Excalibur Aircraft Archives - ByDanJohnson.com

Excalibur Aircraft

Website: https://excaliburaircraft.com/ea/

Phone: 863-471-0099

Sebring, FL 33876 - USA

Affordable and Familiar — Well-Established Excalibur Continues to Please Customers

By Dan Johnson || October 21, 2021 9 Comments

Video Updated 10/25/21 — See at bottom for a video recorded at Sun 'n Fun 2021… —DJ Ever in search of recreational aircraft pilots can afford, I had a closer look at Excalibur's display at Sun 'n Fun 2021. I'll excuse you for thinking this is a Quad City Challenger. It's not. I’ll also excuse you if you never saw this aircraft before. Developer Tom Karr has been building Excalibur for 25 years, nonetheless, Sun ‘n Fun 2021 was his first time displaying at the season-starting event.

Excalibur’s Edge

Developer Tom Karr (in hat) speaks to a prospective customer at Sun ‘n Fun 2021.

In his effort to differentiate his Excalibur kit aircraft from similar looking models, Tom made numerous changes, for example: He uses all push-pull tubes to control surfaces, not cables. The tandem seater has a “wide-body” cockpit that should fit more Americans. Shock cord suspension and a spring-loaded nosewheel make for soft, well-supported landings. Instead of flaperons, Tom uses discreet flaps. Excalibur’s engine — any of several choices — are mounted upright.

Big wide doors and a low side rail height make entry to Excalibur easy.

Better clearance from the engine mounted higher allows a 68-inch prop. Although they cost a little more, Excalibur uses streamlined struts. Perhaps most importantly, Tom said Excalibur has an “unblemished safety record.” With hundreds of Excaliburs shipped, a good track record speaks to a reliable design. The first one was delivered in 1997.

Kit manufacturers do not apply for the aircraft registration so they often have to determine their flying fleet by other means. Readers can investigate further with our complete list of registered light aircraft using Tableau Public. (This valuable tool is often used by business people and enthusiasts. It features every SLSA, ELSA, and kit aircraft with FAA-issued N-numbers that Sport Pilots may fly. The list is kept up-to-date by our Datastician Supreme, Steve Beste).

FAA Approved Kit

With that many Excalibur kits shipped, you could guess that many of them made it into the air because build time is quoted at only 150 hours. No critical dwelling is required; the factory takes care of all the precision tasks. It can go quickly. “You can build and cover a wing in a day,” Tom gave as an example, although time to accomplish tasks will depend on prior experience and mechanical aptitude.

Excalibur is listed on FAA’s 51% approved list, Tom assured, meaning that the low build time has been through the FAA Kit Evaluation Team’s multi-page checklist to assure the owner does truly build 51% of the kit as per current regulation. For those less certain of their skills, builder-assist centers are allowed now and this idea is set to develop further as FAA’s issues its in-the-works Mosaic rule by the start of 2024.

Excalibur can also carry a good load. Tom said it has a 600 useful load capacity. With the standard 10 gallons of fuel, that leaves a whopping 540 pounds for occupants and gear. Fuel capacity can be optional increased to 28 gallons. Those occupants can get in and out easier thanks to lower side rails on the 2021 model. When doors are used they are wide and allow easier-than-common entry to either tandem seat. Shock-cord gear suspension involves 24 wraps of “aviation-grade elastic” that Tom said can absorb quite a load while dampening impact loads from transmitting to the airframe. Getting back up is also easy. “Excalibur exhibits excellent STOL characteristics,” said Tom, “with solo take-offs in 96 feet!” Excalibur’s price at Sun ‘n Fun 2021 was quoted at $33,700 for a complete and flyable airplane but before paint and instruments. If you use analog gauges — or an iPad paired to devices like Levil’s B.O.M., or the Wing Bug — and if you hire out painting as many owners prefer, the total price should still stay well under $40,000. That means roughly the average price of a new car today, making Excalibur a very good bargain that qualifies as “affordable” for many buyers.

Yes, Excalibur Looks Familiar

Do you look at Excalibur and see a Challenger from Quad City Ultralights? Yes, similarities certainly exist but Tom Karr assures you that they are much different. Of course, this is common in aviation. Look how many varieties followed Dean Wilson's first Avid Flyer… which led to Kitfox, Aeropro, ApolloFox, and other variations on the theme.

