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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
DocumentsDescriptionRevisionLast Update
801-assemblyBasic view of the STOL CH 801 airframe assemblysketch7/12/00
801-assembly1Enhanced views of the STOL CH 801 airframe assemblysketch12/28/01
RUDDER TAIL SECTION – KIT ASSEMBLY
DocumentsDescriptionRevisionLast Update
introductionIntroduction to building – 18 pages10/0211/6/02
CSConstruction StandardsDraft3/11
8XR-1Rudder Exploded View Parts 8R1-1 to 8R3-4 dwg3/1/028/26/02
8RU-011 of 3: Rudder Assembly Drawing 1 – internal assembly dwg2/25/028/26/02
8RU-022 of 3: Rudder Assembly Drawing 2 – installing the skins dwg2/25/028/26/02
8RU-033 of 3: Rudder Assembly Drawing 3 – tail light & rudder hinge dwg2/25/028/26/02
rudder0Title Page / Table of Contents2/032/20/03
rudder11 of 5: Building the Sub-Assemblies: Spar and Skeleton 3.08/028/26/02
rudder22 of 5: Building the Sub-Assemblies: Spar and Skeleton 3.02/032/20/03
rudder33 of 5: Installing the Rudder Skins 3.08/028/26/02
rudder44 of 5: Installing the Rudder Skins 3.08/028/26/02
rudder55 of 5: Installing the Rudder Fairings 3.08/028/26/02
HORIZONTAL TAIL SECTION – KIT ASSEMBLY
DocumentsDescriptionRevisionLast Update
tail part listHorizontal Tail Part Number List5/18/045/18/04
8XH-1Horizontal Tail – Exploded View (1 of 3) dwg5/14/145/04
8XH-2Horizontal Tail – Exploded View (2 of 3) dwg5/14/145/04
8HA-1Horizontal Tail – Skeleton Layout (3 of 3) dwg5/14/145/04
elev1ELEVATOR SKELETON ASSEMBLY4.16/18/04
elev2POSITIONING THE ELEVATOR SKINS4.16/18/04
elev3INSTALLING THE ELEVATOR HORN AND HINGE PLATES4.005/14/04
elev4ELEVATOR TRIM TAB4.005/14/04
horizt1HORIZONTAL TAIL SKELETON ASSEMBLY4.106/18/04
horizt2INSTALLING THE HORIZONTAL TAIL SKINS4.005/14/04
horizt3FITTING THE ELEVATOR HINGES4.005/14/04
horizt4INSTALLING THE FIBERGLASS TIPS4.005/14/04
LEADING-EDGE WING SLATS SECTION – KIT ASSEMBLY
DocumentsDescriptionRevisionLast Update
8XS-1Slats Assembly – Exploded View Parts 8S1-1 to 8S2-1 dwg3/1/023/1/02
slats1of3Introduction / Parts List INSTALLING THE RIBS3.112/02
slats2of3POSITIONING THE SKIN3.112/02
slats3of3POSITIONING AND INSTALLATION OF THE SLATS TO THE WING3.112/02
FLAPERONS SECTION – KIT ASSEMBLY
DocumentsDescriptionRevisionLast Update
8XA-1Flaperons Assembly – Exploded View dwg12/0212/02
flaperons1REAR SKINS AND NOSE RIBS ASSEMBLY3.09/02
flaperon2of3INSTALLING THE LEADING EDGE SKIN AND THE SPLICE PLATES3.05/5/99
flaperon3of3a1 of 2: POSITIONING THE FLAPERON TO THE WING AND FUSELAGE4.09/27/00
flaperon3of3b2 of 2: POSITIONING THE FLAPERON TO THE WING AND FUSELAGE4.09/27/00
fr3-6Flaperon Control Horn 8A2-5 dwg 9/19/00
WING SECTIONS – KIT ASSEMBLY
DocumentsDescriptionRevisionLast Update
8XW-1Wing Assembly – Exploded View Illustrated Parts Listdwg01/02/02
