The last two-stroke offered by the big Austrian engine manufacturer — builder of the ubiquitous 9-series four-stroke engines — was the Rotax 582. Producing 65 horsepower and earning a good reliability rating over many years, the 582 has been a dependable powerplant for the lightest powered aircraft that are larger and heavier than genuine Part 103 ultralights.
At Midwest 2020, Chip also introduced an engine he called Hybird. No, not hybrid (I had to correct my spellchecker three times on that one; it did not like Chip's alteration of the letters).
"The Aeromaine Vtwin is a 60 horsepower, liquid cooled, four-stroke, fuel-injected, electronic-ignition engine with electric starting," Chip summarized. "This engine incorporates state-of-the-art technology with decades of reliable history and many in service," he reinforced.
An engine built in the thousands per month makes a solid foundation yet it isn't factory ready to be mounted on an airplane. That requires some added components.
"Our matching reduction drive with custom CAD-designed and matched propeller results in the perfect power system for the Merlin aircraft at an excellent price," Chip maintains. "The Vtwin engine is supplied with a reduction drive and complete Merlin firewall forward package including including: engine mount, Merlin cowl, Aeromarine-LSA carbon propeller and spinner, radiator, and all fittings.
Why did Chip venture down this path? Wasn't developing an airframe and its many aspects enough challenge? The departure of HKS from the aviation market was one driver.
"The void in the availability of a 50-60 horsepower, four-stroke aircraft engine may be one reason that there are few single-seat aircraft," Chip speculated. "Rotax has reduced their offers of two-stroke engines and most pilots prefer four-cycle."
To install on the Merlin, Aeromarine LSA offers a complete package of firewall-forward components for $10,750, including engine mount, Merlin cowl, Aeromarine carbon propeller and spinner, radiator, and all fittings.
If you want features that exceed a Part 103 Merlin Lite, you will need to assemble a kit so you might like to see an example of the instruction quality. 
Without my partner 
A common question from affordable aviation enthusiasts asks about four stroke engines, either for genuine Part 103 ultralights (available but somewhat more challenging) or for very light aircraft. Such inquiries are commonly for aircraft that have previously used a Rotax 582. The last two-stroke offered by the big Austrian engine manufacturer — builder of the ubiquitous 9-series four-stroke engines — was the Rotax 582. Producing 65 horsepower and earning a good reliability rating over many years, the 582 has been a dependable powerplant for the lightest powered aircraft that are larger and heavier than genuine Part 103 ultralights. 2020 Sensation! The one and only airshow in 2020 was the Midwest LSA Expo… about to start this week! Two years ago, in preparation for the show, Chip Erwin lit up the blogosphere with his Merlin Lite entry (image below). Here’s more about that all-metal, weight-making Part 103 aircraft (our most-read article of 2020, which was then our strongest year ever).
Beside importing aircraft to the USA and helping customers build them, Chip experimented with 
Zigolo Mg21 starts out with multiple versions, mainly differences in wings and wing controls.
Since beginning in 2007, Francesco has delivered more than 50 aircraft to 16 countries and the new model looks to be a solid upgrade from the Mg12.
Aviad's three variations address different national regulations. The short-wing version is currently being tested. That will work in Europe, but will be too fast in some countries, such as the USA. A longer wing version will follow — and may be appreciated by those searching for a modestly-priced motorglider. Finally, a longer-wing version with flaps is planned for the American market to fit properly in Part 103. All versions have a single wing strut and will lose much of the wire bracing that helped keep Mg12 so very light.
Mg21's central structure is a lower box beam running from an aerodynamically-shaped nose containing a digital instrument panel to a tubular empennage boom. In the center of the structure, two rectangular box-section beams support a fixed center wing section and the engine.
