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Table Of Contents

From Newsletter #34

We were hoping there wouldn't be any, but we were wrong.

  1. Check your construction manuals to make sure there are no missing pages, specifically Chap. 10, p.5. We think several manuals are missing this page.
  2. Wicks advises that what we show as Styrofoam is really Polystyrene, and listed as such in their catalog. Aircraft Spruce lists it as Styrofoam.
  3. Corrections to the Bill of Materials, per Bud Meyers at Wicks to avoid ordering problems: Chap. 2, page 1.
    • Change l"x6"xl0" 100 PVC to 6 Lb. Clark
    • Change 3/4"x4"x48" 6 Lb. Clark to 4.5 Lb. Clark
    • Change .7"x2"x18" spruce to .7"x2"x24"
    • Change l"xl"xl" spruce to l"xl"x12" spruce
    • Change 1/4" birch plywood to 6mm through out plans Chap. 2, page 2.
    • Screws - add (2) AN526-832R14
    • Washers - change (8) AN960-10 to (10)
    • Washers - change (32) AN960-l0L to (62)
    • Nuts - change (2) AN364-832 to (2) MS20364-832
    • Nuts - change (1) AN365-524 to (1) MS20365-524
    • Nuts - delete (2) AN526-832-14 _
    • Nutplates - change (28) MS21047-3 to (31) MS21047-3
    • Rivets - change BSP-43 to BSPQ-43
    • Bar Stock - delete (1) 1/8"xl.5"x6" 2024T3
    • Bar Stock - change (4) 7/16"x36" CRS to (2) 7/16"x72"
    • Sheet Stock - change 1/4"x4"x9" 2024T3 to 1/4"x6"x8"
    • Tubing - change 1/4"OD x .035W to 1/4"OD x .032W
    • Tubing - add (1) pc. 5/8"0D x .058"x24" 4130 stl.
    • Tubing - add (2) pcs. 3/4"OD x.058"x48" 6061T6 Alum.
    • Misc. - change (2) CWB199-152 to (1) set CWB199-152
    • Misc. - change (2) sq. ft. 1/8" to (4) sq. ft. 1/16" 970-F
    • Misc. - change (2) lengths 303-6 to (2) pcs. (specify length)
    • Misc. - change (2) FC100-02 to (2) FC100-002
    • Chap. 5, Foam - change 6 Lb. Clark to 4.5 Lb. Clark
    • Chap. 5, Foam - change lx24x24 urethane to lx24x48.
    • Chap. 5, Wood - change .7x2x18 to .7x2x24
    • Chap. 6, Foam - change 6 Lb. Clark to 4.5 Lb. Clark
    • Chap. 8, Metal - change l/8" x l" xl/8" to l/8" x 1" x 12" Al angle
    • Chap. 8, Misc. - change MS200001-P6 to MS20001-P6
    • Chap. 9, Hardware - change MK-100 to MK100
    • Chap. 9, Misc. - change (2) CWB199-152 to (1) set
    • Chap. 10, Foam - change R100 PVC to 6 Lb. Clark
    • Chap. 11, Hardware - change BSP43 to BSP-43
    • Chap. 2, page 4.
    • Chap. 13, Hardware - change AN526-832-14 nuts to AN526-832R14 screws
    • Chap. 13, Metal - change 1/4 0D x.035W to .032W
    • Chap. 19, Metal - change (4) 7/16" OD x36" to (2) 72"
    • Chap. 21. Misc. - after B2Dx62 add x 12V
    • Chap. 21. Misc. - change (2) 303-6 to (2) pcs. 303-6
  4. Chap. 3, page 1 - change 18" bandsaw to 14" bandsaw
  5. Chap. 4, p.3, Step 5 - add "Install alum. hard points per drwg. M-7 before glassing.
  6. Chap. 4, p.3, Step 5 - Upper longeron doubler is shown incorrectly on M-7. Doubler is 3/4" wide, not 1" wide. Reduce width of hole through firewall to 1-5/8"
  7. Chap. 14, p.2, Step 3, end of 2nd par. - change LWA2 to LWAl
  8. Chap. 19, p.8, Step 10 - change 3/8" rod to 7/16" rod
  9. Chap. 19, p.,l4, Sections I-I, H-H, J-J - change A11 to A13
  10. Chap. 19, p.17, A13 - change 3/8" rod to 7/16" rod
  11. Chap. 19, p. 17, CS151 - change approx. 30" to 34"
  12. Drwg. M-15 - change join to page M-16 to M-9

Some things may have been lost in the translation, I believe the above is correct but please use at your own risk!

