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If the idea of building your own airplane sounds fun, but a little daunting, Zenith hosts two-day workshops at its Missouri factory, where attendees pay to take part in the hands-on construction of the rudder tail section of an aircraft. Then they can truly fully customize it as they’re choosing the engine on the airplane by choosing the avionics, radios and GPS equipment, for instance.” They get to choose the design because there are quite a few different designs out there. People can build their own airplane and customize their needs. That’s one of the advantages and why the industry exists. “That said, every individual airplane becomes a one-off airplane. That part of the process isn’t really customized,” Sebastien Heintz said. “We design certain features like you would with any other product, like a car or boat: the actual wing, the position and location of the wing, the tail, etc. Plus, you get to pick out the engine, paint colors, upholstery and everything yourself, resulting in a customized plane. The kits can range around $20,000, and the engine and avionics typically cost an additional $20,000 each.Īltogether, the cost of a two-seater airplane compares to a luxury automobile or boat, but the experience of building it yourself is priceless. The company tries to put out one kit per working day, totaling about 250 per year. Zenith designs and manufactures aircraft kits, creating the individual parts to assemble the airframe-tail, rudder, cabin, etc.-leaving customers to purchase the engine and avionics. “There are more kit airplanes registered with the Federal Aviation Association (FAA) every year than there are factory built ones,” Sebastien Heintz said. Though highly specialized, the industry is bigger than one might expect. So, what’s an aircraft kit? Imagine those balsawood planes you might find at a hobby store, blow it up 200 times, replace the wood with aluminum and you can start to imagine what Zenith makes.
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Through Zenith, the younger Heintz not only extended the work of his father, but modernized it, moving the business over from pen-and-paper drafting and manual manufacturing, to a completely digital workflow, including the use of SOLIDWORKS. After attending business school, he founded Zenith Aircraft Company in Missouri in 1992. Sebastien Heintz grew up in the family business, developing a love for airplanes and all things flying. At the time, he wanted to own his own aircraft, but such a dream seemed out of reach- unless he built his own.Ĭhris Heintz went about designing his own two-seat, all-metal aircraft, which led to fellow flying aficionados commissioning designs and parts from him before he ultimately helped spawn an entire aircraft kit industry. The elder Heintz earned an engineering degree in the 1960s, which he applied to design work on the Concorde. Heintz’s father, Chris Heintz, inspired the creation of Zenith. We spoke to Zenith founder Sebastien Heintz to learn what it takes to create an airplane kit, including the CAD tools used to make one.
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These aren’t the sorts of kits you pick up from a hobby shop for a meticulously fun Sunday afternoon. Zenith Aircraft Company sells airplane kits. (Image courtesy of Zenith Aircraft Company.) The CH750 Cruzer from Zenith Aircraft Company.
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Not that I’d trust my piloting skills, but there is one company that might make it possible to make the flight from my tiny town to somewhere globally more relevant.
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This has led me to ask my wife if, someday, we could just buy a tiny plane that we can fly on our own. There are usually stopovers and other obstacles that make any flight out of town a weighty decision. Where I live, there is a small airport that can fly me to a handful of major cities on the West Coast, but it’s not an easy trip.