How to Get Started Building the EMG-6 Updated May 20, 2017
1 Follow the Project
Progress Blog (Shop Notes)
The “Shop Notes” blog follows the progress as we design, build, and fly the EMG-6. This progress blog contains most of the up-to-date information about what is happening within the company and the project.
If you do nothing else make sure that you follow the project. Subscribe to the YouTube channel. Subscribe to the website and blog to get automatic updates of the most recent information.
YouTube Channel
Link to and subscribe to the YouTube channel . The YouTube channel contains multiple videos on designing, building, and flying the EMG-6.
Subscribe
Remember to subscribe to the website and blog. After entering your email address you will receive a confirmation email which you must verify in order to receive email updates.
2 Join
Join The growing list of EMG-6 builders
By becoming a member you have access to all of the construction drawings that are currently available. Although all of the drawings on the builders database are currently open source, we will work directly with each of the builders to supply technical support and parts. In order to purchase parts for the EMG-6 you are required to have a builder serial number. The $500 is a very reasonable fee. It helps subsidize the enormous amount of effort put into the design and drawings that we post on the builders database. By becoming a platinum member the $500 fee for registration is waived.
Platinum Level Member
Platinum Level Pricing $5200 Deposit for Serial Number and a membership. 3% cash discount available. 100% of the deposit applies towards the purchase of parts or kit. This makes the serial number and membership free. Serial number is nonrefundable. Serial number is Transferable back to the Gold level with a $4500 deposit return to customer. Platinum level members have priority access to parts and customer support. This is the most cost-effective membership for those that are 100% sure that they are going to build and complete an aircraft.
Gold Level Member
Gold Level Pricing $500 for Serial Number and the membership. (S/N priority) Serial Number is nonrefundable. S/N is Transferable to Platinum Level registration for $4500 using a 3% cash discount available. This membership allows for the average builder to start building the project. this gold level membership allows for entry level cost with minimal risk while still building a substantial portion of the aircraft. It also allows the membership fee to be applied towards parts and materials should the builder elect to upgrade to the Platinum level.
Silver Level Member
The Silver Level membership is a new option which will facilitate a builder’s who would like to begin the project with a minimal investment. I remember when I was young and became interested in building airplanes. I just didn’t have the funds available, or even the facilities available, to make a commitment to building an airplane. If you fit into this category, we have an option here that will provide you with an opportunity to start building this wonderful airplane with an extremely small investment. the $500 serial number and membership fee can be paid over time with a $50 per month credit card charge.*
3 Start Building
Fuselage Frame
Our recommendation is that you begin the project starting with the fuselage frame. The fuselage frame is by far the most complex part of the aircraft. This is also the most labor-intensive and is one of the areas where an individual builder can save a substantial amount of cost when building the aircraft. Building the fuselage frame yourself is not particularly difficult, but will require the ability to Oxyacetylene weld or Tig weld.(recommended). We’ve gone to great lengths to provide a system by which welding the fuselage frame becomes exceptionally easy and accurate by providing welding jigs that can be purchased, rented, or manufactured locally by a cabinet shop using our downloadable DXF files and cutting the fixturing templates from plywood.
Landing Gear
The landing gear is one of those low-cost segments that can be built at any point in time. But normally this would become a task to be completed efficiently after the fuselage frame has been completed.The landing gear on the airplane allows the builder to configure the aircraft in any one of a number of ways. Aircraft can be made with a Mono wheel which provides for low drag configuration more suited for a glider type of operation, a nose wheel version which is better suited optimal ground handling. Or a tail wheel version which provides for a compromise which still provides for good ground handling characteristics with a reduced increase in weight, and complexity. The aircraft can also be configured as a glider with only a simple skid. additional options include training wheels which can be used to assist moving the Mono wheel version of the aircraft during ground handling as well as providing ground stability while the pilot is learning to fly the Mono wheel version of the aircraft.Fuselage Boom
The normal sequence for building the fuselage boom is after the completion of the fuselage frame, and before or after, the landing gear has been installed. In addition, the fuselage boom will need to be manufactured prior to beginning the assembly of the Empanage (tail assembly). The fuselage boom assembly is a sheet metal CNC manufactured and pop riveted together construction. Once this assembly has been built, it simply bolts to the fuselage frame using 4 AN bolts. Average build time for the fuselage boom can take as little as 10 hours or as much is 30 hours for the 1st time builder.Vertical Stabilizer
The vertical stabilizer cannot be assembled until after the fuselage boom has been completed. The vertical stabilizer is a very simple low-cost part of the assembly. build time can be as little as 2 hours. In addition, the tail skid/wheel is part of the vertical stabilizer assembly and if you’re going to be moving the aircraft around after putting it up on the landing gear it would be a good idea to complete the vertical stabilizer assembly.Rudder Assembly
The rudder assembly can be completed at any point in time, however it cannot be attached to the rest of the aircraft until after the completion of the fuselage boom and vertical stabilizer.The ultralight version of the aircraft (UL) incorporates the use of a Dacron sailcloth type of construction.