8XW-2Wing Assembly – Exploded View Wings Struts / Fuel Tankdwg01/02/02
wings-section1Parts List FLAPERON BRACKET AND REAR RIB SUB ASSEMBLY3.08/12/99
wings-section2SLAT BRACKET AND NOSE RIB SUB ASSEMBLY3.08/12/99
wings-sectionREAR WING SPAR SUB ASSEMBLY3.08/16/99
wings-section4MOUNTING RIBS TO MAIN SPAR3.08/16/99
wings-section5INSTALLING THE REAR SPAR3.08/16/99
wings-section6INSTALLING BOTTOM REAR WING SKIN3.08/18/99
wings-section7INSTALLING THE BOTTOM SECTION OF THE LEADING EDGE SKIN3.08/18/99
wings-section8INSTALLING THE FORWARD STRUT ATTACH DOUBLER3.08/18/99
wings-section9FITTING THE REAR SKIN3.08/18/99
wings-section10INSTALLING THE TOP PORTION OF THE LEADING EDGE SKIN3.08/18/99
wings-section11INSTALLING THE FLAPERON AND SLAT BRACKETS3.08/18/99
wings-section12TRAILING EDGE INSTALLATION3.08/18/99
8-wtFUEL TANK INSTALLATION DRAWINGS – 9 Pages3.0 (8/02)8/14/02
wings-section13FUEL TANKS INSTALLATION3.08/18/99
wings-section14INSTALLING THE INBOARD WING TIP3.08/18/99
wings-section15FLAP ATTACH STIFFENER3.08/18/99
FUSELAGE ASSEMBLIES
DocumentsDescriptionRevisionLast Update
8XF-1Fuselage Exploded View (rear) Parts 8F1-1 to 8F5-11dwg12/02
8XF-2Fuselage Exploded View (fwd) Parts 8F7-1 to 8F8-7dwg01/16/02
8XF-3Fuselage Exploded View (cabin) Parts 8F9-SA to 8F11-16dwg9/14/01
8XF-4Fuselage Exploded View (cabin) Parts 8F14-1 to 8F18-1dwg12/02
8XF-5Fuselage Exploded View (cabin) Parts 8F19-2 – 8F22-9 (doors & seats)dwg12/02
fuselage-viewOverview of the full fuselage assembly with gearsketch7/12/00
fuselageOverview of the full fuselage assembly (drawing)sketch5/00
F5-3ZTop Channel “Zee” Reinforcement Dated10/200110/15/01
FINAL ASSEMBLY
DocumentsDescriptionRevisionLast Update
top-viewTop View of Aircraft Assemblydwg11/30/01
8XC-1Control System: Exploded View Parts 8C1-1 to 8C6-9dwg12/02
8CX-2Control System: Exploded View Parts 8C8-1A – 8C9-5dwg01/25/02
8XL-1Landing Gear Exploded View: Parts 8L1-1 to 8L2-4dwg12/02
8LS-1Drawing: Main Landing Gear Spring Assembly – drawing.dwg1/15/01
gear-s11 of 3 Nose Gear to Fuselage 2.02/14/036/03
gear-s22 of 3 Nose Gear Bungee 2.02/14/036/03
 Nosewheel Bungee Installation Tool allows you to install or replace nose gear bungee easily in minutes.  
gear-s33 of 3 Main Gear Spring 2.02/14/036/03
final-assy-s4-a1 of 3 Assembly of the Cabin Doors3.211/03
final-assy-s4-b2 of 3 Assembly of the Cabin Doors3.211/03
final-assy-s4-c3 of 3 Door Stop / Opening Latch3.211/03
final-assy-s5Installing the Fin to the Fuselage / Stabilizer3.05/5/00
AIRCRAFT FINISHING
DocumentsDescriptionRevisionLast Update
8VV0Slat Position Detaildwg12/22/00
8SO-1Slat Position Templatedwg4/16/01
front-seatAssembly of the Front Seatdraft11/10/00
windowsInstallation of the Windows & Windshield3.18/22/00
Web linkLP Aero Plastics‘ online documentation on handling drilling trimming and cleaning the acrylic windshield.  