As nearby images show, this new Mg21 model has wings that can be folded "by one person in less than two minutes," according to a report in 
Flight testing is ongoing but stall speeds are estimated at 63 kilometers per hour or 34 knots for the short wing, 60 km/h (32 knots) for the long wing, and 52 km/h (28 knots) for the long wing with flap. Francesco will need to slow it another 4 knots to meet 
"For the USA market, I’m sure we can have a 55 knot cruise speed with climb at 800-900 feet per minute plus the easy-fold system (nearby photo), and a competitive price for an advanced [quick-build-type] kit. Due to very small pack size, we can use air shipment. I’m working with DHL to have worldwide fast shipment without the expensive container charges. I worked very hard to keep all measures inside the maximum permitted by DHL" Given numerous reports of container shipment costs rising by double, triple, or even more, air shipment might ironically turn out to be cheaper for such a cleverly-packaged product.
Francesco added, "I prefer Mg21 as a taildragger, but I'm studying a tricycle-gear version."
"All production will be managed internally from my workshop," observed Francesco. "We can fabricate all components."
"Accessories, engine, and instruments are included in the kit but will be shipped separately," said Francesco. "A customer will receive the airframe kit with all necessary to start the work, and a second shipment will bring the accessories.
Please keep in mind these prices are subject to change given supply problems affecting all industries. "In any case, I will state an offering price for each batch of airplanes because the prices change on all materials," said Francesco. A first batch of 10 kits will be offered at close to the prices mentioned above but 
Maybe I should clarify: I mean the on-site camera work plus the keeping track of what we're doing next, handling a load of gear, planning the next day's video stories, downloading huge video files each evening and placing them somewhere to be used later, and charging up everything you own as you sleep. While we're shooting a video, Dave takes a director's view of where we're going and guides us along. He's also very aircraft-savvy so if we lack a piece of information, he can often provide it. The show must go on, you know.
Despite the challenges of working at a great distance, I've been sending loads of raw video up to Dave in Canada and he has been editing away hour upon hour. In this article, I want to introduce you to four recently released videos I think you will enjoy.
Billionaires are investing in, uh, what to call them? …drones, multicopters, eVTOLs, UASs, UAVs, Powered Lift aircraft, the list literally goes on and on. The lack of a widely accepted generic name is one of several indications these air taxis of tomorrow are still in a fairly distant tomorrow.
Two industry experts gave me their judgment after viewing the Volocopter and BlackFly demonstrations. Both agreed the Volocopter presented better, performing a true demonstration of its vertical launch then transitioning to forward flight, manuevering, and then doing a landing. Both also said the BlackFly was much less impressive. "They just kind of bobbed and floated around, not doing any maneuvering or making a transition to forward flight," each agreed. Both wanted to like each aircraft but one clearly won in their minds.
This story is not about either of these developmental vehicles, but here are two links for those interested in the 
I recall when 
Fusion eNano
I have a video in the works where Chip will explain this more fully and talk about its merits.
Here I will note that accelerating airflow over ailerons is very helpful to slow speed flight and not a new idea. You may have seen the photos of a modified Tecnam Twin with multiple small electric motors lined up all along the leading edge. The idea is to accelerate airflow over the entire wing so this aircraft could perform feats a conventional Twin could not.
By pushing air across the aileron, Merlin Lite with these small motors buried in the wings could maintain control down to nearly zero airspeed. The small wing mounted motor accelerates air over the wing, too, making for very, very short takeoffs. "It could cut takeoff roll by three times," Chip suggested.
So Merlin doesn't use electric power for main thrust but does make effective use of electric propulsion.
As a side note, Merlin Lite definitely will be offered with battery electric for primary thrust. Combine the wing (and possibly tail) in-wing thrust units with main power and you could have an ultralight with up to six motors, said Chip. Does that sound like a lot? Maybe, but Volocopter has 18 motors.
Electric has a future, I'm sure, but it has a present as well and it is in Part 103-type ultralights today. I'll try to keep up for those many of you intrigued by electric.
Whatever the product timelines, these machines have large appeal.
