INSTALLING THE FIBERGLASS TIPS 4.0 05/14/04
LEADING-EDGE WING SLATS SECTION - KIT ASSEMBLY
Documents Description Revision Last Update
8XS-1 Slats Assembly – Exploded View Parts 8S1-1 to 8S2-1 dwg 3/1/02 3/1/02
slats1of3 Introduction / Parts List INSTALLING THE RIBS 3.1 12/02
slats2of3 POSITIONING THE SKIN 3.1 12/02
slats3of3 POSITIONING AND INSTALLATION OF THE SLATS TO THE WING 3.1 12/02
FLAPERONS SECTION - KIT ASSEMBLY
Documents Description Revision Last Update
8XA-1 Flaperons Assembly – Exploded View dwg 12/02 12/02
flaperons1 REAR SKINS AND NOSE RIBS ASSEMBLY 3.0 9/02
flaperon2of3 INSTALLING THE LEADING EDGE SKIN AND THE SPLICE PLATES 3.0 5/5/99
flaperon3of3a 1 of 2: POSITIONING THE FLAPERON TO THE WING AND FUSELAGE 4.0 9/27/00
flaperon3of3b 2 of 2: POSITIONING THE FLAPERON TO THE WING AND FUSELAGE 4.0 9/27/00
fr3-6 Flaperon Control Horn 8A2-5 dwg 9/19/00
WING SECTIONS - KIT ASSEMBLY
Documents Description Revision Last Update
8XW-1 Wing Assembly – Exploded View Illustrated Parts List dwg 01/02/02
8XW-2 Wing Assembly – Exploded View Wings Struts / Fuel Tank dwg 01/02/02
wings-section1 Parts List FLAPERON BRACKET AND REAR RIB SUB ASSEMBLY 3.0 8/12/99
wings-section2 SLAT BRACKET AND NOSE RIB SUB ASSEMBLY 3.0 8/12/99
wings-section REAR WING SPAR SUB ASSEMBLY 3.0 8/16/99
wings-section4 MOUNTING RIBS TO MAIN SPAR 3.0 8/16/99
wings-section5 INSTALLING THE REAR SPAR 3.0 8/16/99
wings-section6 INSTALLING BOTTOM REAR WING SKIN 3.0 8/18/99
wings-section7 INSTALLING THE BOTTOM SECTION OF THE LEADING EDGE SKIN 3.0 8/18/99
wings-section8 INSTALLING THE FORWARD STRUT ATTACH DOUBLER 3.0 8/18/99
wings-section9 FITTING THE REAR SKIN 3.0 8/18/99
wings-section10 INSTALLING THE TOP PORTION OF THE LEADING EDGE SKIN 3.0 8/18/99
wings-section11 INSTALLING THE FLAPERON AND SLAT BRACKETS 3.0 8/18/99
wings-section12 TRAILING EDGE INSTALLATION 3.0 8/18/99
8-wt FUEL TANK INSTALLATION DRAWINGS – 9 Pages 3.0 (8/02) 8/14/02
wings-section13 FUEL TANKS INSTALLATION 3.0 8/18/99
wings-section14 INSTALLING THE INBOARD WING TIP 3.0 8/18/99
wings-section15 FLAP ATTACH STIFFENER 3.0 8/18/99
FUSELAGE ASSEMBLIES
Documents Description Revision Last Update
8XF-1 Fuselage Exploded View (rear) Parts 8F1-1 to 8F5-11 dwg 12/02
8XF-2 Fuselage Exploded View (fwd) Parts 8F7-1 to 8F8-7 dwg 01/16/02
8XF-3 Fuselage Exploded View (cabin) Parts 8F9-SA to 8F11-16 dwg 9/14/01
8XF-4 Fuselage Exploded View (cabin) Parts 8F14-1 to 8F18-1 dwg 12/02
8XF-5 Fuselage Exploded View (cabin) Parts 8F19-2 – 8F22-9 (doors & seats) dwg 12/02
fuselage-view Overview of the full fuselage assembly with gear sketch 7/12/00
fuselage Overview of the full fuselage assembly (drawing) sketch 5/00
F5-3Z Top Channel "Zee" Reinforcement Dated 10/2001 10/15/01
FINAL ASSEMBLY
Documents Description Revision Last Update
top-view Top View of Aircraft Assembly dwg 11/30/01
8XC-1 Control System: Exploded View Parts 8C1-1 to 8C6-9 dwg 12/02
8CX-2 Control System: Exploded View Parts 8C8-1A – 8C9-5 dwg 01/25/02
8XL-1 Landing Gear Exploded View: Parts 8L1-1 to 8L2-4 dwg 12/02
8LS-1 Drawing: Main Landing Gear Spring Assembly – drawing. dwg 1/15/01
gear-s1 1 of 3 Nose Gear to Fuselage 2.0 2/14/03 6/03
gear-s2 2 of 3 Nose Gear Bungee 2.0 2/14/03 6/03
Nosewheel Bungee Installation Tool allows you to install or replace nose gear bungee easily in minutes.