Judd Stewart

From Newsletter #35

  1. Drwg. M-6: Change 3.6 to 3.3.
  2. Drwg. M-17, template F: Top of template F is not shown at the correct angle. Change it to agree with top of template G on Drwg. M-18.
  3. Chap. 7, p. 5 Step 5: Delete para. 4 starting with "Now...".
  4. Chap. 12, p. 1, Step 2, Para. 2: Add this note, "Change top of template F on Drwg. M-17 to agree with top of template G on Drwg. M-18.
  5. Chap.12, p. 2, Step 3, Para. 2: Change "open up the 1/4" holes into the doublers" to "open up the 3/16" holes...".
  6. Chap. 14, p. 3, Step 8: After "clean and sand them..." add "install them with flox as shown in sections BB and CC".

From Newsletter #36

  1. Drwg. M-4: Change the 3.3" dimension on F-28 to 4.0", and curve the top edge of F-28 gently from the center to each side. This will make the top of the nose more rounded (less flat) and enhance its appearance. If F-28 is already installed, epoxy a strip of 1/4" foam on the top and glass each side with 1 layer of BID.
  2. Drwg. M-6: Change 7.4" to 7.2".
  3. Chap. 2, p. 2, Metal: For 1/8" and 1/4" bar stock note T4 also OK.
  4. Chap. 8, p. 1, Fig. 1: For the head rest bottom piece, change 3" to 3-3/8" and change 7" to 7-3/4" and show the ends beveled to match the sides.
  5. Chap. 9, p. 2, Step 2: Add note to trim 2-1/2" from each leg of the main gear strut and then trim the end at 13 deg. (leading edge longest) to avoid fuselage sitting high in the rear.
  6. Chap. 9, p. 2, Step 2, and Fig. 7: Keith Spreuer suggests that that 13 strips of UND should be sufficient.
  7. Chap. 13, p. 9, Fig. 41: Change the thread size on Rosenhan Cylinder from 1/4" x 20 to 1/4" x 28.

From Newsletter #37

Thanks to those of you who discover them and call them in.

  1. Chap. 2, p. 1, Equipment, Tools & Supplies: Add (1) 3/4" counterbore (needed in Chap. 8)
  2. Chap. 2, p. 2 & 3. Change (16) MS24694 S58 screws to (16) MS24694 S60 screws.
  3. Chap. 2, p. 2 & 3. Add (2) AN525-416RI8 and (2) AN525416R14 screws (needed in Chap. 8).
  4. Chap. 2. p. 2 & 4. Add (2) AN960-516 washers (needed in Chap. 13).
  5. Chap. 8, p. 1, Step 1, last para. You may wait until you have Chap. 18 to install the hinges.
  6. Chap. 9, p. 6, Fig. 30. Change .049 wall to .063 wall.
  7. Chap. 14, p. 3, Fig. 14. Chang 3.5 to 5.25 (both sides).
  8. Chap. 14, p. 7, lower left hand corner. Change 33.21 to 33.58 (thank you Larry Sligar).
  9. Chap. 19, p. 9, Step II, Para. 2. Change layup #11 to layup #12.
  10. Chap. 19, p. 18, Para. 1. Change p. 19-8 to p. 19-7.
  11. Chap. 20. p. 1, Step 1, 2nd line. Change Chap. 23 to Chap. 3
  12. Chap. 21, p. 6, Fig. I 1. Change 1.8 to 3.5. 1.4 to 3.1 . and 1.35 to 2.5. Also 6.0 to 4.0, 7.0 to 5.0, and 7.2 to 6.2.
  13. M-10. Change join to M-17 to join to M-19.

From Newsletter #38

Thanks to those of you who discover them and call them in.

  1. Chap. 5, p.3, Step 3: Change 2-1/2" tape to 2" tape.
  2. Chap. 7, p.4, Fig. 21: Change 20-1/2" to 19", & 22 to 20-1/2
  3. Chap. 9, p.6. Para.2 & Fig. 31: Change #30 holes to #30 dimples (not through).
  4. Chap. 10, p.6. Para. 4: Delete "Fig. 43' & substitute Fig. 36 in Chap. 19, p.7.
  5. Chap. 10, p.7, Para. 1: Change Fig. 46 to Fig. 43.
  6. Chap. 11, p.2: Add this note: Dimensions are correct, but drawing is not. Micro joint does not align with elevator.
  7. Chap. 13, p.4. Step 3, Para. 2: Add: Open the pivot hole for MKNG-6 to 5/16" I.D.
  8. Chap. 20, p.1, Fig. 1: Change 48" to 47" & 39" to 40".
  9. Chap. 21, p.2: Correct calculated fuel volume to 26 gal. each side at FS 102.5.
  10. Chap. 21. p.3: Some of these sections might he reversed.
  11. M-4: The hole for the nose gear torque tube should be off-center to the right and need only be 3/4" I.D.
  12. M-5: Change 4.l" to 4.3".
  13. M-6: Change 3.65' to 3.85" and adjust other dimensions accordingly.
  14. Change .75" min. to .75" max./.70" min.

