Why does this take so long?

[eric_marsh]

Originally Posted by Danny King

Someone said to do something everyday. That really works. I tell builders to spend five minutes a day on their plane. Five minutes! Anyone can fit in five minutes a day, right?

You know, I really like that idea. In fact, I just spent five minutes making a spacer for the aileron bell crank mounts. While I'm out here I might as well lay them out on the rib and see what else I can get done.

[Brantel]

I really bought into the "do something no matter how small every chance you get" theory. It works!

[wrongway john]

Originally Posted by Danny King

Ok, there's a trick! Like a good book on your night stand, the hardest part is to pick it up, and start reading. But, as soon as you start reading, you get into the story, and your probably won't stop reading until you reach the end of that chapter. I found the hardest part building the Doll was getting off my butt and going out to the shop and picking up a tool. But....... just like reading that book, once I got started on my five minutes, I couldn't seem to stop. Then, I'd look up at the clock and hours had passed. That's the trick.

The Doll was a slow build and it took me two years and seven month to complete, including the paint job. I know that most builders will not work that fast, but the five minutes a day plan will really speed up your project.

I like this attitude as well. It's like you say too, the trick is just getting out in the shop and doing something. If you are making progress, it's real easy for that five minutes to turn into hours. Not so easy, if one doesn't know or isn't so sure about what the plans or correct procedure should be.

Another problem that Glasiar aircraft noticed is the organization of the shop and how much time is spent looking for tools or parts. All of theirs is pretty much all there. No ordering, or waiting involved. They calculate their factory assist program is about 85% efficient vs the homebuiler's of 20%. The jigs are already made. My shop for the first time build is going to be a work in progress until it finishes, if it ever does.

Glasair aircraft seems to know a lot about why it takes so long. They have this program in which you build your aircraft yourself in less than two weeks at their factory, and is ready to taxi during that time. It also meets the 51% rule. This is an interesting 5 page story, and explains how an organized shop makes all the difference in the world and why they are far more efficient having the builder there at their shop, than at theirs: http://www.wired.com/autopia/2010/11...ng-in-14-days/

Van’s has probably got enough irons in the fire, but perhaps some other builder could organize such a shop similar to Glasair’s. It would take a very big organized shop that probably couldn't match the factory's efficiency, but it would still be very worthwhile to many, that would participate in such a thing if it existed. Even in this lousy economy, I think this would go over big.

[Sam Buchanan]

Originally Posted by wrongway john

Another problem that Glasiar aircraft noticed is the organization of the shop and how much time is spent looking for tools or parts. All of theirs is pretty much all there. No ordering, or waiting involved. They calculate their factory assist program is about 85% efficient vs the homebuiler's of 20%. The jigs are already made. My shop for the first time build is going to be a work in progress until it finishes, if it ever does.

There is a similar thread currently running and I posted this link for those who haven't seen this article on shop time management I wrote several years ago:

Working Smart

An airplane is a huge project and must be approached in a methodical, consistent manner.

[Jaypratt]

Having an organized shop is Key to working smart. I wish I could help beginners get started. But unfortunaly some are beyond help.
I have seen hoplesely disorganized 'shops'. As I have have been called out to help on a lot of RV builds. I have seen some really good ones too. But not as often. I think the ones that have a good shop just do not need me. Makes since to me.

[PaulR]

Originally Posted by wrongway john

Van?s has probably got enough irons in the fire, but perhaps some other builder could organize such a shop similar to Glasair?s. It would take a very big organized shop that probably couldn't match the factory's efficiency, but it would still be very worthwhile to many, that would participate in such a thing if it existed. Even in this lousy economy, I think this would go over big.

Van's already has at least one of these places that I know of. Mr. Jay Pratt's RV Central. When I visited Jay a 2 or 3 years ago when I had just started, I was amazed at how organized his shop was. Though I've tried to mimick that in mine, I've failed miserably. You guys in Texas have all the neat stuff!

[GAHco]

I have been working on my slow built 6 for over 12 years.

