Medicine On The Move Stahlhart papercraft

This is owed to a number of features,

such as the special high-lift wing with
fixed slats, a flaperon (which combines
aileron and flaps into one) and inverted
horizontal stabilizers. It’s large wheels
and fixed landing gear allow landing on
rough terrain.
Another special aspect of the CH
801 as of other kitplanes is its “Open
Design“, that allows builders to modify
parts where they see fit. The most im-
portant aspect here is that the CH 801
was designed to work with a number
of different engines, even though the
standard engine for the CH 801 is the
Lycoming 360 4-cylinder engine.
The CH 801 can be equipped with am-
phibian floats, which are available from
a sub-company of Zenith, Zenair floats.
The floats are available as complete
floats or as a kit for builders. These
floats increase the versatility of the CH
801 even more.
Its ability to land in many different
places, even where space is scarce and
the ground is rocky, in combination with
a payload that is higher than that of
typical “Funplanes” and the low cost in
purchase and maintenance make the CH
801 a perfect bushplane.
The CH 801 can be found in all kinds

Zenith Aircraft 450kg combined with easy construction parts, that a homebuilder can’t construct
of remote areas in the bushplane role,
flying for small companies or charity

CH 801
and maintenance. at home, such as the cowling, the engine organisations. The aircraft being a kit is
The CH 801 is based on the successful and all the equipment. very helpful, because it not only allows
CH 701 from 1986 and shares its basic Inspite of it’s simple structure that the plane to be assembled on location,
capabilities and features, while having allows the CH 801 to be build by aviation but also allows the operator to easily
The Zenith Aircraft STOL CH 801 is de- seats for four instead of two people, enthusiasts at their homes, it was still make repairs when needed, without hav-
signed as a SUV (Sports Utility Vehicle) greater dimensions and a higher speed. designed as a rugged and sturdy plane, ing to return to the factory.
aircraft. While it may not be pretty or Like its predecessor, the CH 801 was allowing it to land even on unprepared Medicine On The Move is currently
fast, it was designed from the begin- designed as a kit, which makes it very landing strips, which makes it a true building a CH 801 in Ghana to be used
ning with utility features in mind. Mainly, affordable. One can either order a sports utility aircraft, that can land for bringing much needed medicals and
that means the ability to start and land complete kit, that features all the parts almost anywhere: From gravel strips to supplies to remote areas that are hard to
on very short fields with payloads up to or a basic kit, which features only those soccer fields, to the beach or a glacier. be reached on the ground.
Zenith CH 801 1:33 SCALE Page 1

These are the instructions for the 1:33-version. Make sure you have the right model plans.

1. If you don’t build the cabin, jump to 6

Build the cabin walls, then glue in the main structures
2. Install the seats, fuselage spars and control equipment
4
9
5 6
2 9

3 7

10

7
10
8 8

11
12
Fold the front seats
1 glue tabs to
like this:
joystick
the outside
of the wall

port wall not shown for better view

13 pedals

14

port wall not shown for better view

Zenith CH 801 1:33 SCALE Page 2

3. Install the seatbelts

15 4. Close the cabin roof and glue transparent foil on the windows
17 16

2x
repeat Transparent foil
for port
Glue tab to the outside
18 side

19

20

Transparent foil
Zenith CH 801 1:33 SCALE Page 3

5. Cut out the windows in the main fuselage (21)

21
Zenith CH 801 1:33 SCALE Page 4

! don’t glue in
this area
! don’t glue in
this area
6. Build the fuselage and if you have built the cabin, install it inside.

21

22

7. Install the fuselage bottom

Zenith CH 801 1:33 SCALE Page 5

8. Install the firewall according to how you want to build the engine

24 For the regular engine

install the former.

When finished, it
the grey surface should
should look like this
face the cabin

25

23

28

9. Install the panel

For NO engine
install the firewall with
parts 26 & 27 For the detailed engine
install the firewall with part 26 and
part a (to be found on the detailed engine sheet)
27

?
a 26
the grey surface should
face the cabin
Zenith CH 801 1:33 SCALE Page 6

If you are building the regular engine, jump to 30

! The detailed engine is not on the standard sheets. Make sure you have the detailed engine sheet

10. Glue together the two 11. Push a slim round stick or 12. Build the engine main section
halves of the propeller wire through the holes and and propeller axis
glue in place
b
make a hole
c
rounden
The logos on the
propeller should d
be in front
make a hole e
29 rounden 2.5mm
thick wire or
slim round f
wooden stick
30 ~
~ 1.5mm g Section:

i
You can build the engine
without propeller by us-
engine shaft ing part h instead of g

13. Push the propeller axis

14. Glue the shaft hub to the end.
through the shaft, Don’t glue ! Make sure no glue gets between
toothpick and shaft.
Then glue the rear side shut.

