Amateur-built and experimental aircraft

142 Pages·2009·4.87 MB·English

PA ATSB TRANSPORT SAFETY REPORT
arm Aviation Research and Analysis Report – AR-2007-043 (1)
ta
1t Final
e
A: u
r
s-b
uu
rvil
et
y a
on
fd
ow e Amateur-built and experimental
x
np
ee
rr
s aim aircraft
ne
dn
bt
ua
ildl a
eir
rc
sr
oa
f Vft Part 1:
H
- r A survey of owners and builders of
e
g
i
s VH- registered non-factory aircraft
t
e
r
e
d
n
o
n
-
f
a
c
t
o
r
y
a
i
r
c
r
a
f
t
AR2007043(1).indd 1 18/06/09 11:46 AM

ATSB TRANSPORT SAFETY REPORT
Aviation Research and Analysis
AR-2007-043(1)
Final
Amateur-built and experimental aircraft
Part 1
A survey of owners and builders of
VH- registered non-factory aircraft

- i -
Published by: Australian Transport Safety Bureau
Postal address: PO Box 967, Civic Square ACT 2608
Office location: 62 Northbourne Ave, Canberra City, Australian Capital Territory, 2601
Telephone: [phone], from overseas [phone]
Accident and incident notification: 1800 011 034 (24 hours)
Facsimile: 02 6247 3117, from overseas [phone]
Email: [email protected]
Internet: www.atsb.gov.au
© Commonwealth of Australia 2009.
This work is copyright. In the interests of enhancing the value of the information contained in this
publication you may copy, download, display, print, reproduce and distribute this material in
unaltered form (retaining this notice). However, copyright in the material obtained from other
agencies, private individuals or organisations, belongs to those agencies, individuals or organisations.
Where you want to use their material you will need to contact them directly.
Subject to the provisions of the Copyright Act 1968, you must not make any other use of the material
in this publication unless you have the permission of the Australian Transport Safety Bureau.
Please direct requests for further information or authorisation to:
Commonwealth Copyright Administration, Copyright Law Branch
Attorney-General’s Department, Robert Garran Offices, National Circuit, Barton, ACT 2600
www.ag.gov.au/cca
ISBN and formal report title: see ‘Document retrieval information’ on page v.
- ii -
CONTENTS
THE AUSTRALIAN TRANSPORT SAFETY BUREAU ................................. vi 
EXECUTIVE SUMMARY .................................................................................. vii 
ABBREVIATIONS ................................................................................................ ix 
1  INTRODUCTION .......................................................................................... 1 
1.1  Background ........................................................................................... 1 
1.1.1  What are amateur-built and experimental aircraft? ................... 1 
1.1.2  Shifts in the ABE aviation industry ........................................... 5 
1.1.3  Previous research ....................................................................... 7 
1.2  Objectives ............................................................................................. 8 
1.3  Legislation for ABE aircraft ................................................................. 8 
1.4  Aircraft associations ........................................................................... 17 
1.5  Phases of ABE aircraft ownership ...................................................... 18 
1.6  Aims ................................................................................................... 20 
1.7  Scope .................................................................................................. 20 
2  METHODOLOGY ....................................................................................... 21 
2.1  Survey distribution and response ........................................................ 21 
2.1.1  Survey response rate ................................................................ 21 
2.2  Survey design ..................................................................................... 22 
2.2.1  Structure ................................................................................... 22 
2.2.2  Questions ................................................................................. 22 
2.3  Survey user testing .............................................................................. 24 
2.4  Survey analysis ................................................................................... 24 
2.4.1  General method ........................................................................ 24 
2.4.2  Aircraft analysis methods ........................................................ 24 
2.4.3  Statistics ................................................................................... 27 
3  RESULTS AND DISCUSSION ................................................................... 31 
3.1  Survey details ..................................................................................... 31 
3.2  Respondents ........................................................................................ 32 
3.2.1  Age ........................................................................................... 32 
3.2.2  Type of pilot licence ................................................................ 32 
3.2.3  Flying background ................................................................... 33 
3.2.4  Total pilot hours ....................................................................... 34 
3.2.5  Pilot hours in the last year ........................................................ 36 
- iii -
3.2.6  Type of flying performed in ABE aircraft ............................... 38 
3.3  Aircraft ............................................................................................... 38 
3.3.1  Aircraft types and models ........................................................ 38 
3.3.2  Aircraft components ................................................................ 42 
3.3.3  Operating certificate ................................................................ 51 
3.3.4  Aircraft age and owned time .................................................... 52 
3.4  Reason for purchase ............................................................................ 52 
3.5  Building .............................................................................................. 59 
3.5.1  Built and flown ABE ............................................................... 59 
3.5.2  Type of build process ............................................................... 60 
3.5.3  Build modifications.................................................................. 62 
3.5.4  Build challenges ....................................................................... 65 
3.5.5  Build resources ........................................................................ 70 
3.5.6  Flying activities during construction ....................................... 77 
3.6  Test flight ............................................................................................ 78 
3.6.2  Initial test flights ...................................................................... 83 
3.6.3  Post-test flight evaluation ........................................................ 85 
3.7  Aircraft building cost .......................................................................... 88 
3.8  Second-hand aircraft ........................................................................... 88 
3.9  Transition training .............................................................................. 90 
3.9.1  Access and usefulness .............................................................. 91 
3.9.2  Aircraft and training ................................................................. 92 
3.9.3  Effect of pilot type, operation type and flying activity ............ 93 
3.9.4  Aircraft performance and training ........................................... 96 
3.9.5  When transition training was not undertaken ........................ 100 
3.9.6  Bias and transition training .................................................... 101 
3.10  Maintenance ..................................................................................... 101 
3.10.1 Airframe maintenance ............................................................ 104 
3.10.2 Engine maintenance ............................................................... 105 
3.10.3 Avionics maintenance ............................................................ 106 
3.10.4 Maintenance comments ......................................................... 107 
4  CONCLUSIONS ......................................................................................... 109 
5  REFERENCES ............................................................................................ 111 
APPENDIX A:  SOURCES AND SUBMISSIONS ....................................... 117 
APPENDIX B:  SURVEY ............................................................................... 118 
APPENDIX C:  TABLES OF RESPONSES ................................................. 126 