As Tom suggests about Excalibur, all those Avid Flyer variations claimed to have differences… “improvements” their developers prefer to call them. Here's how Excalibur differs, according to the manufacturer. Check the link out for greater detail, but here are the highlights:

Our engine is right side up, their’s is upside down.
We can use a larger 68-inch prop. The largest prop they swing is 60 inches. We use Hirth’s own gearbox that has no side-loading. Challengers commonly use an aftermarket belt drive.
Our engine sits right in the airstream and gets lots of air to run cooler. Challenger’s hangs down behind the fuselage where the airflow is more restricted to the engine since the fuselage is in the way.
We have the Excalibur Shock-Cord™ landing gear, not a rigid system like theirs.
We have a larger vertical stabilizer.
We have a larger rudder.
We have shorter ailerons with the same responsiveness — 8 feet versus their 15-foot ailerons.
We have a torque tube flight control system, utilizing push-pull rods. They use cables and pulleys.
We feature aircraft grade streamlined aluminum struts.
We have a smaller nosecone for better forward visibility.
We have widened the backseat so both passengers have the same degree of comfort.
We have stretched the fuselage from the back seat forward to give both passengers the same amount of leg room, and it helps maintain center of gravity.

Here is the new video recorded at Sun 'n Fun 2021. The previous video used remains available below. https://youtu.be/v6v9se1ROBw While we waited for editing to be completed on our Sun ‘n Fun 2021 video interview with Tom Karr, we presented this one from Sebring 2015. https://youtu.be/jrzZGFgp1KY

Video Updated 10/25/21 — See at bottom for a video recorded at Sun ‘n Fun 2021… —DJ Ever in search of recreational aircraft pilots can afford, I had a closer look at Excalibur’s display at Sun ‘n Fun 2021. I’ll excuse you for thinking this is a Quad City Challenger. It’s not. I’ll also excuse you if you never saw this aircraft before. Developer Tom Karr has been building Excalibur for 25 years, nonetheless, Sun ‘n Fun 2021 was his first time displaying at the season-starting event. Excalibur’s Edge In his effort to differentiate his Excalibur kit aircraft from similar looking models, Tom made numerous changes, for example: He uses all push-pull tubes to control surfaces, not cables. The tandem seater has a “wide-body” cockpit that should fit more Americans. Shock cord suspension and a spring-loaded nosewheel make for soft, well-supported landings. Instead of flaperons, Tom uses discreet flaps.

Sun ‘n Fun 2021 / Wrap Up — More Airplane News Will Follow, but How Was this Year’s Event?

By Dan Johnson || April 21, 2021 12 Comments

Just today, I learned that Aero Friedrichshafen has been cancelled for 2021 — after twice changing the dates in the effort to schedule a time that works for vendors and pilots plus assures safety for those attending. Aero will next be held in 2022. Main organizer Roland Bosch said, "We have to postpone the Summer Edition of Aero 2021. It's hard, but it is the best solution [given these] circumstances, I think." Europe remains much more locked down and restricted than the USA — certainly moreso than Florida, which has been open for many months. Instead, Roland said, "Now, we look straight forward to Aero 2022, which will be held April 27-30."

Next Airshow: EAA AirVenture Oshkosh

Even while Sun 'n Fun 2021 enters the history books, light aircraft news will not stop. How was this year's event? In a word: successful, in my opinion. I saw a healthy number of vendors — around 80% of 2019's roster, according to officials.

Big crowds surrounded the four Texas Aircraft Colts in the main display area of Sun 'n Fun 2021.

I witnessed good crowds that went huge a couple days; Wednesday and Saturday (both days featured the night airshow) were thick with attendees. Main man, John "Lites" Leenhouts said Saturday was the biggest day in their 47-year history. Fellow aviation journalist Isabel Goyer of Plane & Pilot wrote, "Automated exhibits [were] cool [but] didn’t seem to work. Exhibitions by Textron Aviation and ForeFlight and Jeppesen, among others, were well conceived and executed …and no one seemed to care (had almost no foot traffic), though we celebrate them being there at all." After being forced to cancel the 2020 edition of Sun 'n Fun and taking a massive financial hit from losing those revenues, it was certainly great to see plenty of activity in Lakeland. I'm sure organizers gave an enormous sigh of relief. The total number of paying visitors likely exceeded the number of people that could gather at two of the largest sports stadiums in the USA on popular game days. Good for Sun 'n Fun! I have more to report in the days ahead while the pilot and vendor community takes a well-deserved breather before starting preparations to attend The Big Show: Oshkosh.

A sky-watching crowd at EAA AirVenture Oshkosh (vintage file photo).