There were large chunks of time lost to the build while I grew our business.

I am also meticulous in attention, sometimes even in results.

Get a BIG calender and log your time each month on each days square and see if you can get X# of hours in each month consistently.

At the end of the project add up the pages. You will have fun reviewing the notes you put in each days square.

Remember Have Fun!

[wrongway john]

It?s good to have Jay?s input on this. It?s not his first rodeo, that?s for sure. Assuming Jay can work me in when that time comes, I imagine that may be the time I bring in the 4 for the FWF package, assuming he handles such cases as that too. I?ve been to Hick?s Airport a few times, haven?t stopped by to see Jay?s place yet, but been to Avery?s a few times. That whole airport is hopping with RV activity.

I took a look at Jay?s homepage. On his site, he gives a time frame of 8 months if you start with the Quickbuild kit. I imagine Jay doing his own build with a QB kit could probably beat that time by a wide margin as well, since he has built so many.

I remember many years back reading from one builder who built a RV-6 from a standard kit in four months. I think this was back before they even had pre-punched skins, and the kits still weren?t nearly as advanced. Many said the workmanship was good on it too; not Oshkosh Grand Champion material, but better than the average plane. Can?t remember his name, but he did this by himself. I remember the article commenting by saying just think what he could do with a QB kit.

When asked how he did it, I remember a few things. He had built before, so knew what was to be expected. Of course his jigs were ready as well as his shop. He thought working short periods of time was one of the most inefficient ways to build a plane. He believed in working long hours at a stretch, that way, he said, you know where everything is at, no time wasted on looking for parts and tools, and he thought you stayed more focused on what needed to be done this way too.

Another thing he did, as soon as he inventoried the kit, was to immediately prime everything that needed priming. After assembly, he went back and touched up the parts that needed it.

Glasair says in the article:

Glasair knew much of the time spent building an airplane isn?t actually spent building an airplane. A lot of it is spent tracking down tools, searching for parts and trying to make heads or tails of the instruction manual. If it could shave a lot of that time out of the process and still let customers do the heavy lifting, it could stay within the 51 percent rule.

Their program does it in 11 days, working 10 hour days. I doubt their kits are not that far different or advanced than Van?s. They all have to meet what the FAA thinks is the builder doing the 51% rule and I think both factories do about as much as they can in this area.

What would you envision a Super Efficient Builder program from Van?s or somebody else?s shop looking like to start getting their times similar to Glasair?s and still meet the 51% rule? I think this would be a worthy goal. Could it be done? If not 11 days, at least a three week or maybe a six week program to shoot for.

[Allan Stern]

From glancing at your blog, it seems you bought a kit from someone else who started on that project and gave up? Looks to be a "slow" build project? That was why I decided to go with a quick build 6A kit. And my quick build took me @ 6years to complete. So work on it a bit at a time each day and you will get it done one piece at a time.

My second quick build 8A went together in less than two years so your learning curve does improve exponentially.

Allan Stern
RV 6A and RV 8A

[RVbySDI]

Originally Posted by Jaypratt

Having an organized shop is Key to working smart. I wish I could help beginners get started. But unfortunaly some are beyond help.
I have seen hoplesely disorganized 'shops'. As I have have been called out to help on a lot of RV builds. I have seen some really good ones too. But not as often. I think the ones that have a good shop just do not need me. Makes since to me.

Jay,
I am glad you were around when I needed your help. I cannot put into words how much I appreciate your help. THANK YOU for getting me moving forward on my project when you did. I will admit here that I was really struggling before you gave me the push I needed. I would not have a flying RV if it was not for you!

As so many others have said, just stay with it. Perseverance is the most important skill needed to build these planes. Just keep plugging away one little task at a time and it will come together. If you were like me and struggling to get something done, ask for help from someone. It will all be worth it when you finish.

Quote for all you sci-fi spoof fans; From the movie Galaxy Quest:
NEVER GIVE UP! NEVER SURRENDER!