- iv -
DOCUMENT RETRIEVAL INFORMATION
Report No. Publication date No. of pages ISBN
AR-2007-043 June 2009 139 978-1-921602-73-3
Publication title
Amateur-built and experimental aircraft. Part 1: A survey of owners and builders of VH- registered
non-factory aircraft
Author(s)
Stanton, D.R.
Taylor, R.P.
Prepared By Reference Number
Australian Transport Safety Bureau INFRA-08548
PO Box 967, Civic Square ACT 2608 Australia
www.atsb.gov.au
Acknowledgements
Thank you to the ABE owners who completed this survey
Mr Paul Halliday, Bureau of Infrastructure, Transport and Regional Economics
Mr Graham Malcolm, CEO Australian National Aviation Museum, Moorabbin
Mr Keith Meggs DFM, Aviation Historical Society of Australia
Mr John Hopton, Aviation Historical Society of Australia
Mr Roger Meyer, Civil Aviation Historical Society
Mr Brian Hunter, Sport Aircraft Association of Australia
Mr David Francis, Sport Aircraft Association of Australia
Ms Hirut Yigezu, Department of Infrastructure, Transport, Regional Development and Local
Government
Mr Rod Carter, Civil Aviation Safety Authority
Figure 6: Grumman F9F Panther replica aircraft courtesy of Robert Frola
Figure 27: A Glasair IIS-RG aircraft courtesy of Neville Murphy
Figure 30: Stipa Caproni courtesy of Falco Builders Newsletter
Figures 49, 50: Van’s kit aircraft courtesy of Van’s.
Abstract
Non-factory amateur-built and experimental (ABE) aircraft are a popular alternative to general
aviation aircraft. In Australia, there is little comprehensive data on these aircraft and what people do
when building or buying them second-hand. Key players in this part of aviation were consulted in
developing a survey to better understand these aircraft builders and owners. The survey was
distributed electronically and in hard copy to owners of VH-registered ABE aircraft, and about 50 per
cent of active ABE aircraft owners answered the survey. It focussed on choice of aircraft,
construction and modifications, test flights, transition training, and maintenance. It provides a
valuable reference point for aircraft operators, those considering ABE aircraft, aviation regulators,
and aircraft associations. In developing a more comprehensive understanding of this sector of
aviation, relevant parties are in a better position to plan, build and operate ABE aircraft in the future.