On that point, EAA had people in Lakeland to observe how things were being handled and how it went. After their own cancellation in 2020, all eyes will now turn to Wisconsin in July and EAA leadership is taking their task very seriously. "We won't do everything exactly the same as Sun 'n Fun, Inc.," said one top official, "but we see how well it is working in Florida and it gives us support and guidance for our event this summer." Go EAA AirVenture Oshkosh! I've made all my travel arrangements — my first airline flight in almost a year and a half, the longest I can remember going without flying the airlines in decades. I hope to see many of you in July.

Continuing News from Sun 'n Fun 2021

—UL Power completed ASTM testing for their engines and expects to offer ASTM approval for their entire line. UL Power — whose North American launch was significantly supported by Zenith in the USA — has been a player for years but has been relegated to Experimental Amateur Built projects. That has been a good way to establish the brand and the Belgium-based company can now start to approach LSA builders with its FADEC-enabled engines. UL Power engines are modern air-cooled, direct drive powerplants favored by those who prefer legacy GA engines because of their more familiar revolutions and lack of liquid-cooling hardware. My interview with Robert Helms will provide more details after editing (be patient). For more info: UL Power or email Robert Helms

—The electric Aerolite 103 was unnamed at my last report (read here). It has since been named. Welcome to "Aerolite EV-103." Many more details on all versions of the popular Part 103 aircraft are available on this website. People were clearly excited to see the electric propulsion debut; some placed orders. A ready-to-fly model is about eight months out and a kit is five months, however, U-Fly-It is working with their top dealers to get more of these in-demand aircraft available for the summer flying season. For more info: Aerolite 103 or email U-Fly-It

—The much-beloved Rotax 503 will not be returning to the market. The Austrian company discontinued the popular two-stroke engine years ago, meaning many who still want one must search among used engines. The good news: many have only a few hundred (or less) hours on them; a good used engine is both a bargain and a worthy powerplant for your light aircraft kit. Now, though, a very similar engine is coming from Russia, of all places. It's called the RMZ 500. Aviator Paramotor's Eric Farewell is importing the engine and will make it available to others. When I asked about parts and service Eric said he is stocking the most common elements at his base in Lake Wales, Florida and anticipates being able to help service these new engines. If RMZ 500 is even partly as good as the much-celebrated Rotax 503, I predict more will come into the USA. For more info: Aviator Paramotor or email the Florida company

—Excalibur has been around for years but developer Tom Karr has never once displayed at Sun 'n Fun. That changed this year and many saw the aircraft prominently displayed in Paradise City, home to many light aircraft companies at the Lakeland event. Although Excalibur resembles the Challenger line, close observers will find differences. A video to follow will feature Tom discussing points about his aircraft, in production for a quarter century. Excalibur is not available fully built but it is approved by the FAA as a 51% kit. Free for the asking: a 60-minute DVD with flying scenes, construction photos, and more. For more info: Excalibur Aircraft or email Tom Karr

Crowds were thick by the fence at the edge of the Paradise City turf runway. Nightly STOL competitions started after the main airshow ended, followed by a flock of vendor flying until dark. Here Steve Henry's screaming Yamaha 300-horsepower Just Highlander blasts off after a ground roll barely longer than the aircraft.

Many vendors I asked were pleased with the turnout and response. As I've said for years about smaller sector-specific shows (such as Midwest or DeLand), those who attended were keen to be present and many were ready to buy. Several vendors I asked said they felt somewhat hesitant before the event, yet ended up being pleased they went forward. I gather the same might not have been true for the big companies that mounted virtual displays but sent no human representatives. Ah, well… maybe next year for them. As time moves on from Sun 'n Fun 2021 toward Oshkosh 2021, I'll do my best to keep you informed about all things new in Light-Sport Aircraft, Sport Pilot kit-built aircraft, and Part 103 ultralight aircraft. It's all we do here and I was pleased to hear from many readers and viewers that they love the content.

Everyone has returned home from the first major airshow in too long (other than the wonderful sector-specific event called Midwest LSA Expo). Well… everyone went home except a substantial group of volunteers who stick around for days or even weeks afterward to clean up and prepare for next season. Thanks to all volunteers for their efforts that make these events possible! However, while we celebrate Sun ‘n Fun 2021 having a worthy success, aviation is not out of the woods yet. Just today, I learned that Aero Friedrichshafen has been cancelled for 2021 — after twice changing the dates in the effort to schedule a time that works for vendors and pilots plus assures safety for those attending. Aero will next be held in 2022. Main organizer Roland Bosch said, “We have to postpone the Summer Edition of Aero 2021. It’s hard, but it is the best solution [given these] circumstances, I think.” Europe remains much more locked down and restricted than the USA — certainly moreso than Florida, which has been open for many months.