The Merlin was designed in 1986 by John Burch. The Merlin’s fuselage is all pre-welded at the factory and consists almost entirely of 5/8″ x .035 4130 chromoly steel tubing, versus 1/2″ tubing found in most tube and fabric kits. This framework provides the foundation for the Merlin’s ruggedness. The entire steel structure and all pieces are sandblasted and epoxy-primed, ensuring no worry of rust.

Fiberglass cowlings are custom designed and manufactured for each of the standard Merlin GT engine packages. These easy-to-install two- piece cowlings enable the builder to enclose his powerplant simply and efficiently.

The Merlin cockpit is a 41″ wide, and leg and headroom are sufficient to handle a pilot up to 6’6″ tall, plus passenger. For storage, a standard-equipment 10 cubic foot cargo pod is normally installed inside the cockpit, behind the seats. A skylight in the roof is available as an option.

The landing gear is a chromoly steel tube and bungee shock cord arrangement. Each Merlin GT is supplied with standard 8.00 x 6 tundra tires (approx. 19″ high x 8″ wide). Independent hydraulic toe brakes are also standard on every Merlin GT.

The Merlin is an aircraft designed to fly out of short unimproved strips. The plane is fairly tail-heavy on the ground, ensuring no tendency to nose over and damage the prop. This feature also makes the Merlin easier to handle on landing, with ample positive control of the fully steerable tailwheel.

Wing construction on the Merlin has a leading edge built of 2024T6 aircraft aluminum. The 9″ aluminum “I”-beam main spars (0.080″ laminated) and wing leading edges (“D-cells”) are completely pre-built by the Merlin Aircraft factory. The wing ribs are constructed by the builder, using high-density foam for lightweight and strength. These easily assembled ribs are capped with heavy-duty 0.040″ aluminum “U” channels. These “U” channel rib caps are joined from top to bottom of the rib by 1 ” straps of aluminum. There is no structural wood in the aircraft. Foam has been chosen because of its durability. Fewer ribs are required due to the rigidity they provide, simplifying construction and installation. The foam ribs can be repaired, if necessary, much more easily and affordably than either wood or aluminum stamping. Slotted full span ailerons have been incorporated into the design, for slow flight control and a responsive roll rate. The aileron horns are made of heavy aluminum and have never experienced any cracking or in-flight failures. The ailerons are controlled by push rods inside the cockpit, not by cables in the wing. This system eliminates high maintenance pulleys, hardware, bell cranks and control cables. The aileron control rods are easily accessible for routine inspection. Combined with the pre- fabricated “D” cells and aluminum capped foam ribs, these simple wings are the key to the Merlin GT’s established 350 hour quick build time. Each Merlin GT also comes with simple “folding-wing” capability, to facilitate trailering and road transport.

Typical take off distances with the 65 HP Rotax 582 is 150 to 200 feet dual, and about 100 feet solo. With a power-off stall as low as 34 mph, with low inertia and plenty of induced drag during landing (from the simple high-lift wing), landing rolls at full gross weight are often only 250 ft, and a true cruise speed of 85 mph.

Being designed in Ontario, Canada, operation on floats and skis were a prime concern from day one. The first Merlin off the production line was fitted with Full Lotus amphibious floats. Each kit since has float-mounting plates welded to the airframe, making every aircraft easily adaptable to floats. In winter, the floats can easily be replaced by skis. These fit directly onto the existing axle tubes. Cruise speeds observed on skis are the same as on wheels-85 mph with the standard 68″ ground adjustable two-blade prop.

The Merlin GT is built using tried and proven building techniques, materials and aircraft hardware. Component kits were also available.

First flown in January 1985, the Merlin GT-582 operates on wheels, floats or skis. One option is the Rotax 618 engine.

The AirComp Merlin GT-Rotax 912 features a wing folding option, and a 100 hp Continental option. First flown in January 1993.

Gallery

Aerocomp inc Merlin
Stall: 30 kt / 35 mph / 56 kmh
Cruise: 78 kt / 90 mph / 145 kmh
VNE: 104 kt / 120 mph / 193 kmh
Empty Weight: 261 kg / 575 lbs
MTOW Weight: 590 kg / 1300 lbs
Climb Ratio: 1500 ft/min / 8 m/s
Take-off distance (50ft obstacle): 400 ft / 122 m
Landing distance (50ft obstacle): 400 ft / 122 m

Aerocomp Merlin GT-582
Empty weight: 220 kg
Wing span: 9.1 m
Wing area: 15.3 sq.m
Fuel capacity: 49 lt
Engine: Rotax 582, 64 hp
MAUW: 520 kg
Seats: 2
Max speed: 190 kph
Cruise speed: 135 kph
Minimum speed: 65 kph
Climb rate: 7.5 m/s
Fuel consumption: 15 lt/hr

Merlin GT-582
Speed max: 120 mph
Cruise: 85 mph
Range: 333 sm
Stall: 34 mph
ROC: 1100 fpm
Take-off dist: 105 ft
Landing dist: 150 ft
Service ceiling: 18,000 ft
Engine: Rotax 582, 65 hp
Fuel cap: 16 USG
Weight empty: 480 lb
Gross: 1300 lb
Height: 6.5 ft
Length: 20 ft
Wing span: 30 ft
Wing area: 167 sq.ft
Seats: 2
Landing gear: tail wheel

AirComp Merlin GT-Formula 110
Speed max: 120 mph
Cruise: 98 mph
Range: 379 sm
Stall: 40 mph
ROC: 1600 fpm
Take-off dist: 120 ft
Landing dist: 175 ft
Service ceiling: 18,000 ft
Engine: Subaru, 110 hp
HP range: 65-120
Fuel cap: 16 USG
Weight empty: 615 lb
Gross: 1300 lb
Height: 6.5 ft
Length: 20 ft
Wing span: 30 ft
Wing area: 167 sq.ft
Seats: 2
Landing gear: tail wheel

AirComp Merlin GT-Rotax 912
Speed max: 120 mph
Cruise: 93 mph
Range: 350 sm
Stall: 38 mph
ROC: 1500 fpm
Take-off dist: 100 ft
Landing dist: 150 ft
Service ceiling: 18,000 ft
Engine: Rotax 912, 120 hp
HP range: 65-120
Fuel cap: 16 USG
Weight empty: 615 lb
Gross: 1300 lb
Height: 6.5 ft
Length: 20 ft
Wing span: 30 ft
Wing area: 167 sq.ft
Seats: 2
Landing gear: tail wheel

Blue Yonder Merlin GT/EZ
Cruise: 92 mph
Range: 810 sm
Stall: 32 mph
ROC: 1500 fpm
Take-off dist: 100 ft
Landing dist: 200 ft
Engine: Rotax 912S, 100 hp
HP range: 65-130
Fuel cap: 24 USG
Weight empty: 796 lb
Gross: 1450 lb
Length: 21 ft
Wing span: 33 ft
Wing area: 186 sq.ft
Seats: 2
Cockpit width: 41 in
Landing gear: floats

Blue Yonder Merlin
Top Speed: 100 mph.
Cruise Speed: 70 mph.
Stall Speed: 35 mph.
Fuel Capacity: 32 gal.
Range: 350 n.m.
Takeoff Distance: 50 ft.
Landing Distance: 175 ft.
Service Ceiling: 15,000 ft.
Empty Weight: 789 lbs.
Gross Weight: 1400 lbs.
Height: 7 ft.
Length: 23 ft.
Wingspan: 35.5 ft.
Wing Area: 235 sq. ft.
Number of Seats: 2