j
Zenith CH 801 1:33 SCALE Page 7

15. Build the propulsion unit 16. Add the lower parts 17. Build the cylinders.
Use cardboard to thicken part t

k 4x
t
cardboard
p u
q v
r
s
l
m
n
o
w

18. Install the cylinders. The up

arrows on the cylinders and on 19. Install more parts on
the lower side z y When finished, it
part b show where is the top
should look like this

air intake
x

B
C
D
Zenith CH 801 1:33 SCALE Page 8

20. Install parts on the back side

21. Install parts on the top
and right side M
When finished, it
E N
should look like this

F N
N
O
P
H G
J

K L

G
J H
L

22. Build the exhausts

23. Attach the exhausts

Q

R
Zenith CH 801 1:33 SCALE Page 9

25. Install the baffles on

top of the engine.
don’t
glue here
Glue the tabs to the
main part and the
S holes to the cylinders
24. Glue the inside of the
engine baffles
T

26. Glue together the sides of the

engine mount

27. Fold the mount and

glue the inner part inside,
so that the sides become
two crossing triangles

don’t score
this tab
W

X
don’t score
this tab
Zenith CH 801 1:33 SCALE Page 10

When finished, it
should look like this
29. Install the last details on the
top and back.

28. Glue the mount to the

backside of the engine,
under the slits left between
baffles and main part

Y
Z

engine
main part ß

baffle baffle

mount mount
tab tab

The detailed engine is finished,

jump to 38
Zenith CH 801 1:33 SCALE Page 11

31. Attach the upper fairing. Then build in the engine plate
and engine shaft. The front end of the engine shaft should be
flush with the front end of part 38 .

30. Glue together the upper and

lower half of the cowling, using the 34
glue strips
35

31
36
38
37

33
33

32. Attach the Air scoop and exhausts 39 41

40

32
Zenith CH 801 1:33 SCALE Page 12

33. Glue together the two 34. Push a toothpick through 35. Push the propeller axis
halves of the propeller the holes and glue in place through the shaft, Don’t glue !

The logos on the

propeller should
be in front

make a hole rounden

rounden
make a hole
!
toothpick
29

30

36. Glue the shaft hub to the end. 37. Build the spinner on and glue
Make sure no glue gets between it to the propeller
toothpick and shaft.

42 43
Zenith CH 801 1:33 SCALE Page 13

38. Cut out the wing centerpiece and cut

out the windows and the middle square

If you didn’t build the cabin,

you can ignore this step.

44

discard

discard
Zenith CH 801 1:33 SCALE Page 14

39. Glue the strengtheners on If you didn’t build the cabin, 40. Form two wires to the shape of the
the wing centerpiece after you can ignore 46 and the foil strengtheners and glue them on the sides
glueing transparent foil on

46

wire
45 wire

transparent foil

45

41. Fold and glue the wing centerpiece 42. Glue the lower plates on 47
the wing centerpiece

47
Zenith CH 801 1:33 SCALE Page 15

43. Rounden and glue together the tail 43. Glue the tailtop on its top

49

48

48

51

50

44. Rounden and glue together 45. Glue the tips on both ends.
the horizontal stabilizer

51
Zenith CH 801 1:33 SCALE Page 16

46. Install the wing centerpiece and the tailplane 52

LEX
tail

wing centerpiece

52

horizontal stabilizer

! Note:
the flat side of the horizontal stabilizer
faces upward (inverted stabilizer)
Zenith CH 801 1:33 SCALE Page 17

47. Install the windscreen

If you didn’t build the cabin,

simply score the windscreen
(53) slightly along the struts
53

compass

55

54
windscreen

If you did build the cabin,

use the windscreen (53) as a reference to
cut a transparent part and glue the wind-
screen struts (54) on that in the right posi- transparent foil
tion. Then score the window as above. 53
Zenith CH 801 1:33 SCALE Page 18

48. Glue the inner wing structure parts on cardboard

59
58

cardboard

56 cardboard

cardboard

57

49. Glue the inner wing structure together

Zenith CH 801 1:33 SCALE Page 19

50. Glue the inner structure into the wing

and then glue the wing together

60 (61)
Even numbers are port side
uneven numbers (in brackets)
are starboard side

make sure this area

can pe pushed on the
wing centerpiece

51. Glue the wingtip on the edge and glue the

overlaps on the wingroot side

62 (63)
1
2
Zenith CH 801 1:33 SCALE Page 20

51. Construction of the slat. Enforce the brackets with cardboard

brackets: 70

cardboard

71

64 (65)
bracket
68 (69)

bracket

bracket

bracket

64 (65)

66 (67)
Zenith CH 801 1:33 SCALE Page 21

52. Construction of the flaperon. Enforce the brackets with cardboard

brackets: 76
cardboard

77

72 (73)

bracket

bracket
section

bracket

bracket

72 (73)

74 (75)
Zenith CH 801 1:33 SCALE Page 22

53. Install slat and flaperon on the wing

wing

flaperon

slat

2x
Repeat steps 48 to 53
for the second wing
Zenith CH 801 1:33 SCALE Page 23

54. wing installation 58 56/57 59

section:

wing centerpiece

starboard
wing

port wing

Glue the Flaperon to the fuselage

for extra strength
Zenith CH 801 1:33 SCALE Page 24

78 (79)
82 (83)

cardboard
88
cardboard

84 (85)
80 (81)
78/80

86

87
82/84

79/81
54. Strengthen the wing struts with 83/85
cardboard. Then install them along with
the additional details.

