Zenith CH 650 Photo Assembly Guides

Zodiac CH 650

Photo Assembly Guides: 
Copyright (c) 2000-2012 by Zenith Aircraft Co. (see note)

Note:  The Zenith CH 650-B is the newest Zodiac model, replacing the CH 601 XL model.  Most of the construction between the Zodiac XL and the Zodiac CH 650 is the same and not all of the manuals below reflect the changes or updates.  Please check the online builder resources for the newest information, and remember that the Drawings (blueprints) take precedence over the manuals.

See the online ZODIAC Photo Assembly Guides page for a complete list of the latest available Photo Assembly Guides.
Title Page Photo Assembly Guides Title Page (one page)
introduction Basic Introduction to Building (rudder)
Construction Standards for Zenair Light Airplanes (draft edition)
Illustrated Parts
Zodiac Illustrated Parts Catalog.  This new draft Parts Catalog makes it easy to identify parts and assemblies of the Zodiac XL airframe (and to use with the new online parts ordering system).
Tail Sections
65-T-4 Rudder Spar & Ribs
65-T-5 Rudder Trailing Edge & Leading Edge Skins
6-T-1A Stabilizer Front Spar & Doublers
6-T-1B Stabilizer Rear Spar & Doublers
6-T-1C Stabilizer Skeleton
6-T-2A Stabilizer Skin
6-T-2B Piano Hinge
6-T-2C Stabilizer Installation to Fuselage
6-T-3A Elevator Ribs & Skin
6-T-3B Elevator Horns
6-T-3C Elevator Cutout
6-T-3 Elevator Matched Drilled
6-T-6 Trim Tab
6-NSO-1 Rudder Position Light
6-W-1 Wings Photo Manual - Flaps
6-W-2 Wings Photo Manual - Ailerons
6-W-3 Wings Photo Manual - Outboard Wing Spar Assembly
6-W-5 Wings Photo Manual - Spar Tip / Nose Rib
6-W-6 Wings Photo Manual - Rear Ribs / Aileron Bellcrank
6-W-7a Wings Photo Manual - Wing Assembly
6-W-7b Wings Photo Manual - Wing Assembly
6-W-8a Wings Photo Manual - Wing Skins: 1 of 2
6-W-8aa Wings Photo Manual - Wing Assembly: Checking Wing Twist
6-W-8b Wings Photo Manual - Wing Skins: 2 of 2
6-W-9 Wings Photo Manual - Tie Down Ring/ Access Cover/ Wing Tip / Pitot Tube
6-W-10 Wings Photo Manual - Aileron Control / Bellcrank/ Deflection / Stops
6-K-1 Wings Photo Manual - Leading Edge Wing Tanks
6-K-1b Wings Photo Manual - Fuel Sender
6-LLO-1 Wings Photo Manual - Landing Light Option
6-B-1 Fuselage Bottom / Horizontal Tail Frames
6-B-2   Rear Bottom Longerons / Rear Fuselage Members
6-B-3   Rear Side Skins / Rear Fuselage Members
6-B-4 Rear Fuselage Riveting
6-B-5 Gear Channel
6-B-6 Firewall & Stiffener/ Engine Mount Fittings
6-B-7 Firewall Riveting/ Firewall Front & Rear Stiffeners/ Nose Gear Upper Bearing
6-B-8  Front Floor Skin
6-B-9   Rudder Pedal / Toe Brakes
6-B-10 Front Floor Skin/ Center Wing Spar
6-B-11A Upper Front Longerons / Fuselage Side Skins
6-B-11B Upper Front Longerons / Fuselage Side Skins
6-B-11C Upper Front Longerons / Fuselage Side Skins
6-B-11D Upper Front Longerons / Fuselage Side Skins
6-B-12 Fuselage Bulkheads
6-B-13 Wing Jig / Center Wing Spar Uprights
6-B-14 Joining Fuselage Assemblies / Main Gear Attach.
