America's Composite FX Can Put a Real DIY Helicopter Into Your Hands: Best Project Ever!

While the name Composite FX may mean absolutely nothing to you at this point, by the time we're done with this article, you may find yourself scrounging up all the loose change you've got and making a phone call to Composite FX. Why?

Believe it or not, this American-born team is in the business of manufacturing helicopters. But, not just any old chopper, DIY ones that you can build in your very own backyard, and if you've got the necessary documentation, a pilot's license, and a "Special Airworthiness Certificate," you can be up in the air in no time, or at least, in the time it takes. You to put one of these babies together.

Overall, four models are available from Composite, the XEL, XE, XE 290, and XET, and all are based around a one-seater design, AKA experimental helicopters. Composite also mentions that they've delivered over 350 such units since the first one they ever sold back in 2004.

Why go for something like this? Well, they're light, simple, and durable to ensure countless helicopter newcomers and veterans clock in the flight hours they need and even use them for numerous other tasks. Best of all, these seem to be some of the cheapest on the American market, so let's dive a tad deeper into a DIY project that can be life-changing. If, however, you feel you don't have what it takes to craft your own with the hands god gave you, Composite can also deliver a completed chopper right to your door or hangar.

But what can we get our hands on? That's the question. Well, it all depends on the sort of cash you've got to spend on something like this and your level of building know-how. If you're handy with an array of tools and processes that are needed to craft one of these rotor aircraft, you can end up saving around $15K.

For example, the XE, the baseline model, and the one upon which all other Composite units are based is sold as a kit for $53K (€48K at current exchange rates), and that probably doesn't include shipping. If you let Composite handle the building process, you'll be looking at a bill of $68K (€61,500). I think some helicopter engineering and mechanics classes are going to cost you less. If all else fails, there's always YouTube.

Now, for $53K, I feel you're purchasing a rather amazing machine. For instance, the XE is rocking an MZ202, carburated and air-cooled engine that can hit a top speed of 80 mph (129 kph). It also comes in with a dry weight of 298 lbs (135 kg), so two to three burly dudes can literally pick this thing up and carry it to your launch pad; this is not recommended.

On a full tank of gas (12 gals), you'll be able to fly around for a bit under two hours, which, considering what the heck you're actually moving around with, is quite a lot. Think about the things you'll see around your town or local wilderness in one of these.

At the opposite end of the Composite FX spectrum stands the XET, their proverbial flagship. Here, a different kind of engine is in place, which is a modified T62-T2a Solar Turbine powerhouse that runs on Jet A fuel and produces 95 hp. I'm not in the helicopter or aircraft business, and I already feel like this one's definitely up the speed-lovers' alley.

This version is selling for a solid $70K (€63K) as a kit and $90K (€81,400) as a complete aircraft, and it'll weigh 420 lbs (190 kg), so you'll need to bring in more men if you don't have any cargo-carrying options. While this version is a bit more expensive, it can hit a top speed of over 100 mph (161 kph) and can climb an estimated 1,200 ft (366 m) in a minute's time. With an auxiliary tank, you can fly around for 1.9 hours max.

Yet, what does it take to build one of these? According to the manufacturer's website, basic hand tools, a flashlight, a vice, a drill press, a flexible drill, and even a pneumatic or hand rivet gun are on the list. Oh, you'll also need to know how to handle Bondo-style body filler/epoxy. You will, however, be given a construction manual too, so if life-sized LEGO or IKEA projects are your thing, you know, the ones where an extra screw can mean the difference between life and death, then heck, go for it!

That last bit is really about thinking this whole king of project through: Is it something you can handle? Do you have previous experience with these kinds of machines? Are you willing to go through all the extra steps to be a certified pilot? That last one is sure to cost you some extra cash and time.

But, if all the above-mentioned questions mean nothing to you and you're a YOLO (You Only Live Once) kind of human, to heck with the extra screw left over, go for it! It's one hell of a DIY project and one that puts a helicopter for a lot less than what most people would believe.