Getting stall down to 24 knots (27.6 mph, where Chip saw "30") is tougher but with full flaps, it will be closer; he reported using deep but not full flaps ("32°" when 50° is available). However, a surer way to achieve the right speeds may be a longer wing that is already built and has flown; see the engineering drawings (below video). Weight from a longer wing may require that the pilot fly without the door, but Chip believes room still exists to lighten Merlin Lite enough for buyers to have it all — full enclosure including door, engine cowl, and most or all of the options seen in the photos and video.
The video documents the weighing action conducted inside a hangar that Mt. Vernon airport manager, Chris Collins generously provided so Merlin Lite was not affected by wind. Although I witnessed this using bathroom scales, I checked these with my own weight to see they were within one pound or so of one another (about one-half of one percent deviation). However, Chip will shortly perform a formal weighing using certified scales and an official observer. He's confident Merlin Lite will still qualify and based on what I saw, I agree.
Thor 250 outputs 36 horsepower from a single cylinder that Evolution Trikes boss Larry Mednick describes as a smooth running engine that rivals Rotax's 912. That's a big statement but it appears this Polini powerplant dominates the market for the lightest aircraft. Evolution's 
A new engine was debuted at 
He quoted an introductory price of $7,500 for Hybird used on Merlin, the somewhat bigger brother to Merlin Lite. Hybird for Merlin includes an engine mount, custom cowl for Merlin, the freshly-developed Aeromarine carbon propeller and spinner, radiator, and all fittings.
"There is no TBO (Time Between Overhaul)," Chip bragged! "Our engine replacement price is lower than the cost of most overhauls, so it is cheaper to buy a new engine." A run-out Hybird could still be overhauled, of course, but if that costs close to as much as a new engine, the decision to skip the overhaul time and expense sounds easy.
"We adapted a proven belt reduction drive to this engine and designed a custom engine mount, exhaust, and wiring harness," Chip explained. "We even arranged with a PhD-qualified prop designer to create a custom carbon propeller made to match this engine’s torque and power curve."
Are you looking for an affordably-priced airplane? On this website, you can find many choices of aircraft that qualify, with something to fit the budget of almost any pilot.
Using the Search bar at the top of the page, you can look for any text anywhere on this website. Have you tried it? More on this below…
However, such "alternative aircraft" may not be what you had in mind. Many are open cockpit and pilots trained in a Cessna or Piper can feel uneasy being out in the open (even if behind a pod and windscreen). Also, weight shift trikes, powered parachutes, or gyroplanes handle differently from stick (or yoke) and rudder.
Other pilots may want an aircraft that can cope with the elements better. Metal can offer better endurance. 
Chip believes his new Part 103 "magic" ultralight is truly revolutionary.
“This is not your 1980s ultralight," claimed designer Chip. “I know, I was there. Our new Merlin Lite has real aircraft features and appeal: seven windows, a cockpit door, decent baggage capacity and space, an instrument panel with an EFIS and GPS. And the list goes on.”
Merlin Lite is available with either tricycle gear or taildragger, Chip reported, and features all-aluminum construction, dual independent hydraulic brakes, tundra tires, five-position flaps, pushrod controls with bearings, and substantial aft cabin area with the CG envelope to use it. "Deep deploying 50-degree Fowler flaps and tundra tires with independent dual brakes make the Merlin Lite an ultralight bush plane," he added.
"Based on Merlin PSA, a popular single seat personal sport aircraft that costs less than $40,000 and cruises at 120 mph, Merlin Lite's cockpit is almost as large as the Merlin's, but the powerplant is scaled down and the 3-D tapered wing aspect ratio is increased," said Chip.
Merlin Lite is available completed and ready to fly away, or can also be built as an Experimental and flown with a Sport Pilot ticket, or even a glider certificate, flying Merlin Lite as a motorglider.