From Newsletter #39

Thanks to those of you who discover them and send them in.

  1. Clarification. Item #14 in the last newsletter, changing .75" minimum to .75" max./.70" min. referred to the landing gear attach Chap. 9, p.4, Fig. 21, and M-9.
  2. Chap. 4, p.3, Step 5, 1st para: Add, "cut out and install the two 1 x 1 x 1/4" in. alum. inserts for the engine mount shown on M-7and the two shown on M-8 before glassing the firewall pieces".
  3. Chap. 4, p.3, Step 5, 2nd para: Add, "Locate the two groups of three MS24694-S54 blind screws 2.0 in. higher than shown on M-7 and M-8 and detail D-D to provide more clearance between the rudder cable and the aileron push rods.
  4. Chap. 5, p.3, Sec. A-A: Change ??? (typ.) to 3/8 (typ).
  5. Chap. 5, p.6. Some of you noticed the pictures do not agree with the drawings on the previous page. Follow the drawings. The layup was changed after the pictures were taken to provide more shoulder room in the back seat.
  6. Chap. 9, p.6, Fig. 45: Change 22.25" to 24.25".
  7. Chap. 21, p.8, Sec. A-A Spacers for gascolator: Change 3/8"OD x 3/l6"ID to 5/16"OD x .065W 2024-T3 as shown in material list or substitute 5/l6"OD x 3/16"ID 1015 stl bushing stock.

From Newsletter #40

Thanks to those of you who discover them and send them in.

  1. Chap.2, p.2, Misc.: add 1 pc.2 x 4 x 1/4 phenolic
  2. Chap.2, p.4, Chap.19, Misc.: add 1 pc. 2" x 4" phenolic
  3. Chap.6, p.8, 2nd line: Change "medium" to "low" density.

From Newsletter #41

  1. Thomas H. McKeag discovered that we had unintentionally omitted an important paragraph (in both 3 and 4 place plans) which should have appeared at the bottom of Chapter 3, page 3.There is a difference in the way BID and UNI are joined. When joining the edge or the end of one BID ply with another BID ply, it is necessary to overlap it one inch onto the ply it is being joined to. When joining UNI across the major fibers, it is lapped 1 inch per ply, but when joining UNI along the major fibers, it is butted next to the piece it is joining, not overlapped. Also with UNI it is not necessary to remove the selvage (edge of cloth) when making a wide layup such as a wing layup at 30 degrees. Lay the first piece on with the selvage at 30 degrees and butt the selvage of the next piece to it. With BID the selvage is always removed.
  2. Chap. 2, p. 2 and Chap. 2, p. 4: Add (2) AN4-16A bolts and (2) MS210424 nuts needed in Chap. 19.
  3. Chap.4, p.1, para. 2: Change reference Chap. 5 to Chap. 6.
  4. Chap. 4, p. 2, para. 1: After (Fig. 7) add: See also Chap. 2, p. 5
  5. Chap.9, p. 2, Step 2, para. 2: Change 13 deg. to 8 deg. (3 plcs)
  6. Chap. 13, p.12: Change referenced Dwg. M-17 to M-l9.
  7. Chap. 16, p. 1, Schedule B: Change 11" for CS126L to 12.25".
  8. Chap. 16, p. 6, Step 4, para4: Change 19-5 & 19-6 to 19-15 & 19-16.
  9. Chap. 16, p. 6, Step 5: Change 82" long to 86" long.
  10. Chap. 16, p. 7, Step 6: Change Fig. 2 to Fig. 3.
  11. Chap. 16, p. 7, Fig. 8: Delete 4" rudder deflection. Maximum deflection is 26 deg. which is only 1-3/4" at the top.
  12. Chap.18, p. 1, Step 2: Change two sheets to three sheets.
  13. Chap. 19, p.9, Step 11, para.3: ChangeAN3-4A to AN3-5A
  14. Chap. 19, p. 16: Change nut for AN4-16A to MS21042-4.
  15. Chap. 23, p. 1: Top of page change Chap. 25 to Chap. 23.
  16. Dwg. M-11: Elevator hinge NC-3 is shown installed too deep in canard. Install hinge so bottom surface is approx. 1/8" below bottom of canard. 17) Dwg. M-11: Trailing edge of canard extends slightly farther aft than shown.

