Zenair CH 640 · 4 seats · Non-EASA
The detail · Cabin access
The door opens upwards, with its own window, and is held up by a strut. Access to the seats is completely clear.
Specifications · Drawing 640-0-1
180 HP Lycoming O-360, 117 × 188 cm cabin and 454 kg useful load. Dimensions are taken from the manufacturer's original drawing.
Take-off 300 m · landing 350 m at maximum weight. Preliminary Zenair figures measured with a 180 HP Lycoming O-360 and a fixed-pitch Sensenich propeller, at 1,000 kg unless stated otherwise; at 755 kg (1,665 lb) they improve. Drawing dimensions in millimetres.
The kit · Fast Build
This is Zenair's Quick-Build: the sub-assemblies are manufactured and assembled at the factory using many of the jigs and procedures of the certified CH 2000. You close what is left open and fit the parts together.
Made in Midland · Ontario, Canada
Zenair, founded in 1974 by engineer Chris Heintz, builds the CH 2000 at its Midland plant: a two-seater with an FAA type certificate since 1996 and a production certificate. The CH 640 Quick-Build is manufactured and assembled in that same plant, using many of the jigs and procedures of the CH 2000.
Heintz designed the aircraft with as few parts as possible, to save cost and assembly hours. The idea of the kit is that all parts and components arrive ready to assemble, so that only basic skills and tools are needed.
“The most complete FAA-approved 49%–51% kit on the market.”Zenair, on the CH 640 Quick-Build
Part by part
Main spar complete. Ribs riveted to the spar; bottom skin riveted to the spar and ribs, including the bottom of the leading edge.
Aileron bellcrank installed and riveted. Top skins fitted and drilled.
Ailerons and flaps complete, with one side open for inspection.
Add the 20 in (≈ 50 cm) spar extension to the main wing section.
Fit the fuel tanks and rivet the open side of the ailerons and flaps.
Stabilator complete, with one side open for inspection.
Electric trim kit and fibreglass tips.
Assemble the rudder: it is the only section of the aircraft built entirely at home.
Main fuselage complete. Sides riveted to the floor, the firewall and the tail frame.
Rear bulkheads installed, with the top skins in place but not riveted.
Install the front and rear seats and rivet the rear top skins.
Fit the instrument panel and other minor parts.
Wheels with hydraulic disc brakes. Landing gear ready to install.
Nose gear bearings already fitted to the firewall.
Drill the axle holes in the gear, fit axles and wheels and attach the assembly to the fuselage.
One-piece fibreglass canopy, ready to install.
Install the canopy on the fuselage and bond the windshield to the canopy.
Control components ready to install.
Fit the control wheels, control cables and minor parts in the fuselage.
Wing tanks supplied with the kit.
Place the tanks in the wings before closing the skins.
Install the lines, the gascolator, the selector and the rest of the system.
Engine and propeller: the recommended engine is the 180 HP Lycoming O-360, with a separate firewall-forward kit.
Instruments, avionics and wiring, paint and upholstery.
Factory-builtUp to you
Semi-monocoque aluminium structure, with single-curvature skins riveted to the internal structure. Work is done on a flat table with basic tools: drill, hand riveter, clecos, spanners, files and tin snips. It fits in a garage.
The recommended engine is the 180 HP Lycoming O-360, with a firewall-forward kit available. The design accepts 150 to 240 HP and up to 200 kg of installed powerplant, although the manufacturer has only tested the O-360.
Manufacturer information (Zenair, 2008 document), supplemented with public sources on Zenair and the CH 640. Build hours are estimates: Zenair puts it at around 1,500 h for the standard kit and the Jane's reference at around 750 h for the Quick-Build. Kit for amateur construction, experimental category; it is not certified or approved by the FAA. The FAA evaluated it on 2 May 2001 against the intent of 21.191(g) (the 51% rule), which is not equivalent to certification.
Gallery · Some details up close
A selection of parts and details of the kit; not everything is shown. You can see all of it during the visit.
Visit and inspection · 22 Oct – 1 Nov
At Casarrubios del Monte Aerodrome (LEMT), Toledo. Book as much time as you need to look it over calmly. Get directions
You can book several consecutive hours: tap the next or previous slot to extend the appointment.
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