finish1of3-stab-attachInstalling the horizontal tail to the fuselagedraft9/15/00
finish2of3-rudder-attachInstalling the rudder to the fuselagedraft9/15/00
finish3of3-wings-attachInstalling the wings to the fuselagedraft9/19/00
brake-linesInstalling brake lines1.02/12/02
LYCOMING 0-360 Engine Installation
DocumentsDescriptionRevisionLast Update
thrust-lineLycoming Thrust Line Position dwg8/26/028/26/02
cowl-a1Lycoming O-360 – Section A1 – Installation of the engine cowl1.001/10/02
baffles-1aLycoming O-360 – Section 1a – Installation of the engine baffles1.011/30/01
baffles-1bLycoming O-360 – Section 1b – Installation of the engine baffles1.011/30/01
oil-cooler-2Lycoming O-360 – Section 2 – Installation of the Oil Cooler1.011/30/01
fuel lines-3Lycoming O-360 – Section 3 – Installation of the Fuel Lines1.011/30/01
carb-heat-4Lycoming O-360 – Section 4 – Installation of the Carb Heat Box1.011/30/01
mixture-ctrl-5aLycoming O-360 – Section 5a – Installation of the Mixture Control Cable1.011/30/01
mixture-ctrl-5bLycoming O-360 – Section 5b – Installation of the Mixture Control Cable1.011/30/01
muffler-6Lycoming O-360 – Section 6 – Installation of the Muffler1.011/30/01
oil-pressure-7Lycoming O-360 – Section 7 – Installation of the Oil Pressure Sender1.011/30/01
spinner-9Lycoming O-360 – Section 9 – Installation of the Propeller Spinner1.01/19/04
OTHER
DocumentsDescriptionRevisionLast Update
parts-listParts List – Complete kit Indexed by Part Number (14 pages) Part List rev.12/20/0212/02
panelInstrument panel blankdwg2/27/02
manual updatesAssembly Manuals Update (32 pages)text12/20/02
VCI-373Cortec 373 Corrosion Protectionbrochure 
Material Safety Data Sheetbrochure 10/2003
pneu-riveterUsing the pneumatic rivet puller 12/18/01
801-w&bSTOL CH 801 Weight & Balance Worksheet: Form FWB-8016/25/026/25/02
801-cgSTOL CH 801 Center of Gravity Limits: Form FCG-8018/20028/6/02
8XE-1Fuel System (standard firewall mounted gascolator)dwg10/18/01
8XE-2Fuel System (auxiliary wing tanks)dwg10/18/01
8XE-3Fuel System (standard under cabin mounted gascolator)dwg10/18/01
8FE-1Fuel Line Trim Around Doordwg2/13/01
8FE-1.1Fuel Line Routing Around Door – standard fuel system.dwg2/13/01
8FE-2Fuel Line Trim Around Door – dual wing tanksdwg2/13/01
8FE-2.1Fuel Line Routing Around Door – dual wing tanksdwg2/13/01
flap-circuit-fig1-2Electric Flap Circuit Drawingdwg3/3/00
8ZV-01Pitot Tube Airspeed Markings and Wing Tie-Down Ringsdwg6/29/01
8ZZ-1Rear Tunnel Assembly and Center Seat Belt dwg12/15/0212/15/02
8CN-01Elevator / Rudder Control Cables dwg8/16/028/02
8CN-02Flaperon & Elevator Control System (hardware). Two Pagesdwg12/4/00
8CN-3.1Control Deflections: Flaperon Elevator and Rudderdwg09/22/04
8CN-3.2Elevator and Flaperon Deflection Templatesdwg9/15/00
8ZE-1Fuel Pump Assembly and Air Box Locationdwg11/19/01
wing-dihedralSetting the Wing Dihedral Drawing dwg12/20/0212/02
strut fairingInstalling the Wing Strut Fairing Option 

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