From Newsletter #42

  1. Chap. 10, p.4, Delete para. 6.
  2. Chap. 239 p.2, Fig. 3, Reduced dimension engine mount nuts. Change MS21042-7 to NAS1291-7. Make same change Preface p.2 and Preface p.4, Chap. 23.
  3. M-9 Belcrank assembly MKCS 122/124 is shown incorrectly as 2.5" long. It should be 13-1/8" long per Chap. 16, p.2.
  4. M-15: Change "join to M-16" to "join to M-9".
  5. M-25, Sec. A-A: Change 2" to 2-1/2".

From Newsletter #43

  1. Newsletter #39, p.4, correction #6: The dimension change from 22.25 to 24.25 is for Fig. 45 on p. 8, not p.6.
  2. Preface p.2, Bolts: Change (1) AN4-35A to (1) AN4-31A, and change (1) AN4-36A to (1) AN4-33A.
  3. Preface p. 3, Chap. 17: Same change as above.
  4. Drawing M28. Same change as above.
  5. Chap. 1 1, p. 1, Fig. 4: Make sure elevator core is firmly against table top as shown during cure.
  6. Chap 1 1, p. 7, para. 2: delete "until they bottom" and add "until they are about 1/8" exposed from the canard, and not as deep as shown on M-11.
  7. Chap 13, p.12, View AA: Add note "After assembly with wheel and bearings, check to see whether there is enough pressure on the bearings so they rotate inside raceway. If they rotate around the MKNG-1 bushings instead, shorten the length of the bushings with a file until the bearings rotate on the raceway."
  8. Chap. 17, p. 8, Step 5: K-mart #82-20-57 may not be available. Use any similar after-market lamp and modify linkage to suit.
  9. Chap. 17, p. 9: The LL-2 should not be purchased from Brock because length varies depending upon lamp used.
  10. Chap. 21, p. 5, para. 2: Assemble with flox as shown on Chap. 21, p. 3, and radius corners with micro before taping.

From Newsletter #44

  1. Newsletter #43, Correction #4, change M-11 to M-28.
  2. Chap. 2, p. 3, Fuselage: Change 2" x 12" x 12" to 2" x 24" x 24" urethane.
  3. Chap. 2, p. 3, Elevators: Change (2) pcs 1" OD x .035w x 57" to (1) pc 1" OD x .035" w x 36" 2024T3 Al. Tube
  4. Chap. 16, p. 1, Step 1, para. 2: Change l" to 7/8" diam. holes through firewall.
  5. Chap 19, p. 2, Step 3, Fig. 6: The instructions call for adding a scrap of foam 14" x 12" x 1-1/2" on top. Keith Spreuer advises the foam block should be a parallelogram 10" x 24" x 1-1/2" and added to the bottom.
  6. Chap. 19, p. 5, para. 1: Change 3 plies (typo) thick to 2 plies thick from B.L. 132 to B. L. 169.
  7. Chap. 19, p. 1, Step 10, para. 3: Keith Spreuer advises to change 23 to 24 pop rivets to agree with rivet layout Chap. 19, p. 17, and to add 48 BSPQ-43 Cherry pop rivets to the material list for Ailerons, Chap. 2, p.4, and the summary list Chap. 2, p. 2.

From Newsletter #46

  1. Chap. 2, p. 1: Change (1) Sheet 3/4" x 32" x 48' H45 PVC to (1.5) Sheets 3/4" x 24" x 48" H45 PVC and make the same change Chap. 2, p. 3, foam needed in Chap. 4.
  2. Chap. 2, p. 2: Change (2) CWB199-152 wheels & brakes to (1) CWB199-152 wheels & brakes. kit.
  3. Chap. 2, p. 5: Change (5) 7" x 14" x 41" pieces styrofoam to (4) 7" x 14" x 41" pieces styrofoam.
  4. Chap 9, p.2, Step 2: The landing gear strut is now being supplied about 95-1/2" long by Featherlite. Check inside length and trim to 95".
  5. Chap. 11, p. 1, fourth para: The torque tube offsets listed as CZNC-12A are shown in the Brock catalog as MKCZ-12A. Until their catalog is changed, change all references in Chap. 11 and the material lists to MKCZ-12A, left & right.
  6. Chap. I 1, p. 6, first para: Instructions call for installing the two NC-6s with Cherry BSC-44 pop rivets. Add to the material list. You will need (2). Better order extras.
  7. Chap. 11, p. 6, last para: Change AN3-12A bolts to AN3-13A bolts to agree with Fig. 16, same page.
  8. Chap. 16, p. 1: You will need 7 ft of 1/2" O.D. x .035" w 4130 STL tubing. Make this change in the Sec. II bill of materials Preface p. 3, and add to bill of materials p. 2
  9. Chap. 16, p. 1, Prefab parts: Change CS-1 to CS-50. These inserts were originally made to fit inside .028" w. tubing, but have been changed to fit inside .035" w tubing. If you have the earlier ones, the .035" w tubing can be reamed so they will fit.
  10. Chap. 23, p. 2, para. 1 and Fig. 1: Change (4) AN6-40A to (4) AN6-34A. Make the same change in the Bill of Materials Sec. II, Preface p. 2 and p. 4. (The engine mount is now being supplied by Brock with 2" rather than 2-1/2" stand-offs as shown on Drwg. M-29).
  11. Chap. 23, p. 4, Fig. 18: Change 1 ply BID to 4 plies BID.
  12. Drwg. M-7: Delete bushing in engine mount detail so it looks like Chap. 23, p. 2, Fig. 1.