"Its cantilevered high wing means no lift strut," explained Chip, "making Merlin Lite quite easy to get in and out, a feature with increasing importance. Plus, the large baggage area can carry a full-size airline roll-on bag, camping gear, or even your favorite pet."
Merlin Lite finished and ready-to-fly — $31,000 equipped with electric-starting 
To find truly affordable aircraft, for one example, search for "vintage ultralights" you will be lead to our April 2020 series on ten super-affordable airplanes, all of which are available second hand for less than $10,000. You may not know that Search can be more specific. After you use Search, a page shows you whatever is found but you can drill down further — click "Try our advanced search option."
After your initial search, you will see, "Not finding exactly what you expected? Try our advanced search option." Click on the "Try our advanced search option" link and you can narrow the search to: 1️⃣ specific brands of aircraft manufacturers, 2️⃣ specific aircraft models, or 3️⃣ FI.R.M. List companies, meaning products and services that do not make airframes or engines. This Advanced Search is quite powerful to sift through more than two million words or hundreds of different aircraft reported on ByDanJohnson.com.
I hope you can attend 2020's 
MC-01 by Montaer
SmithSilver by Tri-State Kite
Sparrow by Carlson
F2 by Flight Design
Vashon Ranger
VL3 by JMB Aircraft
Fusion 212 by Magnus
Rob Rollison the proprietor of the very successful 
Deon will have the InnovAviation FX1 we saw at Midwest 2019 (
I interrupt the ongoing battle with Covid-19 to take you on a nostalgic tour of Oshkosh-19. View this excursion by video below.
Hey, when you can't go to 
Oshkosh is so sprawling you can't see it all but this post along with the video below tries to capture objects of interest to readers of this website and viewers of Dave's 
This year celebrates 15 years of Light-Sport Aircraft and its companion pilot certificate, Sport Pilot. This year also celebrates the 12th year of LAMA providing the LSA Mall. What a fascinating ride it has been!
For 2019, 
For 2019, the LSA Mall will add a few previously-owned LSA, as this part of the light aircraft market is developing. I've 
In addition to dozen Light-Sport Aircraft and Sport Pilot kits all parked wingtip-to-wingtip, LAMA will also again host a display of engines used on Light-Sport Aircraft and Sport Pilot kits.
Pilots have a understandable fascination with engines and the display in the LAMA tent at the LSA Mall in Paradise City is the one-and-only place where you can see them all in close proximity to one another.
If you visit the core area of Sun 'n Fun, you know it is a fair walk to Paradise City. Yet it is a great draw as many see that Sun 'n Fun's "alternate airport" in Paradise City represents something of an airshow-within-an airshow.
As with AirVenture, 
Look for the golf carts with the Rotax logo prominently displayed and stick your thumb out for a ride.
I hope you are coming to Sun 'n Fun 2019. If you cannot, check back here for news as I find it.
Now think of Merlin's price tag. It can be held to less than $50,000 today even with a four-stroke ASTM-compliant engine that provides an abundance of power for Merlin. That amount is approximately the same as $36,000 in 2002. Using the potent (and also ASTM-compliant) 
Merlin goes a further step beyond. The holes already have special, colored rivets that hold the parts in place. A builder removes them, does the under-skin work as needed — wiring, linkages, fuel lines — and re-rivets. I watched some of this occur and it is fairly amazing as a process. I might even attempt it and I'm not a builder.
With dedication and especially with some professional assistance as is possible today, a builder can finish the project in as little as two weeks.
Is that work effort worth it, considering you can hold the price below the once-expected price of a LSA? Only you can answer that question but Erwin's 
Tomorrow's forecast:
Chip continued, "The crisp performance hasn’t changed [with the HKS versus the Rotax 582]. In fact, the early tests are showing near-identical takeoff and climb, but with higher cruise numbers, compared to the Merlin with the Rotax 582 two-stroke." The Rotax engine outputs 65 horsepower while the HKS has 60. Two-stroke engines also spool up quicker than a four stroke. However, the HKS offers higher torque, useful during launch and climb out.