The low drag ( LD) version of the aircraft incorporates the use of Poly Fiber type covering system (Dope and fabric).
Horizontal Stabilizer
Like the rudder assembly the horizontal stabilizer and elevator can be completed at any point in time, however they cannot be attached to the rest the aircraft until after completion of the fuselage boom and vertical stabilizer.
The ultralight version of the aircraft (UL) incorporates the use of a Dacron sailcloth type of construction.
The low drag ( LD) version of the aircraft incorporates the use of Poly Fiber type covering system (Dope and fabric).
Like the rudder assembly the horizontal stabilizer and elevator can be completed at any point in time, however they cannot be attached to the rest the aircraft until after completion of the fuselage boom and vertical stabilizer.
Wings
The ultralight version of the aircraft (UL) incorporates the use of a Dacron sailcloth type of construction.The low drag ( LD) version of the aircraft incorporates the use of Poly Fiber type covering system (Dope and fabric).
The construction of the wings are fairly simple, but because of their size they are normally reserved for one of the last things that we will assemble on the aircraft.
Ailerons
Like the other flight control systems the ailerons can be manufactured at any point in time. However, they cannot be attached to the rest of the aircraft until after the wings have been completed.The ultralight version of the aircraft (UL) incorporates the use of a Dacron sailcloth type of construction.
The low drag ( LD) version of the aircraft incorporates the use of Poly Fiber type covering system (Dope and fabric).
Power Plant Package
The aircraft has been designed so that the powerplant packages that we are developing are modular in nature. The choice of the power plant will dictate some of the finishing techniques, but the basic airframe remains the same. Generally speaking the fuselage frame assembly will need to be completed before the power plant package can begin to be installed. Additionally, the cost of the power plant package can be substantial and as a result this cost can be deferred until after the rest of the airplane nears completion.Components
There are literally hundreds of components that could be built at any point in time. If you are limited on and/or budget this might be a great place to get started
NOTES:
1. Limited Budget
We continue to develop the plans for the aircraft with the intent of providing drawings for as many of the components as we possibly can which the individual builder may wish to build themselves. In addition, we will have all of the parts available for purchase should the individual builder not be able to build the specific component because of the lack of tools, equipment, or know how. There are many components on the aircraft that are simple and small and no matter what your budget is you can start with these small components putting your own labor into the manufacturing process saving $. We are currently working on a database that will categorize the parts by size, cost, and building difficulty. Even if you only have access to an EAA chapter shop or a friends shop or a school shop there is no reason that you won’t be able to build a substantial portion of the aircraft with limited facilities. And even a limited budget will not prevent you from scrounging and building a substantial portion of the aircraft.
2. Drawings and Builder Videos
We continue to work on the development of the builders videos and our intention is to have written drawings and building instructions as well as a corresponding video for every single component on the aircraft. As you might imagine, making the builder videos is quite time-consuming and may take some time to complete every one of the videos. As it stands right now we are ahead of most of the builders with the videos and construction drawings.
3. Foreign Builders
We recognize that there are a lot of builders who are interested in the aircraft but live far away from our facility or in another country. It is our intent, as we go along, to have enough drawings in place that the majority of the aircraft can be built obtaining supplies from their country or state. This should make a substantial difference when it comes to shipping the large and heavy components. In addition, we have begun to work with partners who are interested in supplying components pre-manufactured in their area or their part of their country.
4. Complete kits
We also recognize that there are many of you who are interested in building a fast build kit from a complete kit with a minimal amount of construction time. We assure you that we are working towards this end goal of being able to supply complete kits. As it stands right now our primary focus is on supplying components to the existing builders. We continue to build inventory and we continue to work on the drawings and assembly instructions. However, we will not be releasing complete kits until we have everything ready to go and done right.