From Newsletter #47

Darn it! Builders keep finding little mistakes we made in the Mark IV plans and instructions. Sure is embarassing!

  1. Chap. 2, p. 1, Prefab Parts: The elevator torque tube offsets we list as CZNC-12A may be listed by Brock as MKNC-12A.
  2. Chap. 2, p. 1, Prefab Parts: The rudder pedals we list as CZRPLR etc. may be listed by Brock as MKRPLR etc.
  3. Chap. 2, p. 1, Prefab Parts: The elevator torque tubes (2 rights req'd) are listed by Brock as NCTT-R.
  4. Chap. 2, p. 1, Prefab Parts: The torque tube sleeve NGT-63 is shown in Chap. 13, p. 3 and in Brock catalog as NG-63.
  5. Sec. H, Preface p. 2 and p. 3 for Chap. 16: Add 4" of 3/8" OD x .065" W 4130 steel (for CS112 and CS131 in Chap. 16).
  6. Sec. Il Preface p. 2, Rivets: (100) Avex flush pop rivets, change 1604-0414 to 1604-0412. Make the same change to material list for Chap. 16, 18, and 23.
  7. Correction (5) in Newsletter #42 said to change 2" to 2-1/2" v on Sec. A-A of drwg. M-25. It should have been drwg. M-35.

From Newsletter #48

  1. Chap. 2, p. 1, Wood: Change 1"x1"x1" to 1"x1"x12" Spruce. Also, you may accept .75" instead of .7" for all of the Spruce dimensions.

From Newsletter #49

  1. Chap. 23, p. 4, 3rd para. and Fig. 18: Change 1 ply BID to 4 plies BID to agree with drwg. M-7, Section BB.

From Newsletter #50

Seat Belts - In his last newsletter (Cosy Europe, April `95) Uli Wolter reported meeting with a seat belt company at Aero `95. He was told that a safety organization in Europe ran tests and determined that the spacing of shoulder harness attach points should be between 17 cm min. to 22 cm max. Their tests revealed that if the attach points are farther apart than 22 cm it is possible for an occupant to slide out of the shoulder harness during a crash. 22cm is equal to 8.66". If you check both the 3 and 4-place plans, you will see that the specified spacing for the front seat shoulder harness attach points is 11.5". This is 2.84" farther apart than the maximum recommended. This is a safety matter which we think is important enough to make it MANDATORY to move the shoulder attach points closer together so that they are no farther apart than 8.5". This will require installing new hard points, same procedure as shown in the plans. The bolts may just clear the head rest, but the triangular harness brackets will not, so it will be necessary to notch the forward corners at the base of the headrest to provide the necessary clearance for the brackets.

From Newsletter #51

  1. Drawing M-8 calls for 5 plies BID reinforcement over the lower engine mount hardpoint. Change this to 2 plies BID and 3 plies UND to agree with Chap. 7, p.5, Fig. 24.

From Newsletter #52

  1. Ellison throttle body installation, Chap. 23, p.13, Step 9:

    Fig. 54 shows the throttle in the correct position but it should be labeled B rather than A, to agree with Ellison's schematic. Also, we have been advised by Cablecraft that for aircraft applications, the cable designation should be #580-700-109. Please make these changes.

  2. Chap. 14, p.5, shows a bulkhead installed at the centerline of the centersection spar, but this bulkhead is not shown on p. 7. Make and install this bulkhead similar to bulkheads 6 & 7. One inch diameter holes may be cut in the bulkheads for routing electrical wires and co-ax cables through centersection spar.