The four-stroke, horizontally-opposed, two-cylinder HKS and its gearbox "weighs a bit more" than the two-stroke option, Chip noted.
“We moved the battery aft, and the whole airplane gives up about twenty pounds of payload,” Chip said, “but the HKS burns less fuel so its flight time is longer at any given weight.” Another positive: HKS can run on avgas or premium mogas.
“We will bring a Merlin from our build program that isn’t yet 100% completed,” said Chip. "That will give people a chance to see how easy it is to build their own Merlin.” The fully enclosed Merlin claims to be one of the quickest-build 51% kits available.
I went to observe a customer building his own Merlin to see how easy and quick it really was. I came away suitably impressed.
"So complete and builder-ready is the Quick Build Kit that most major assemblies and skins are already tacked into position for shipping (using colored soft rivets)," Chip explained, "requiring the builder to actually do some disassembly to bring it to the 51% stage."
“There is no 'Slow Build' option,” deadpanned Erwin in his characteristic humor.
“Precision matched-hole technology means that the holes punched are not just pilot holes; the accuracy is so high that holes in the skins match the holes in the ribs and bulkheads at final size, so next to zero drilling is required," Chip said. "This precision saves dozens if not hundreds of assembly time hours.” My own eyes proved to me that this precision matched-hole technology works as advertised.
A key phrase for this website is "Affordable Aviation" (in fact, we bought AffordableAviation.com for future use). Our focus is on aircraft that can work within the budgets of many recreational or sport pilots. Reading about bizjets or self-flying drones in major magazines may be interesting but those of us who love to fly prefer flying machines we can genuinely afford.
A kit-built aircraft is one way to make airplanes more affordable, and more personal. The great news is you have many wonderful choices. What you may not have is time and that's why this article covers Merlin PSA.
How much time must you invest to get airborne? Would you believe a mere two weeks? Many kits ask for months, even years of your labor plus a place to do this work. If you love the craftsmanship, that may be fine but if you build so you can fly, why not have the process be easier and swifter?
To see for myself, I went to observe a Merlin PSA under construction.
Matched-hole construction pilot holes must still be drilled to the finished size before riveting can begin. With precision matched-hole methods, Chip notes the holes are punched to the correct rivet size, ready to be attached with temporary clecos. Multiplied by thousands of rivet holes, this represents large time savings.
Many components — the entire horizontal stabilizer and elevator, for instance — come significantly pre-assembled. Every fifth hole has a temporary rivet securing the part. The temp rivet is color marked and after the builder rivets the surrounding holes, he replaces the temporary. This idea is widely used on the Merlin PSA quick build kit.
In addition, a Merlin QBK airframe includes spars and sub-assemblies that are factory riveted together (photo). All parts in the QBK are pre-fabricated and pre-drilled but major portions are delivered in fully finished form. Even paint priming is already done in many areas. For first-time home builders, the combination makes for a far easier set of tasks. It also helps assure builder and FAA that the job is done correctly.
Merlin QBK also includes composite gear, wheels, brakes, control and fuel systems. The overall basic airframe costs only $16,500.
You will need the firewall-forward package involving an engine mount, nose cowl, throttle, oil tank, exhaust, propeller, spinner, air filter, radiator, plus related hardware and fittings. Add another $3,800 (now $20,300).
Your choice of powerplant presently includes Rotax 582: 65HP Electric Start, B Drive, Oil Injected for $6,950 or a HKS 700E 4-Stroke for $12,000 ($27,250 to $32,300). An electric propulsion option remains in testing but is coming.
Instruments, interior, options, and paint will add more but Aeromarine LSA owner Chip Erwin reports you can get airborne for around $35,000. With the Rotax 582, that expense looks achievable and those who prefer four strokes could still finish for $40-45,000. Such investments purchase quite a bit of airplane for a sum many can afford.