5. Supply and Demand
Most of our efforts within the development and supply of parts to our existing customers is centered around them and their needs. We work one-on-one with each of our customers to try and anticipate their needs and have parts available when they need them.
6. Reality
It’s very important that we are honest and forthright about where we are in the total scheme of things. Everyone that has begun to build the airplane understands that the project is still in the development stages. There is much manufacturing capability that we still need to develop and fund. And there is still a significant amount of flight test program that still needs to be completed. We have completed a great deal of the structural testing, design work, and flight testing to the extent that we are comfortable proceeding into the manufacturing environment with the design as we have built it to date. Suffice it to say, that even if we are able to determine that a portion of the structure is not up to snuff during the remaining testing phase, there is virtually no portion of the design that cannot be modified to accommodate any design changes. For example increasing the tube wall thickness in an area. This design testing for both structural and flight may continue for several years. Our anticipation is that we will conduct enough testing to make this aircraft one of the best and safest aircraft on the market.
7.Research and Development
Probably the biggest area of change that will come about on the aircraft in the following years will be in the area of the power plant development. We have approached the design of the aircraft with the anticipation that any of the power plants that we use in the early years will become obsolete fairly quickly. We have been watching closely the development of batteries, controllers, motors and cannot help but realize the coming changes within the industry. We anticipate that this will be one of the greatest changes in aviation history that we will all ever witness. In the coming years as we focus on the airframe development we anticipate that the number of options available for power plants will continue to proliferate the industry. Many of the early builders of the airframe are anticipating that they will have an airframe built and ready for accepting one of these options as they become available. Additionally we are approaching the development of a perfect reciprocating engine power plant package that will be able to be used in the interim should the development of the electric power plant systems be delayed for some reason or for those that are very interested in the efficient platform but are not yet convinced that electric power is within their future.
8. Be Part of the Team
If you are a builder of the EMG-6 you may find that you have some expertise in a certain area that may help other builders. We are interested in individuals that are part of the team contacting us if they have an interest in manufacturing certain components,or sub assemblies.
Comments 7
Hi Brian, what brand is the little red TIG unit? Great Article on Metal Brake
That is a MT-125 Tig Welder. For more information visit weld.com
Thank you for the information. I would like to call you regarding some information on the Gold Membership. I have been interested in building an ultralight You and Brian have been instrumental in the development of the what I see is a very safe and well thought out airframe.
What would be the best time to call ?
Hi Herbert-
It’s always best to set up a phone appointment, since we are on the go most of the time.
This week any time between 12pm and 4pm PST works.
If you can call right at 12 pm – we can include Brian? That would be best.
My cell phone number is 530-567-5141.
If you call the office line Peggy normally answers and would just take a message.
You can by pass this by just using my cell phone number.
Thanks, I am off for a week so that makes it convenient. 1 to 4 pm NOR-CAL Time. I will try to call Tuesday ( tomorrow).
Herb Smit
Hi. I am Iván, from Puerto Rico, a former hang glider pilot, and just wanted to say that your EMG-6 caught my entire attention. I understand that your EMG-6 kits is not available in this state of your project, so I will be just pending for the moment when it does.
My main interest is soaring, although I also would appreciate the convinience of the electric motor. I am wondering about the cappacities that your E.M. would have for taking off without any other mean to assist such launch. As for the pure glider performance, I am wondering about the efficiency it has during thermal circling and ridge soaring floatability.
I am about to start paragliding instruction, but will consider your glider as an option in the not so far future. I just want to ad that your you tube videos and your website are very encouraging and inspirational. Your dedication and your talentos are amazing!!!
As for now, thanks for having me here.
Sincerely,
Iván G. Martínez,
San Juan, Puerto Rico 00921 (U.S.A.).
Hi Ivan,
Thank you for your kind comments. It’s good to hear you are enjoying the videos and the website.
Currently we have 15 registered aircraft builders these customer airplanes are in different stages of completion.
We are providing these current builders with “sub” kits and supporting them as they build.
They are aware that components are still being developed, however, we have been keeping up with them fairly well as they build their aircraft.
The best source for the pure glider performance is the website. In the next week we’ll try to post this type of information so it is easily available.