From Newsletter #53

Paul Burkhardt advises that on the drawing shown in Chap. 23, p. 15, the mounting hole should be 11/32" rather than 9/32", and the 1.06" radius should be increased to approx. 1.27".

Mark IV Cozy builder Russ Fisher methodically went through all of the plans corrections we had published in our newsletters for the 1st Edition (there were quite a few) and found some that we had failed to correct in the 2nd Edition. Most of them are minor, but it will avoid future confusion if you make the corrections. We are grateful to Russ, and very sorry we goofed! Here they are:

  1. Chap. 2, p. 2, and p. 4, (Chap. 13, hardware): Add (2) AN5268R14 screws for the nosegear crank bearing on the instrument panel.
  2. Chap. 2, p. 2, Misc: Change FC100-2 to FC100 002.
  3. Chap. 5, p. 3, Step 3: 21/2" wide tape not necessary. OK to use 2" wide.
  4. Chap. 11, p. 6, Step 4: Change BSC 44 to BSPQ- 44.
  5. Chap. 13, p. 12: Change reference drwg from M17 to M19.
  6. Chap. 16, p. 7, Step 6, 3rd line: Change to read "no more than 4.5" at bottom".
  7. Chap. 18, p.5, para. 3: Delete relocating screws per design change in NL #39.
  8. Chap. 19, p. 14: Change A11 to A13 in sections I-I, H-H, and J-J.
  9. Chap. 19, p. 16: Change nut for AN4-16A bolt from MS21042-3 to MS21042-4.
  10. Chap. 19, p. 17: Change A13 from 3/8" to 7/16" steel rod.
  11. Chap. 21, p. 2: Fuel tank capacity is 26-30 gal. per side, depending upon how built.
  12. Chap. 23, p. 2, Fig. 3 and Step 7 text: Change MS21042-7 to NAS1291-7 (new designation for small profile nut).
  13. Chap. 23, p. 4, para. 3: Change 1 ply BID reinforcement to 4 plies BID to agree with Fig. 18.
  14. Drwg. M-7: Where upper longeron and doubler penetrate firewall, doubler is shown as 1" wide, when it should have been shown as .75" wide.
  15. Drwg. M-7: Change washer call out under engine mount bolt head from AN960-616 to AN970-6.
  16. Drwg. M-8: Change 5 plies BID reinforcement over lower engine mount hardpoint to 2 plies BID and 3 plies UND to agree with Chap. 7, p.5, Fig. 24.
  17. Drwg. M-8, sec. E-E: Change to "select height so cable misses pushrods and leads in to CS 72. This height should be approx. 1-7/8".
  18. Drwg. M-13: This drawing incorrectly shows the landing brake attached to LB-23 with AN3 bolts rather than the AN525 screws and aluminum slugs specified in Chap. 9.

From Newsletter #55

  1. Chap. 6, p.4, Fig. 18: Change 24-5/8" to 24-7/8" to agree with Fig. 15.

From Newsletter #56

  1. Builder Tom Riley found some discrepancies in the material list for Chapter 9. The 4 pieces of .063 x 1.25 x 1.25 aluminum angle should have been 1 piece of .063 x 1.25 x 1.25 x 4". It is needed to make the LB-18 brackets.
  2. In the same chapter, I believe the 8" x 12" x .063 aluminum was intended to make heat shields, placed between the axle and strut to shield the strut from red hot brake discs.
  3. The 2" x 4" x .063 aluminum shown on Wicks material list appears to be a mistake, because I couldn't see a use for it.
  4. Another builder (I lost his name) noticed some discrepancies in Section II, Preface, P. 1, Table of contents: Change Chap. 4 from 9 to 4 pages, Chap. 16 from 7 to 8, Chap. 18 from 17 to 18, and Chap. 23 from 21 to 22 pages. Sorry for the confusion.

From Newsletter #57

Cozy Mark IV builder Samuel Walker found a couple of places where we didn't correct the dimensions for the canard span after shortening it 3" each side over what was originally shown in the 1st edition of the Cozy Mark IV construction manuals.

  1. On the back covers of both Section I and Section II, both editions, change the canard tip leading edge B.L 75.5 to B.L. 72.5, and the canard tip trailing edge B.L. 78.5 to B.L.75.5. In the Owners Manual, the dimensions are correct.
  2. On Chapter 10, page 1, both editions, change the canard span (not including tips) from 147" to 141".
  3. On Chapter 10, paw 4,- fig. 26, both editions, the outboard jigs for aligning the canard sections are shown at 71. from center. They will have to be moved inboard slightly. 69" from center is suggested.

Thank you, Samuel Walker!

