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[Cozy MKIV Information]
COZY MKIV PLANS CHANGES/CORRECTIONS
We were hoping there wouldn't be any, but we were wrong.
- 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.
- Wicks advises that what we show as Styrofoam is really Polystyrene, and listed as such
in their catalog. Aircraft Spruce lists it as Styrofoam.
- 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"
- 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
- Chap. 3, page 1 - change 18" bandsaw to 14" bandsaw
- Chap. 4, p.3, Step 5 - add "Install alum. hard points per drwg. M-7 before
- 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"
- Chap. 14, p.2, Step 3, end of 2nd par. - change LWA2 to LWAl
- Chap. 19, p.8, Step 10 - change 3/8" rod to 7/16" rod
- Chap. 19, p.,l4, Sections I-I, H-H, J-J - change A11 to A13
- Chap. 19, p.17, A13 - change 3/8" rod to 7/16" rod
- Chap. 19, p. 17, CS151 - change approx. 30" to 34"
- 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!
- Drwg. M-6: Change 3.6 to 3.3.
- 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.
- Chap. 7, p. 5 Step 5: Delete para. 4 starting with "Now...".
- 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.
- 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...".
- Chap. 14, p. 3, Step 8: After "clean and sand them..." add "install them
with flox as shown in sections BB and CC".
- 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.
- Drwg. M-6: Change 7.4" to 7.2".
- Chap. 2, p. 2, Metal: For 1/8" and 1/4" bar stock note T4 also OK.
- 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.
- 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
- Chap. 9, p. 2, Step 2, and Fig. 7: Keith Spreuer suggests that that 13 strips of UND
should be sufficient.
- Chap. 13, p. 9, Fig. 41: Change the thread size on Rosenhan Cylinder from 1/4" x 20
to 1/4" x 28.
Thanks to those of you who discover them and call them in.
- Chap. 2, p. 1, Equipment, Tools & Supplies: Add (1) 3/4" counterbore (needed in
- Chap. 2, p. 2 & 3. Change (16) MS24694 S58 screws to (16) MS24694 S60 screws.
- Chap. 2, p. 2 & 3. Add (2) AN525-416RI8 and (2) AN525416R14 screws (needed in Chap.
- Chap. 2. p. 2 & 4. Add (2) AN960-516 washers (needed in Chap. 13).
- Chap. 8, p. 1, Step 1, last para. You may wait until you have Chap. 18 to install the
- Chap. 9, p. 6, Fig. 30. Change .049 wall to .063 wall.
- Chap. 14, p. 3, Fig. 14. Chang 3.5 to 5.25 (both sides).
- Chap. 14, p. 7, lower left hand corner. Change 33.21 to 33.58 (thank you Larry Sligar).
- Chap. 19, p. 9, Step II, Para. 2. Change layup #11 to layup #12.
- Chap. 19, p. 18, Para. 1. Change p. 19-8 to p. 19-7.
- Chap. 20. p. 1, Step 1, 2nd line. Change Chap. 23 to Chap. 3
- 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.
- M-10. Change join to M-17 to join to M-19.
Thanks to those of you who discover them and call them in.
- Chap. 5, p.3, Step 3: Change 2-1/2" tape to 2" tape.
- Chap. 7, p.4, Fig. 21: Change 20-1/2" to 19", & 22 to 20-1/2
- Chap. 9, p.6. Para.2 & Fig. 31: Change #30 holes to #30 dimples (not through).
- Chap. 10, p.6. Para. 4: Delete "Fig. 43' & substitute Fig. 36 in Chap. 19, p.7.
- Chap. 10, p.7, Para. 1: Change Fig. 46 to Fig. 43.
- Chap. 11, p.2: Add this note: Dimensions are correct, but drawing is not. Micro joint
does not align with elevator.
- Chap. 13, p.4. Step 3, Para. 2: Add: Open the pivot hole for MKNG-6 to 5/16" I.D.
- Chap. 20, p.1, Fig. 1: Change 48" to 47" & 39" to 40".
- Chap. 21, p.2: Correct calculated fuel volume to 26 gal. each side at FS 102.5.
