In the last couple years, I've created videos with Merlin developer, Chip Erwin that have been among the most-watched on Dave Loveman's Light Sport and Ultralight Flyer 
So it's hardly any wonder that I would be pleased to continue our Top 50 video series with one from just a couple of years ago. In a short time, it passed the 275,000-views mark. Since then, I did another on Merlin that went over well on 
In more recent years, the Merlin Lite erupted onto the Part 103 scene, lighting up cyberspace in a way very rarely seen. The design emerged during the darkest days of Covid delivering a much-needed breath of fresh air.
At the 
Chip is far from done.
In 2022 we saw the emergence of the Merlin Lite as a motorglider and in 2023 we saw yet another long wing Merlin Lite fitted with floats, an "ultralight motorglider floatplane."
I need to go back in time briefly to remind readers that Chip Erwin is also the man who created what became known as PiperSport, more correctly called the 
Clearly, this is a developer who knows how to bring an aircraft to market and put it into production. It's taking some time for him to bring Merlin completely online because he is doing this in the modern way. Components are coming from various places around the world, where Chip established connections after years of globetrotting.
Now he is joining together aircraft elements. One of those was a set of floats that he developed during the Czech Aircraft Works days. Chip has deep experience with water flying and long ago developed metal floats as demonstrated by the straight (non-amphibious) floats seen nearby.
Paul told me of new equipment he has acquired to facilitate assembly of Merlin Lites. "This is a very straightforward kit," Paul observed. He has several coming together at this time. Those that have been waiting for the Merlin Lite will see their delivery times get closer.
We have a "year back log" Chip said on a recent phone conversation. USA assembly is now operating and delivering and that should steadily pull down the back log. "Paul has the skills, the facilities, the knowledge, and the tools to consistently build aircraft. He is also a longtime FAA Designated Airworthiness Representative (DAR)," so Paul knows exactly what is permitted under agency rules.
As a Part 103, Merlin Lite can be fully built for you and delivered ready-to-fly if you wish. The kit version is quite straightforward as I have reported in the past. Some people may prefer to build it to add further equipment than permitted under Part 103.
As a Part 103 vehicle, no medical is needed. As an EAB, only a driver license is needed. In the case of motorglider, no medical is needed after you prove you can fly a glider and can operate a motorglider. These skills are not particularly challenging but a few steps are involved. The reward you can now fly an aircraft faster (and heavier) than a Part 103 vehicle but still has no medical requirement.
With 278,000 views in a fairly short time, this popular video helps you understand the great interest in Chip's Merlin Lite in all its configurations.
https://youtu.be/BeMjJbo2yv4?si=2-JYhbKTyqRmhuN_
On my own channel, here's an update from earlier in 2023, already with 60,000 views. Now you see the aircraft in full dress, ready for first deliveries soon.
https://youtu.be/5jEPGUASzmk?si=FR__7REVa9G0EVI0
You hear references to Chip's V-Twin. Here's a fairly recent video about that (viewed 57,000 times):
https://youtu.be/jn3rv7RaWME?si=fxj3p9t-ecKbbJ1z
This Merlin has nothing to do with kids in colorful costumes seeking sweets from their neighbors. It does have to do with pilots liking interesting airplanes that they can fly over their neighbors… especially when they can afford the airplane. In the last couple years, I’ve created videos with Merlin developer, Chip Erwin that have been among the most-watched on Dave Loveman‘s Light Sport and Ultralight Flyer YouTube channel. I interviewed numerous industry leaders like Chip in around 1,000 videos. The 50 most popular of those productions have been watched more than 10 million times. In addition, when I write about Merlin on this website, lots of readers seem to love it. So it’s hardly any wonder that I would be pleased to continue our Top 50 video series with one from just a couple of years ago. In a short time, it passed the 275,000-views mark. Since then, I did another on Merlin that went over well on my own channel (see below).
What you didn't know is that this idea was unique enough to win a patent. That's uncommon in recreational aviation, though, of course, an idea like this may go far beyond sport flying.
Chip Erwin is one of those restless people who probably lays awake night cooking multiple ideas in his brain at the same time. Many industries have their "Elon Musk" type who moves forward on several fronts despite plenty of people telling him he can't do what he does every day.
As the mainstream media hyperfocuses on multicopter air taxi ideas consuming vast amounts of money (why media pays attention in the first place), people like Chip have different thoughts about using electric power on aircraft. Depod is one of those concepts.
Depod is not intended for 
Indeed, Chip's term sounds made-for-military. DEPOD is awkward but does describe the idea.
NASA likes distributed electric propulsion (DEP), spending millions. Chip added the "on demand" part, spending thousands. His appears to be a clever, effective, and simpler way to use electric propulsion on an aircraft.
Let's learn what Chip has to say about the development.
"Now covered by two U.S. patents (see at bottom) this new on-demand propulsion system gives the pilot instant added thrust for takeoff or for a go-around, and instant reverse thrust to allow shorter landing rolls," explain Chip.. "It helps achieve extreme short takeoff and landing performance in three ways, and it provides added aircraft 'envelope protection'."
Chip continued…
These small wing motors, used briefly to enhance a phase of flight, need only a battery you can hold in your hand because they are not primary thrust power (though they add a good measure to the total).
Accelerating airflow over ailerons is very helpful to slow speed flight but it is not a new theory. You may have seen photos of a modified Tecnam Twin with multiple small electric motors lined up all along the leading edge. NASA calls this "distributed lift" and at its base, this and Depod are not so different.
By pushing air across the aileron, a Merlin Lite with these small motors buried in the wings could maintain control down to nearly zero airspeed. The small wing-mounted motor also helps generate more lift, making for very short takeoffs. “It could cut takeoff roll by three times,” Chip suggested.
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. 
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.
While recognizing they are very capable airplanes, many lament the cost of carbon fiber speedsters with glass cockpits and autopilots. 
The first U.S. Merlin PSA is powered with the 65 horsepower 
Licensed as an Experimental Amateur Built aircraft Merlin PSA easily fits within the LSA parameters of weight and speed. Therefore, it can be flown with a Sport Pilot certificate — or by a higher certificated pilot exercising the privileges of Sport Pilot, meaning no medical is needed.
A complete kit including Aeromarine-LSA's builder's assist program is only $34,900. You need to invest some labor hours but you will be guided and the effort is said to be quite rapid. An all-aluminum design, Merlin PSA is available as a quick-build kit. Because it was created using 3D CAD/CAM equipment, Merlin offers easy-to-build, matched-hole assemblies that require no fixtures. "Build time is measured in days rather than months or years," said Chip. "Builders can enjoy a couple of weeks at our Builders' Center in Florida and fly their new Merlin PSA ... not 'taxi.' Fly." That's some promise.
As debuted at Sebring 2016, Merlin PSA is nicely equipped with a digital EFIS/EMS, GPS, radio transceiver, an ADS-B out-equipped Mode S transponder, BRS parachute system, electric trim, and the new 
