Ercoupe lover’s heaven

Let’s start with placards. In the flying universe, a “placard” is a small sign or plaque installed in the cockpit. It relays critical information to the pilot about the operation of the airplane. For example, a placard will tell you what fuse or circuit breaker powers which part of the plane’s electrical system. In a plane with flaps, a placard will tell you the maximum speed at which it’s safe to deploy them. In planes with complex fuel systems, placards will guide pilots in the operation of the fuel tank selector switches. In planes with retractable landing gear, placards will instruct the pilot on how to operate the system.

We have no flaps. We have no fuel selectors. And our landing gear stays in the same place all the time. Accordingly, our placards are pretty simple.

One says, “This airplane characteristically incapable of spinning.” That one was a Godsend. The government actually required the manufacturer to place the plane’s number one marketing claim on a cockpit placard. Another placard says, “Beware propeller. Leave airplane from rear of wing.” Well, never underestimate the stupidly of the human race. A third is an ON-OFF placard for the nav lights switch.

But Syd Cohen’s immaculately restored Ercoupe Scampy has an unusual placard on the panel, probably the only thing in his plane that’s not 100% authentic. It reads: “AREN’T WE LUCKY?”

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Photo: Lisa F. Bentson

We sure the hell are.

Lucky for lots of reasons, but foremost among them is the fact that the maker of our nearly 80-year old airplanes is still in business. Well, sort of. It’s kinda complicated, and to be honest, the story of the Ercoupe is rather sordid. Yes, like a movie starlet from the golden age of Hollywood, the Ercoupe has had a lot of husbands.

The plane started life as the brain child of a company called Engineering and Research Corporation, also called ERCO. Development began in 1936, and ERCO launched sales of the plane in 1940. After the war, when the aviation economy collapsed, ERCO decided to get out of the plane-building biz and sold the Ercoupe lock, stock, and barrel (literally) to Sanders Aviation in 1947. Next, the plane, and its all-important type certificate, was picked up by Univar Aircraft Industries in 1950. But that union didn’t last either. Her next husband was the Forney Aircraft Company in 1955. But a stable wedlock just was not to be for the Ercoupe. In 1960 Air Products Company took over, but again it was a short marriage, and in 1964 Alon Inc. bought the Ercoupe. That union lasted until 1967 when the Mooney Airplane Company purchased the plane. Then, finally, just like Elizabeth Taylor and Richard Burton, the Ercoupe returned to her third husband, Univar, in 1974—where she finally settled down, the two staying together for 45 years and counting.

Of all her suitors, Univair is the only one that didn’t actually build new Ercoupes. Both in the early ‘50s, and since ‘74, Univair has focused solely on the spare parts biz.

So let’s talk about those parts.

Apparently, each time the Ercoupe took up with a new manufacturer, more than just a marriage license was involved. The bride came complete with all her household goods, including her parts inventory and the various jigs and machines used to make them.

And that’s why we’re lucky.

Unlike the owners of most really old airplanes, we have an outfit that continues to support us. To supply us with parts. Univair has all the machining tools and expertise necessary to make virtually every part that makes up the Ercoupe from the original decades-old drawings, all of which came back home with the bride. That’s cool. But they also have a large supply of what would be called “new old stock” on eBay. But still, how many original parts could possibly still be around from the 1940s?

You would be amazed. I was. I have seen the promised land, and it’s Ercoupe heaven. So this is a PlaneTale of many parts. Literally.

It all started when AOPA assigned me a Rusty Pilot Seminar at Centennial Airport, on the south side of the Denver Metro area up in Colorado. Tessie looks more like a greenhouse than an airplane right now, so flying up the east side of the Rockies to get there was out of the question.

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Catching a commercial flight would require me to drive two hours in the wrong direction, only to be delivered an hour away on the other end, so driving up was the obvious choice. And as I was driving, it would cost me nothing extra to have a copilot on the adventure, and Rio agreed to come along.

I needed to arrive a day early to set up for the seminar, but I knew we’d have some spare time, especially if we got an early start, so I cast around for something to do. And then it occurred to me: Maybe we could visit Univair, who are located on the East side of the metro area. I guess they were in my mind because we’d just recently needed to order a pile of those parts I’m lucky to be able to order. Or maybe it was because I’d been in contact with them to hit them up for donations for the Ercoupe Owners Club scholarship auction as part of my duties as the Coordinator of this year’s convention. Anyway, I reached out about dropping in, and they were gracious, inviting us to come by for a tour.

Given the age of the company (it was founded in 1946) and the fact that they focus on older airplanes, I’d sorta expected them to be in, well, you know, and older building. But in fact, when we pulled up, we found the Univair building is surprisingly modern-looking on the outside.

