Van's Aircraft extensively manufactures its own kit components in-house, utilizing a blend of modern CNC technology like punch presses and tubing benders, alongside reconditioned historic wartime tools such as a WW2 spar riveting machine and a Farnham roller.
The company's success is attributed to producing kits that are easy and straightforward to build, offering options like QuickBuild kits (with partial assembly from the Philippines) and new Lycoming engines at OEM rates.
The entire production process is comprehensive, covering everything from milling and welding parts to meticulous packing and daily shipping of a wide range of aircraft components and complete kits.
A photo tour shows how things have changed in RV Land. Photography by Robert Goyer.
Neatly organized cowls, fairings and door skins await shipment.** Van’s manufactures almost all their own aluminum parts. Stacks of wing ribs are arranged in bundles.**** All the small bits are milled and drilled in-house.**** Engine mounts for the different models are welded and powder-coated.**Gear leg fairings – think of them as horsepower without fuel.** Engine mounts for the different models are welded and powder-coated.**** The West Wing houses engines, QuickBuild kist and stacks of crates ready to ship.**** A day’s shipping, courtesy of Van’s crate builders and packers.**** Van’s offers new Lycoming engines at OEM rates.**RV-12 center-sections ready to go.Back from the assembly center in the Philippines, QuickBuild kits are stored in roll-around racks.** Cabin tops for the RV-10 are one-piece composite units.**QuickBuild wings ready to ship.An RV-14 wing spar is riveted together.Van’s spar riveting machine was built in WW2. Seventy years later, it’s still doing exactly what it was designed to do.Rivets…lots and lots of rivets.** Aluminum sheets are coated in plastic to protect the surface during manufacture and shipping.**** Van’s uses a computer controlled tubing bender to make exhaust systems and canopy frames**The Farnham roller – another wartime tool resurrected and reconditioned by Van’s – makes accurate conical bends.Ain’t no computer in this baby – big pushbuttons, electric jackscrews and knobs run the show.Three CNC punch presses are at the heart of Van’s operation.** Hundreds of die sets punch holes of all sizes and dimensions.**** Hundreds of die sets punch holes of all sizes and dimensions.**** Hundreds of die sets punch holes of all sizes and dimensions.**** Hundreds of die sets punch holes of all sizes and dimensions.**Every scrap of steel and aluminum remnant is recycled.Every scrap of steel and aluminum remnant is recycled.** An Aero Lift helps store the demo fleet.****What’s the secret to Van’s remarkable success in turning out winning kit designs? The secret is that there aren’t really any secrets at all: It’s all about making great flying airplanes, creating kits that are easy and straightforward to build, and putting that package together at a price that makes customers out of potential customers. Ease of building is a critical component to Van’s recipe, and there is a secret here. Van’s kits are easier than ever to build. Here’s how they do it, and without any spoilers, it’s a blend of cutting-edge and antique technologies blended to make the best selling kits in the world. **
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