gear-s3 3 of 3 Main Gear Spring 2.0 2/14/03 6/03
final-assy-s4-a 1 of 3 Assembly of the Cabin Doors 3.2 11/03
final-assy-s4-b 2 of 3 Assembly of the Cabin Doors 3.2 11/03
final-assy-s4-c 3 of 3 Door Stop / Opening Latch 3.2 11/03
final-assy-s5 Installing the Fin to the Fuselage / Stabilizer 3.0 5/5/00
AIRCRAFT FINISHING
Documents Description Revision Last Update
8VV0 Slat Position Detail dwg 12/22/00
8SO-1 Slat Position Template dwg 4/16/01
front-seat Assembly of the Front Seat draft 11/10/00
windows Installation of the Windows & Windshield 3.1 8/22/00
Web link LP Aero Plastics' online documentation on handling drilling trimming and cleaning the acrylic windshield.
finish1of3-stab-attach Installing the horizontal tail to the fuselage draft 9/15/00
finish2of3-rudder-attach Installing the rudder to the fuselage draft 9/15/00
finish3of3-wings-attach Installing the wings to the fuselage draft 9/19/00
brake-lines Installing brake lines 1.0 2/12/02
LYCOMING 0-360 Engine Installation
Documents Description Revision Last Update
thrust-line Lycoming Thrust Line Position dwg 8/26/02 8/26/02
cowl-a1 Lycoming O-360 – Section A1 – Installation of the engine cowl 1.0 01/10/02
baffles-1a Lycoming O-360 – Section 1a – Installation of the engine baffles 1.0 11/30/01
baffles-1b Lycoming O-360 – Section 1b – Installation of the engine baffles 1.0 11/30/01
oil-cooler-2 Lycoming O-360 – Section 2 – Installation of the Oil Cooler 1.0 11/30/01
fuel lines-3 Lycoming O-360 – Section 3 – Installation of the Fuel Lines 1.0 11/30/01
carb-heat-4 Lycoming O-360 – Section 4 – Installation of the Carb Heat Box 1.0 11/30/01
mixture-ctrl-5a Lycoming O-360 – Section 5a – Installation of the Mixture Control Cable 1.0 11/30/01
mixture-ctrl-5b Lycoming O-360 – Section 5b – Installation of the Mixture Control Cable 1.0 11/30/01
muffler-6 Lycoming O-360 – Section 6 – Installation of the Muffler 1.0 11/30/01
oil-pressure-7 Lycoming O-360 – Section 7 – Installation of the Oil Pressure Sender 1.0 11/30/01
spinner-9 Lycoming O-360 – Section 9 – Installation of the Propeller Spinner 1.0 1/19/04
OTHER
Documents Description Revision Last Update
parts-list Parts List – Complete kit Indexed by Part Number (14 pages) Part List rev. 12/20/02 12/02
panel Instrument panel blank dwg 2/27/02
manual updates Assembly Manuals Update (32 pages) text 12/20/02
VCI-373 Cortec 373 Corrosion Protection brochure
Material Safety Data Sheet brochure 10/2003
pneu-riveter Using the pneumatic rivet puller 12/18/01
801-w&b STOL CH 801 Weight & Balance Worksheet: Form FWB-801 6/25/02 6/25/02
801-cg STOL CH 801 Center of Gravity Limits: Form FCG-801 8/2002 8/6/02
8XE-1 Fuel System (standard firewall mounted gascolator) dwg 10/18/01
8XE-2 Fuel System (auxiliary wing tanks) dwg 10/18/01
8XE-3 Fuel System (standard under cabin mounted gascolator) dwg 10/18/01
8FE-1 Fuel Line Trim Around Door dwg 2/13/01
8FE-1.1 Fuel Line Routing Around Door – standard fuel system. dwg 2/13/01
8FE-2 Fuel Line Trim Around Door – dual wing tanks dwg 2/13/01
8FE-2.1 Fuel Line Routing Around Door – dual wing tanks dwg 2/13/01
flap-circuit-fig1-2 Electric Flap Circuit Drawing dwg 3/3/00
8ZV-01 Pitot Tube Airspeed Markings and Wing Tie-Down Rings dwg 6/29/01
8ZZ-1 Rear Tunnel Assembly and Center Seat Belt dwg 12/15/02 12/15/02
8CN-01 Elevator / Rudder Control Cables dwg 8/16/02 8/02
8CN-02 Flaperon & Elevator Control System (hardware). Two Pages dwg 12/4/00
8CN-3.1 Control Deflections: Flaperon Elevator and Rudder dwg 09/22/04
8CN-3.2 Elevator and Flaperon Deflection Templates dwg 9/15/00
8ZE-1 Fuel Pump Assembly and Air Box Location dwg 11/19/01
wing-dihedral Setting the Wing Dihedral Drawing dwg 12/20/02 12/02
strut fairing Installing the Wing Strut Fairing Option

 
 

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