6-B-15 Forward Fuselage Stiffeners / Front Seat Panel
6-B-16A Seat Back Support
6-B-16B Baggage Panel 
6-B-16C Longeron Doubler 
6-B-17 Control Stick / Torque Tube 
6-B-18 Arm Rest / Seat Bottom / Seat Belt Attachment
6-B-19-DWG Update: Installing the new style linear flap actuator (10/2007)
6-B-19 Fuselage Assembly 
6-B-21A Shoulder Harness Attachment 
6-B-21B Fuselage Top Skins 
6-B-21C Fuselage Assembly 
6-G Landing Gear / Brake Lines 
6-ADO Fuselage Bottom Access Door 
Canopy (original Zodiac XL canopy)
6-C-1 Canopy Hinge
6-C-2 Canopy Side Frames With Latch & Gas Springs
6-C-3a Canopy Assembly
6-C-3b Canopy Frame
6-C-3c Canopy Assembly
6-C-3d Canopy Assembly
6-C-3 Canopy Frame / Inside & Outside Frame
6-C-4 Canopy Screws & Seals
UL Power UL350iS Engine Installation (see UL Power website for engine specific info including Owners Manual)
Section 1 UL Power UL350iS Engine Installation: Engine Mount
Section 2 UL Power UL350iS Engine Installation: Oil Cooler
Section 3 UL Power UL350iS Engine Installation: Oil Cooler
Section 4 UL Power UL350iS Engine Installation: Fuel System
Rotax 912S Engine Installation  (see Rotax Manuals)
912S Rotax 912S Engine Installation: Table of Contents
912S-1 Rotax 912S Engine Installation: Engine Mount
912S-2 Rotax 912S Engine Installation: Bolting on the Engine
912S-3 Rotax 912S Engine Installation: Engine Controls: Throttle / Choke
912S-4 Rotax 912S Engine Installation: Radiator
912S-5 Rotax 912S Engine Installation: Oil Radiator
912S-6 Rotax 912S Engine Installation: Propeller
912S-7 Rotax 912S Engine Installation: Engine Cowl
912S-8 Rotax 912S Engine Installation: Exhaust / Muffler
912S-9 Rotax 912S Engine Installation: Air Filter
912S-10 Rotax 912S Engine Installation: Electric System
Dual Control Sticks Option
ds-1of3 Dual Control Sticks Option: Section 1 of 3
ds-2of3 Dual Control Sticks Option: Section 2 of 3
ds-3of3 Dual Control Sticks Option: Section 3 of 3
Tail-Wheel (tail dragger) Gear Option
td0 Tail-Wheel Gear Option: Parts List
td1 Tail-Wheel Gear Option: Section 1 of 4
td2 Tail-Wheel Gear Option: Section 2 of 4
td3 Tail-Wheel Gear Option: Section 3 of 4
td4 Tail-Wheel Gear Option: Section 4 of 4
Aircraft Finishing / Kit Options
wfo1 Wheel Fairings Option: Section 1 of 2 (new style 6/06)
wfo2 Wheel Fairings Option: Section 2 of 2 (new style 6/06)
wb Weight & Balance Worksheet
Other Info / Miscellaneous Files
Other Info:
  • HomebuiltHELP.com has produced a highly recommended series of step-by-step instructional builder videos (on DVD) specifically for Zodiac builders.  These instructional videos are an excellent supplement to the drawings and photo guides.
  • Recommended reading: Kitplanesbooks.com supplies useful books specifically for builders and pilots of kit airplanes, including the recommended Standard Aircraft Handbook, builder and pilot logbooks, videos, and more. 
  • Visit the Zenith website for additional information and updates.
Other Info:

For the latest versions of these manuals, see the online ZODIAC assembly manuals updates page
Note: The online versions of the manuals are low resolution (lower photo quality) pdf format files for faster downloads.

   Jabiru 3300A Aircraft Engine

Jabiru 3300 Engine Documentation (from Jabiru)
Online Jabiru Info:

Rotax Engine Documentation (from Rotax)
Online Rotax Info:

FAA Documentation: Online: FAA resources for amateur aircraft builders: http://www.faa.gov

FAA Forms: Online: http://www.faa.gov/library/forms
Other FAA Resources and Publications: Online: http://www.faa.gov/library

    Zodiac CH 650

Zenith Aircraft Online Resources: Zenith Aircraft Company Website

     ZODIAC Updates
     ZODIAC ONLINE KIT PARTS STORE: View all parts and order online!

Sport Pilot Updates
Online Builder Resources

Register Online as a Zenith Aircraft Builder / Owner

Click here to access the Builder Listing Database

Online Kit Store 

ZENAIR: Quality Light Aircraft Since 1974

How to contact us:
Always have your aircraft (drawings) serial number available when contacting us.  If you contact us via different methods with the same technical questions, please note it on your correspondence to avoid duplicate responses and delays.

Tech Support Online Form
General Email: info@zenithair.com
Using our online form allows us to prioritize tech support emails for prompt response.
Monday to Friday
7 AM - 5 PM Central
When calling, it is not uncommon to encounter a busy signal.  We prefer not to use a voice-mail system and sometimes all of our technical support personnel are busy helping other builders.
Online Builder Resources:
Online Builder Resources
Facsimile (24/7):
Mail address:
Zenith Aircraft Co.
PO Box 650, Mexico Memorial Airport
Mexico, MO  65265  USA
Shipping address:
Zenith Aircraft Co.
5710 East Liberty, Mexico Memorial Airport
Mexico, MO  65265  USA
Visit the factory:
Zenith Aircraft Co.
Mexico Memorial Airport
Mexico, MO  65265  USA
By appointment. 
Hours: Monday to Friday
6:30 AM - 5 PM Central
Click here for details

Zenith Aircraft Company Technical Support
When requesting technical support, you must supply your aircraft serial number. If technical questions are both emailed and faxed, please note it on your correspondence to avoid duplicate responses and delays. To send us a photo, email it to us as an attachment to your email message.  Please clearly identify who the message is from and what the photo is about and include your serial number with all correspondence.  Note:  Do not send very large images.

Zenith.Aero Online Community for Zenith Aircraft Builders and Flyers


Demo Video

"The Ultimate Experience"

Includes bonus footage: designer Chris Heintz interview and numerous new builder photos.

Info Manual

ZODIAC Series Info Manual  |  STOL Series Info Manual

The linked documents are in Adobe PDF file format. To open them, you need the free Adobe Reader installed on your computer. If you do not have installed on your computer system, click the link above to install it or visit http://www.adobe.com/acrobat to download a free copy.


Notes / Disclaimer:

The materials comprising this "Photo Assembly Guides" CD-ROM disk are provided by Zenith Aircraft Co. (ZAC) as a service to its builders on an "as-is, as-available" basis for informational purposes only. These photo assembly guides have been written and published strictly for informational purposes to aid in the construction of the ZODIAC kit aircraft. They are not to be used without the official ZODIAC Drawings & Manuals, supplied to the purchaser by Zenith Aircraft Co. with a valid serial number printed on the first page of the Drawings. The photos are used for general identification only, and are not to be taken to represent technical drawings. You should not consider the educational material in the photo assembly guides to be the practice of general aviation nor is it intended for this guide to be a complete account of sheet metal aircraft technology: it is limited to the scope of the assembly of the ZODIAC CH 601 XL or CH 650 kit aircraft.

These guides are not intended to replace, substitute or supersede any technical information contained in the ZODIAC Drawings, Newsletter Updates, or any Federal Aviation Administration regulations. Information contained in these photo assembly guides has been obtained by Zenith Aircraft Company from sources believed to be reliable, however, we cannot guarantee the accuracy or completeness of any information published herein and we shall not be responsible for any errors, omissions, or potential damages arising out of use of this information. 

Info on this CD-Rom may be dated, obsolete or incorrect
See the online ZODIAC Photo Assembly Guides page for the latest updates.

Zenith Aircraft Co. (ZAC) assumes no responsibility for any errors or omissions in these materials. ZAC makes no commitment to update the information contained herein. Any third party information, files or other communications do not necessarily represent the opinions or positions of ZAC.

Zenith Aircraft Co. (ZAC) makes no, and expressly disclaims any, representations or warranties, express or implied, regarding this "Photo Assembly Guides" CD-ROM disk, including, without limitation, any implied warranties of merchantability or fitness for a particular purpose. (ZAC) makes no, and expressly disclaims any, warranties, express or implied, regarding the correctness, accuracy, completeness, timeliness, and reliability of the information, graphics, links to other sites and any other items accessed from or via this webpage or the Internet, or that the information will be error-free or free of viruses or other harmful components. Under no circumstances shall ZAC, its owner, or any of their respective officers, directors, employees, agents or representatives be liable for any damages, whether direct, indirect, special or consequential damages for lost revenues, lost profits, or otherwise, arising from or in connection with this "Photo Assembly Guides" CD-ROM disk, the materials contained herein, or the Internet generally.

All materials contained in this "Photo Assembly Guides" CD-ROM disk are protected by copyright laws, and may not be reproduced, republished, distributed, transmitted, displayed, broadcast or otherwise exploited in any manner without the express prior written permission of Zenith Aircraft Co. (ZAC). You may view and print material from this disk for your personal and non-commercial use only, without altering or removing any trademark, copyright or other notice from such material. 

Zodiac CH 650, Zodiac XL and Zenith Aircraft Co. names and logos and all related trademarks, trade names, and other intellectual property are the property of Zenith Aircraft Co.

Copyright (c) 2000-2012 by Zenith Aircraft Co.  All rights reserved.
Data CD-ROM: 27-Jun-2012