From Newsletter #59

Cozy builder John Epplin called to our attention that the recommended nicopress sleeve to use on SS (stainless steel) cable is zinc plated, 28-1-C, not copper, 18-1-C. We are not aware of any problems in using copper, nor was our local FSDO office, but we suggest that you make this change in the bill of materials for Chapter 16, where they are used on the rudder cables, and Chapter 17, where used on the roll trim. Beware, hardware stores carry aluminum sleeves. They are a no, no!

There has been some question as to whether the shoulder harness attach points are strong enough to resist a 9-g decelleration. We don't know how to calculate this, but reviewed pictures of the crash in Florida, where the pilot/builder hooked his main gear on the static line on a electric transmission line, and crashed nose-first into the ground at high speed. This was about as severe a test as we could imagine. The nose of the airplane was crushed up to the front seat back, but the front seat (and the rear) attach points and harness were still intact. However, now that the question has been raised, and to avoid any remaining concern, we recommend adding 3 additional layers of UND 4" wide x 13" long over each attach point, starting 2" forward of the shoulder support on the seat back, extending over the shoulder support, and then around the back of the seat back. Please make this notation in Chapter 8.

From Newsletter #60

  1. Chapter 2, page 1, Foam: Wicks advises that the 4 sheets of 1/4" PVC foam needed in Chapters 4, 13, and 14 is no longer available in the sheet size shown. It is available in a larger size, which would be more expensive and couldn't be shipped UPS, or a smaller size 29-1/2" x 43-1/4" which can be shipped UPS. The smaller size provides enough material for the necessary parts and will result in less waste, so we approved the smaller size. You should not discard any PVC foam, because it can be pieced together into larger pieces as required with 5 min. epoxy, without sacrificing any structural strength.
  2. Chapter 4, page 1, Fig. 2. Change .65" to .75"to get a 45 degree angle (I used to be pretty good at geometry. Tsk! Tsk!)

From Newsletter #63

  1. Cozy builder Larry Schuler discovered that the instructions for installing the canard in the fuselage in Chapter 13, p. 7 call for riveting K-1000-4 nutplates to a 3/4" x 1-1/4" pice of 0.063" aluminum, while drawing M-11 calls for the nutplate to be riveted to an AN 970-4 wide area washer.  He asked which was correct.  We have used both methods in the several airplanes we have built, and they are equally satisfactory.  Sorry if this has caused any confusion.
  2. Drawing M-25: Delete jig board sketch lower left, and write: See Fig. 5, Chap. 21, p. 4.

From Newsletter #64

  1. Dennis Oelmann alerted us to the fact that when building the canopy frame, if you start the forward cut line at 5.5" aft of the instrument panel, as shown in Chapter 18, p. 8, Fig. 45, then you will have an interference with the canopy latch, if you try to install it at F.S. 46.75, as shown in Chapter 18, p. 13. He is correct. The easiest solution is to start the cut line at 4.5" aft of the instrument panel. Dennis also suggested connecting the two 2-1/2" pads (for the latch and safety catch, Chapter 18, p. 9, top of Fig. 51) together, and widening the pads (Section A-A from 1.6" to 2.0") to make the location of the screws less critical.

  2. Chap. 13, p.10, Step 8: After reference to Fig. 43, add the following warning: WARNING: Over-tightening the four bolts clamping MKNG-15A to the strut will stress the ears of the casting and reduce the safety factor on load carrying ability. Snug the bolts only as much as necessary to hold the assembly together while the flox cures. A limit of 10 in.lbs. is suggested. Fill in the space between the casting and the clamp plate with flox to provide additional bonding to the strut.

From Newsletter #65

  1. The control system rod end inserts have undergone an evolution since they were first designed by Burt in 1976 for the Varieze. The CS-1 insert was originally aluminum with a .427 OD to fit inside .035 wall tubing and drilled and tapped for AN3 rod ends. When Varieze and Long EZ builders were accidently bending the AN3 rod ends while removing and installing their canards, a change was made to the AN4 rod ends, for the elevator push rods, requiring the CS-1A insert, which was drilled and tapped for 1/4 x 28. Then, after a Long EZ experienced an engine fire, the aileron pushrods in the engine compartment were changed to .5 OD x .028 wall steel and the CS-1 insert was changed to a .441 OD for .028 wall tubing with a new designation, CS-50. But the .028 wall steel tubing is almost impossible to obtain, so the OD will probably be changed back to .427. We are dealing with two different wall thicknesses, each with a tolerance of +10%, so some fit problems may occur.
  2. Strakes Chap. 21, p.5, 2nd para. 4th line. Where it says to assemble the parts with micro, use flox.
  3. Quite some time ago, the balance weight for the ailerons was changed from 3/8 in. to 7/16 in. If you find any reference in the plans to 3/8 in., change it to 7/16 in.

