RV-6 Inspection "Just Flawless"

The first inspection of a homebuilt aircraft conducted under the FAA’s new volunteer amateur-built designated airworthiness representative (AB-DAR) program was completed last week. Joe Gauthier, who was designated an AB-DAR under the new program, inspected an RV-6 built by David Faile, EAA and NAFI member, master flight instructor, and professional pilot from Fairfield (CT).

For the record, the aircraft is a quick-build RV-6, N-44DF, powered by a 180-HP Lycoming engine and a fixed-pitch prop with a full IFR panel. Faile spent about 2,200 hours during the last three years building the airplane.

The inspection went as well as could have been hoped, Gauthier said. "Just flawless. I am excited and very pleased with the cooperation from the folks in the Windsor Locks MIDO (Manufacturing Inspection District Office). Thanks to all the preparation, they basically saw an airplane with zero defects, thorough documentation, and a detailed post-completion inspection checklist. All the airworthiness-affecting components on the aircraft were identified with a checklist that each and every one of them had been inspected and approved."

For Faile, who was the 1999 National Flight Instructor of the Year, the procedure was vastly different than 25 years ago when his first project, a Christen Eagle, passed inspection. "The inspection process has improved dramatically," he said. "I think the standardization that we're seeing come down the line with the new (AB-DAR) program is key to the whole thing. It's going to make a safer airplane. It's going to make the builders more aware of what they're building and the ramifications of what they're putting into their airplanes." Faile donated his Eagle to the Connecticut Air and Space Center museum last year.

It was Gauthier who got Faile interested in homebuilding when they worked together about 30 years ago. Faile saw a picture of Gauthier's BD-4 and quipped, "You'd never get me in one of those." But a few months later, Faile was asking for a ride. "The next thing you know I was building an airplane myself. The fact that it worked out that he did his first AB-DAR inspection on my airplane, well the coincidence is way too much for me to believe."

It was a case of so far, so good for FAA's Bob Coleman, MIDO aviation safety inspector (manufacturing). "Today's experience was really super," he said. "The new program is going to be a big help to the agency, and I'm glad that folks like Joe are able to step up to the plate. We had a lot of conversations prior to today, and he was well prepared. I just have to say hats off, to the agency (FAA) as well because they recognized that this would be an important activity to hand-off to the designees."

Coleman's role was to oversee Joe in the paperwork requirements, to make sure the limitations were listed correctly, and the Airworthiness Certificate was correct. "I gave the airplane a quick overlook to see if there was anything missed. It was great workmanship on the part of Mr. Faile. Kudos to EAA and their technical counselors, who do a great job in helping the applicants get to the realization of their projects."

Faile said he made extensive use of the EAA Technical Counselor and Flight Advisor programs throughout the course of the project. Gauthier and David Jackson were my counselors," said Faile, who himself is both a TC and FA. "I wouldn't fly a homebuilt aircraft without using the Flight Advisor program.

Gauthier, a member of the EAA Homebuilt Aircraft Council, praised the support provided by FAA, especially via the web. "The FAA has made so much of the information about the certification process public and easily accessible on the Internet. You can even get the list of DARs off the Internet, along with all of the certification forms. Through this new program folks on the receiving end of this process will know what to expect in advance and there are no surprises.

"I'm beside myself, actually," Gauthier continued. "It's very exciting and the fact that I've done it with a friend and fellow airplane builder makes it even more special." Gauthier already has two more inspections pending, a Kitfox and an SE-5 replica biplane.

FMI: www.eaa.org