- Chap. 21. p.3: Some of these sections might he reversed.
- 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.
- M-5: Change 4.l" to 4.3".
- M-6: Change 3.65' to 3.85" and adjust other dimensions accordingly.
- Change .75" min. to .75" max./.70" min.
Thanks to those of you who discover them and send them in.
- 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.
- 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".
- 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.
- Chap. 5, p.3, Sec. A-A: Change ??? (typ.) to 3/8 (typ).
- 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.
- Chap. 9, p.6, Fig. 45: Change 22.25" to 24.25".
- 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.
Thanks to those of you who discover them and send them in.
- Chap.2, p.2, Misc.: add 1 pc.2 x 4 x 1/4 phenolic
- Chap.2, p.4, Chap.19, Misc.: add 1 pc. 2" x 4" phenolic
- Chap.6, p.8, 2nd line: Change "medium" to "low" density.
- 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.
- Chap. 2, p. 2 and Chap. 2, p. 4: Add (2) AN4-16A bolts and (2) MS210424 nuts needed in
- Chap.4, p.1, para. 2: Change reference Chap. 5 to Chap. 6.
- Chap. 4, p. 2, para. 1: After (Fig. 7) add: See also Chap. 2, p. 5
- Chap.9, p. 2, Step 2, para. 2: Change 13 deg. to 8 deg. (3 plcs)
- Chap. 13, p.12: Change referenced Dwg. M-17 to M-l9.
- Chap. 16, p. 1, Schedule B: Change 11" for CS126L to 12.25".
- Chap. 16, p. 6, Step 4, para4: Change 19-5 & 19-6 to 19-15 & 19-16.
- Chap. 16, p. 6, Step 5: Change 82" long to 86" long.
- Chap. 16, p. 7, Step 6: Change Fig. 2 to Fig. 3.
- Chap. 16, p. 7, Fig. 8: Delete 4" rudder deflection. Maximum deflection is 26 deg.
which is only 1-3/4" at the top.
- Chap.18, p. 1, Step 2: Change two sheets to three sheets.
- Chap. 19, p.9, Step 11, para.3: ChangeAN3-4A to AN3-5A
- Chap. 19, p. 16: Change nut for AN4-16A to MS21042-4.
- Chap. 23, p. 1: Top of page change Chap. 25 to Chap. 23.
- 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.
- Chap. 10, p.4, Delete para. 6.
- 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.
- 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.
- M-15: Change "join to M-16" to "join to M-9".
- M-25, Sec. A-A: Change 2" to 2-1/2".
- 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.
- Preface p.2, Bolts: Change (1) AN4-35A to (1) AN4-31A, and change (1) AN4-36A to (1)
- Preface p. 3, Chap. 17: Same change as above.
- Drawing M28. Same change as above.
- Chap. 1 1, p. 1, Fig. 4: Make sure elevator core is firmly against table top as shown
- 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.
- 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."
- 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.
- Chap. 17, p. 9: The LL-2 should not be purchased from Brock because length varies
depending upon lamp used.
- Chap. 21, p. 5, para. 2: Assemble with flox as shown on Chap. 21, p. 3, and radius
corners with micro before taping.
- Newsletter #43, Correction #4, change M-11 to M-28.
- Chap. 2, p. 3, Fuselage: Change 2" x 12" x 12" to 2" x 24" x
- 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
- Chap. 16, p. 1, Step 1, para. 2: Change l" to 7/8" diam. holes through
- 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.
- Chap. 19, p. 5, para. 1: Change 3 plies (typo) thick to 2 plies thick from B.L. 132 to
B. L. 169.
- 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.
- 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.
- Chap. 2, p. 2: Change (2) CWB199-152 wheels & brakes to (1) CWB199-152 wheels &
- Chap. 2, p. 5: Change (5) 7" x 14" x 41" pieces styrofoam to (4) 7"
x 14" x 41" pieces styrofoam.
- 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".
- 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.
- 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.
- Chap. 11, p. 6, last para: Change AN3-12A bolts to AN3-13A bolts to agree with Fig. 16,
- 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
- 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
- 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.