From Newsletter #66

  1. Larry Schuler found some wrong dimensions in Chapter 14, p.8 (He doesn't let me get away with anything!). Change 8.41 to 8.51, and 8.50 to 8.60. Thanks Larry!
  2. Guy Terren made his headrests according to the dimensions in Chapter 8, p.1, and when he went to install them, discovered they were at least 1" too tall. In Fig. 1, change 14 to 13 and change 15 to 14. Thanks Guy!

From Newsletter #67

  1. Chapter 19, p.17: For A13, change 3/8" to 7/16".

From Newsletter #69

  1. Section II, Preface p.1: Chapter 4 has 4 pages, not 9.
  2. Chapter 14, p.3: Both steps 7 & 8 instruct you to install LWA2 and LWA3. You need to install them only once.
  3. Chapter 20, p.6, View B-B, upper right. Change BL 157 to BL 169.

From Newsletter #71

  1. Section I, Chap.3, p.3: Delete pagagraph referring to starters. A light-weight starter is recommended for the Cozy Mark IV (thanks Scott Shook).
  2. Builder Norm Muzzy discovered an error on the back cover, both sections. Change W.L. -23 to -20, and change W.L. -22 to -19.
  3. Section I, Chap. 10, p.1, last paragraph: Change 10 inches to 13 inches, and 54 in. to 51 in.
  4. Section I, Chap. 10, p.2, 2nd para: Change 54 in. to 51 in.
  5. Section I, Chap. 10, p.2, last para: Change "two aft outboard cores" to "two aft inboard cores".
  6. Section I, Chap. 14, p.4, 7th para. add: Also flox and tape centersection spar to both landing gear bulkheads.
  7. Section II Preface page1, Table of Contents: Chap. 4 has 4 pages (not 9), Chap. 16 has 8 pages (not 7), Chap. 18 has 18 pages (not 17), and Chap. 23 has 22 pages (not 21).

From Newsletter #72

  1. Add a note to chapter 11, p.7, 1st paragraph: The jig block L on drawing M-18 has been revised in the 2nd edition plans to install the elevators at 15 degree trailing edge up and zero gap. Then when the elevators are in trail, as shown in fig. 18, the gap will be 0.2".
  2. Chap. 19, p.7, fig.40: The B.L. references were for the Cozy III. Change B.L.55.5 to B.L.67.5, and change B.L. 106.25 to B.L. 118.25. Thanks Jean-Patrick Lacote.


  • As explained in our aft c.g. flight test report, the canard span shown in the plans is too long and will allow the main wing to be stalled at a c.g. of 101.6 and beyond. This is unacceptable! The span must be shortened by 6" (3" at each tip). In Chap. 11, p.2, shorten the 11" outboard section of the canard to 8". This will put the counterweight recess adjacent to the tip. Also, remove 3" from the outboard end of the elevator. It will then be at B.L. 70.4 and the counterweight will be flush with the end of the elevator. After making this change on our plans model, we were no longer able to stall the main wing with the c.g. as far aft as 103.2. After this change is made, the approved c.g. operating range will be 97.5" to 102. 1", which provides a safety factor at both ends of the range. This design change is mandatory!
  • The only previous mandatory design change for the Mark IV is the one we explained in Newsletter #44 and reminded you of again in Newsletter #45, namely to shorten the canard span by 6" from the 147" shown in Fig. 1, Chap. 10, p. 1 of the plans (3" from each tip). The elevators will have to be shortened by an equal amount. The lower winglets should be built and installed as shown in the plans. They are needed because they contribute toward protecting against main wing stall as well as providing lateral stability when maneuvering at high angles of attack, which is important in landing and takeoff. An added caveat is that the lower winglets protect the rudders (and prop) from damage should you ever tip your aircraft over backwards (believe it or not, this can happen!).
  • If you have an exhaust system with a heat muff welded on to #4 pipe, ground your airplane until you replace it with a new #4 pipe with a heat muff that is clamped on.
  • On drawings M-32 and M-33 indicate that the aft baffles should be reinforced locally with 1/8" aluminum (instead of .032) where they are cut out for the exhaust pipes, and the cut-outs for the pipes should be a .875" radius for a tight fit around 1.75" pipes, and the two exhaust pipe baffles shown on M-33 should be similarly dimensioned and made from 1/8" aluminum. Add a note that each pair of pipes should be clamped together or wired together with safety wire ahead of the aft baffle to prevent any relative movement. Your airplane should be grounded until these changes are made.

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Last Updated Online: July 04, 2004