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And, oddly, for a plane business, Univair sits far from any modern airport. They’re located in an industrial park that’s 50% large blocky commercial buildings and 50% farmer’s fields. Actually, once upon a time, there was an airport literally next door to Univair. Called Sky Ranch, all that is left is a short stretch of crumbling asphalt called Sky Ranch Road, and two World War II vintage hangars, one of which has a control tower on the corner. The runways have evaporated, their foundations buried under warehouses. What must have been the apron is now a parking lot for a fleet of cement trucks.

Dead airports are sad, but having Univair there somehow takes the sting out of it.

We were given a complete tour, staring in the office building, where the lobby has a small museum of key famous products in glass cases, then on to the sales offices, and the printing shop where Univair keeps many otherwise lost tech publications alive. Next, we entered the machine shop. I gotta say, the Univair shop is a museum of manufacturing. They have massive, towering machines dating from the 30s and 40s. Lathes from the 70s. State of the art computerized plasma cutters. With all this gear, if they don’t have what you need in stock, they can make it; and having two engineers on staff makes that process faster. Rounding out the shop are a trailer home-sized sand blast chamber and a huge painting booth. In the Univair shipping department, they build custom crates to fit all manner of oddly-shaped parts ranging in size from jewelry-petite to assemblies larger than cars.

We also got to meet many of the Univair peeps, including the boss, who is sort of royalty, being the third generation of his family to run the place. And it must be a good place to work, as most of the people we met had been there for years.

The highlight of our tour for me was the warehouse, a dimly-lit warren of narrow passageways between towering shelves. It has the creepy but exciting feel of an Indiana Jones/Laura Croft ancient temple. Only, you know, aviation themed.

And like all Hollywood ancient temples, it was full of treasure.

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A wall of wing spars. A shelf of header tanks. A cowl side, glowing pristine aluminum with a lathe-straight hinge. A bundle of throttle cables with faded maroon Bakelite knobs, hanging off a shelf high above our heads, an airplane version of tangled jungle vines high in the trees.

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Box after box after box after box after box of Ercoupe parts. Floor to ceiling, three narrow isles worth. Boxes of things we recognized. Boxes of things we’ve bought. Boxes of things that had us scratching our heads.

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Photo: Rio A. F. Dubois

And boxes of things that left us amazed and in awe, like Ercoupe pretzel yokes, still in their original wood packing crates, each yoke wrapped in newspaper with 1946 datelines.

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But there’s more than just inventory at Univair. Out beyond the warehouse, in the backlot, there’s an odd tombstone-looking object. At first glance it appeared to be the final resting place of the nose bowl, a grey solid granite memorial carved by a sculptor into the likeness of the real thing in its prime.

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But it’s no memorial to the dead. It’s one hand of the creator, a key tool to make new living nose bowls. It’s a mold. Over it, flat sheets of aluminum are placed, then squashed down with room-sized hammering equipment to stamp out the front ends of Ercoupes, each one a clone of the previous one. I’d no idea how they were made. In fact, before seeing the tombstone, I’d never even thought about it.

The rest of the yard is overflowing with giant and slightly rusty assemblages that are hard to identify. Is that a jig for forming an Ercoupe tail? Maybe. Oh, look at this, maybe this was used to make our wings.

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Our guide tells us that when they run out of something, the proper machine tools are moved inside from the yard until the inventory is restocked, then it’s back out to the yard until needed again.

Sadly, given all that Univair has in the Ercoupe department, we’re apparently a very small part of their business; I’m told only about 3%. Luckily (Aren’t We Lucky?), Univair is polygynous—also supporting classic Aeroncas, Champs, Citabrias, Luscombes, Cessnas, Stinsons, Taylorcrafts, and the ever-popular Piper Cubs, so Univair isn’t relying solely on us ‘Coupers for their survival.

And that’s the sad truth of Ercoupes. The line has never been quite a failure, but also never quite a success for any of her many owners throughout history. Ercoupe dreams fly higher than her numbers.

Back in the warehouse once more, on a bottom shelf, I find many wooden boxes of placards, including identification placards—called Data Plates in the biz. Every plane built has one. It records the plane’s serial number and its date of manufacture.

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Photo: Rio A. F. Dubois

There were of hundreds—maybe thousands—of blank data plates in the Univair warehouse; all created many decades ago, each waiting to be riveted onto a new plane rolling off the assembly line on pristine tires. Boxes of data plates for planes never built. Just like all the thousands and thousands of other parts, railcars full of them, it shows the optimism of ERCO in the post war world. How they believed, really believed, that they’d fill the skies with our twin-tailed marvels, put their money where their mouths were, and were ready to do it.

Sadly, it was not to be. Still, by some miracle, everything we need to keep our birds flying, from parts to placards, still exists, and is only a phone call to Colorado away.

Aren’t we lucky?

 

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