- Chap. 23, p. 4, Fig. 18: Change 1 ply BID to 4 plies BID.
- Drwg. M-7: Delete bushing in engine mount detail so it looks like Chap. 23, p. 2, Fig.
Darn it! Builders keep finding little mistakes we made in the Mark IV plans and
instructions. Sure is embarassing!
- Chap. 2, p. 1, Prefab Parts: The elevator torque tube offsets we list as CZNC-12A may be
listed by Brock as MKNC-12A.
- Chap. 2, p. 1, Prefab Parts: The rudder pedals we list as CZRPLR etc. may be listed by
Brock as MKRPLR etc.
- Chap. 2, p. 1, Prefab Parts: The elevator torque tubes (2 rights req'd) are listed by
Brock as NCTT-R.
- 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.
- 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).
- 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.
- 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.
- 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.
- 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.
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.
- 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.
- 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.
- 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.
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:
- Chap. 2, p. 2, and p. 4, (Chap. 13, hardware): Add (2) AN5268R14 screws for the nosegear
crank bearing on the instrument panel.
- Chap. 2, p. 2, Misc: Change FC100-2 to FC100 002.
- Chap. 5, p. 3, Step 3: 21/2" wide tape not necessary. OK to use 2" wide.
- Chap. 11, p. 6, Step 4: Change BSC 44 to BSPQ- 44.
- Chap. 13, p. 12: Change reference drwg from M17 to M19.
- Chap. 16, p. 7, Step 6, 3rd line: Change to read "no more than 4.5" at
- Chap. 18, p.5, para. 3: Delete relocating screws per design change in NL #39.
- Chap. 19, p. 14: Change A11 to A13 in sections I-I, H-H, and J-J.
- Chap. 19, p. 16: Change nut for AN4-16A bolt from MS21042-3 to MS21042-4.
- Chap. 19, p. 17: Change A13 from 3/8" to 7/16" steel rod.
- Chap. 21, p. 2: Fuel tank capacity is 26-30 gal. per side, depending upon how built.
- Chap. 23, p. 2, Fig. 3 and Step 7 text: Change MS21042-7 to NAS1291-7 (new designation
for small profile nut).
- Chap. 23, p. 4, para. 3: Change 1 ply BID reinforcement to 4 plies BID to agree with
- 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.
- Drwg. M-7: Change washer call out under engine mount bolt head from AN960-616 to
- 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.
- 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".
- 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.
- Chap. 6, p.4, Fig. 18: Change 24-5/8" to 24-7/8" to agree with Fig. 15.
- 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.
- 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
- 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.
- 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.
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.
- 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.
- On Chapter 10, page 1, both editions, change the canard span (not including tips) from
147" to 141".
- 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!
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.
- 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.
- 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!)
- 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.
- Drawing M-25: Delete jig board sketch lower left, and write: See Fig. 5, Chap. 21, p. 4.
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.
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
- 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
- Strakes Chap. 21, p.5, 2nd para. 4th line. Where it says to assemble the parts with
micro, use flox.
- 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
- 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!
- 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
- Chapter 19, p.17: For A13, change 3/8" to 7/16".
From Newsletter #69
- Section II, Preface p.1: Chapter 4 has 4 pages, not 9.
- Chapter 14, p.3: Both steps 7 & 8 instruct you to install LWA2 and LWA3. You need to
install them only once.
- Chapter 20, p.6, View B-B, upper right. Change BL 157 to BL 169.
From Newsletter #71
- 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).
- 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.
- Section I, Chap. 10, p.1, last paragraph: Change 10 inches to 13 inches, and 54 in. to
- Section I, Chap. 10, p.2, 2nd para: Change 54 in. to 51 in.
- Section I, Chap. 10, p.2, last para: Change "two aft outboard cores" to
"two aft inboard cores".
- Section I, Chap. 14, p.4, 7th para. add: Also flox and tape centersection spar to both
landing gear bulkheads.
- 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
- 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
- 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
- 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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[Cozy MKIV Information]
Last Updated Online:
July 04, 2004