89

89 89

When finished, it
89 should look like this
Zenith CH 801 1:33 SCALE Page 25

55. Installation of the detailed engine,

ignore if you built the regular engine

match positions of
cut out the air scoop
exhausts to the lower
and exhaust holes if
cowling section
you use the cowling
bottom part The CH 801’s cowling consists of
two fiberglass parts. You can
choose to install either the top or
bottom or none (or both)

The unpainted inside of the cowling

parts is white, so there is no need
for an inner wall.

cowling top only (31,34) cowling bottom only (32)

Zenith CH 801 1:33 SCALE Page 26

If you are building the

land-version, make a
hole for the
nose landing gear

56. Installation of the regular engine,

ignore if you built the detailed engine

If you are building the

land-version, make a
hole for the
nose landing gear
Zenith CH 801 1:33 SCALE Page 27

57. Installation of landing gear on the

land-version
98
wire

99
90 standard version
(94) Glue a wire between the two main landing gear struts,
then bend it according to the reference on page 2.
91 The little arrow on 98 indicates where is the front.
95/96 ? optional

92
901
93
Numbers in brackets: (94)
Nose landing gear 97 main landing optional ?
gear struts

nose
landing
gear

The land-version is finished.

You can still install the
cargo pod.
Jump to 66
A simplfied version of
the wheels is included

simplified version

100
(103)
104/105
101
102
Numbers in brackets: (103) 97
Nose landing gear
simplified version
Zenith CH 801 1:33 SCALE Page 28

Amphibian version

58. Strenghten the Float bulkheads with cardboard

112 114
110
108 cardboard 118
106 cardboard
cardboard
cardboard

cardboard
113 115
cardboard
111
109
107
119

116
114/115

cardboard 118/119

121

117 112/113

110/111

59. Glue together the inner structure

116/117 of the float

120

108/109
106/107
Zenith CH 801 1:33 SCALE Page 29

60. Build the keel and glue the inner structure on it.

122

123

122
Zenith CH 801 1:33 SCALE Page 30

61. Sufficiently rounden the hull and glue it on the float

124

62. Glue the rails to the top of the float 125

Zenith CH 801 1:33 SCALE Page 31

63. Landing gear down. For landing gear up, ignore this

137
126 133
130 outer
127
129
134
131
128
127 135
inner

138
134
136
For a more realistic Landing gear,
the dark grey area on parts 137 & 138
can be cut out, but it reduces stability.

The same applies to 142

142 rudder in raised position

143/144

the strut is glued to

the rear wheel well wall

the landing gear is the front edge should

aligned centered touch the front wall
Zenith CH 801 1:33 SCALE Page 32

64. Landing gear up. For landing gear down, ignore this

126 139
133
132
127 129 outer

134

128
135
127 inner
140
134
136
For a more realistic Landing gear,
the dark grey area on parts 139 & 140
can be cut out, but it reduces stability.

141 The same applies to 142

rudder in lowered position

143/144

142

the landing gear is

aligned centered

132 should be glued on the floor, the hydraulic arm

the hydraulic arm should
the wheel hangs out in the front is beside on the left
touch the front wall
(port) side
Zenith CH 801 1:33 SCALE Page 33

Repeat steps 58 to 64
2x for the second float

Strengthen the struts Section of forward struts

with wire like this.
Glue the vertical struts note the position of 151’s glue tabs!
over the protruding wires
145, 146

151

wire
152

149
147

150
148 146

145

note the position of 152’s glue tabs!

63. Float struts

section of rear struts

Zenith CH 801 1:33 SCALE Page 34

153 154

155
156

155
64. Float struts & rungs

156
Zenith CH 801 1:33 SCALE Page 35

65. installation of the floats

Zenith CH 801 1:33 SCALE Page 36

For the land-version,

66. cargo pods (optional)
you need to cut a hole in
the cargo pods, so they fit
over the landing gear struts

158
157 Cargo Pod B
Cargo Pod A

copyright 2012 by Christoph Stahl

http://www.hoxity.de/papercraft

Licensed to Medicine On The Move

http://www.medicineonthemove.org
If you enjoyed building this model, please consider to give a donation to,
volunteer at or get involved with

Medicine on the Move

It’s for them that this model was originally designed.

They do really wonderful work. They are working and operating aircraft to
bring much needed medical help to those in need living off the paved roads.

Inform yourself here:

http://www.medicineonthemove.org/

Christoph Stahl, Designer