- v -
THE AUSTRALIAN TRANSPORT SAFETY BUREAU
The Australian Transport Safety Bureau (ATSB) is an operationally independent
multi-modal bureau within the Australian Government Department of Infrastructure,
Transport, Regional Development and Local Government. ATSB investigations are
independent of regulatory, operator or other external organisations.
The ATSB is responsible for investigating accidents and other transport safety
matters involving civil aviation, marine and rail operations in Australia that fall
within Commonwealth jurisdiction, as well as participating in overseas investigations
involving Australian registered aircraft and ships. A primary concern is the safety of
commercial transport, with particular regard to fare-paying passenger operations.
The ATSB performs its functions in accordance with the provisions of the Transport
Safety Investigation Act 2003 and Regulations and, where applicable, relevant
international agreements.
Purpose of safety investigations
The object of a safety investigation is to enhance safety. To reduce safety-related
risk, ATSB investigations determine and communicate the safety factors related to
the transport safety matter being investigated.
It is not the object of an investigation to determine blame or liability. However, an
investigation report must include factual material of sufficient weight to support the
analysis and findings. At all times the ATSB endeavours to balance the use of
material that could imply adverse comment with the need to properly explain what
happened, and why, in a fair and unbiased manner.
Developing safety action
Central to the ATSB’s investigation of transport safety matters is the early
identification of safety issues in the transport environment. The ATSB prefers to
encourage the relevant organisation(s) to proactively initiate safety action rather than
release formal recommendations. However, depending on the level of risk associated
with a safety issue and the extent of corrective action undertaken by the relevant
organisation, a recommendation may be issued either during or at the end of an
investigation.
The ATSB has decided that when safety recommendations are issued, they will focus
on clearly describing the safety issue of concern, rather than providing instructions or
opinions on the method of corrective action. As with equivalent overseas
organisations, the ATSB has no power to implement its recommendations. It is a
matter for the body to which an ATSB recommendation is directed (for example the
relevant regulator in consultation with industry) to assess the costs and benefits of
any particular means of addressing a safety issue.
About ATSB investigation reports: How investigation reports are organised and
definitions of terms used in ATSB reports, such as safety factor, contributing safety
factor and safety issue, are provided on the ATSB web site www.atsb.gov.au

- vi -
EXECUTIVE SUMMARY
In the last three decades, both in Australia and overseas, there has been significant
growth in the number of amateur-built and experimental (ABE) aircraft. In general,
ABE aircraft refer to aircraft that are built for personal use from an original design,
established plans or kit, and which are not built in a factory. There are a wide variety
of ABE aircraft from single to twin-engine, piston to jet-powered, and single-seat up
to six-seat aircraft.
While these aircraft continue to increase in popularity, there has been little formal
study of them in Australia and worldwide. Operational and demographic data on
ABE aircraft are largely incomplete in comparison to data held for other types of
aircraft.
This report examines non-factory amateur-built and experimental aircraft in
Australia. It looks at the ABE community, including pilots and their aircraft,
regulatory changes, and growth and development of aircraft associations over time.
Data for this report was gathered using a survey sent to owners and builders of flying
VH-registered ABE aircraft.
This survey focused on the choice of aircraft, construction, and modifications, test
flights, transition training, and maintenance. The intent of the survey was to gain a
picture of ABE aircraft activities in Australia, and in doing so increase awareness of
issues affecting the purchase, construction, and continued safe operation of these
aircraft among builders, owners and pilots, manufacturers and government.
Key results from this survey are:
• ABE owners were primarily of retirement age, and private pilots;
• on average, thirty per cent of their total flying hours were flown in ABE aircraft;
• on average, ABE aircraft accumulated forty-two airframe hours in the previous
year;
• build challenge, personal satisfaction, aircraft performance, price, operational
costs, and ability to perform maintenance were important reasons for purchasing
an ABE aircraft. Ability to customise was less important as a reason for purchase;
• thirty-three percent of builders made major modifications during the build
process;
• seventy per cent of ABE owners undertook transition training, and this was more
likely among private pilots, and those with fewer total hours;
• for eighty-five percent of respondents, one person performed all maintenance on
the aircraft; and,
• automotive engines and avionics were associated with the greatest build
challenge.
This report has presented an interesting picture of VH- registered ABE aviation in
Australia. While many of these facts have been known anecdotally, this report places
greater specificity on different aspects of ABE aircraft building and operation. It
provides a valuable reference point for aircraft operators, those considering ABE
aircraft, aviation regulators, and aircraft associations. In developing a better
understanding of this sector of aviation, relevant parties are in a better position to
plan, build, and operate ABE aircraft into the future.
- vii -
- viii -