The engineer who built an airplane in his backyard is flying around Europe with his family

Initially, he inquired about the planes available for hire. But they were mostly two-seaters and four-seaters that were rusty around the edges. It didn't take Ashok long to consider building one on his own. He started with a kit.

"The Sling TSi - a four-seat, single-engine, low-wing homebuilt aircraft sold in kits by the Sling Aircraft easily fit the bill with the mission I had in mind - regarding the endurance, speed, and load. I was already aware of the approval process for homebuilt planes in the UK. So, I decided to go ahead," says Ashok.

Around $226,000 and some 1,500 hours later, G-Diya was born.

Not your average amateur aircraft builder

"Diya is my youngest daughter, and G is the ICAO airport code for the UK," says Ashok, a native of Alappuzha, Kerala, India, who is currently settled in Billericay, Essex, with his wife Abhilasha Dubey and their two daughters.

Ashok stresses that he didn't 'design' the plane - he just built the aircraft. "Ultimately, even though it's a kit, every aircraft is unique, as builders have various options to choose from - different engines, avionics, and propellers. It's down to the builder to decide their mission and build an aircraft accordingly. And the UK has quite a tradition of such homebuilt aircraft - it's a huge sector. The Light Aircraft Association has been overseeing the construction and maintenance of homebuilt aircraft for decades. So, there's a wealth of information and resources available," he explains.

Then, what makes Ashok different from the other home builders?

"The story broke in the UK primarily because it was a Covid-lockdown project. Also, though homebuilders are pretty common in the [UK], the demographic mostly comprises retired persons who have the time and finances to complete such projects, which can take up to five years. The actual journey of building an airplane is more rewarding than finishing and flying it. Therefore, a lot of people take it solely as a personal project. Another factor is - my entire family got involved in building the plane. You couldn't rely on anyone else because of the lockdown. I suppose these probably made my work distinctive," says the 39-year-old working with the Ford Motor Company.

The entire process spanned over 18 months - Ashok received his kit in April 2020, and by November 2021, the aircraft was ready to scale heights. However, the certification paperwork took quite a long time. "The approval required was the one needed to test fly. That took a while as winter in the UK isn't forgiving, and we had to wait until February," he tells us.

Leaning to fly

Ashok used a Rotax 915 IS, an Austrian aircraft engine.

"I wanted an aircraft that could be flown for a three-hour trip and back without the need for refueling. The Rotax 915 suited my mission, but it was a new model and wasn't available in Europe at the time. The only option was to fly down to Johannesburg in South Africa to test fly [a similar] aircraft. I was rather impressed by its performance and returned after placing an order for the kit," says Ashok.

The engine can generate 141 hp power and travel at a maximum speed of 148 nautical miles (275 kph). It can fly up to 1,630 km at an altitude of 18,000 feet. With avionics from Garmin and Garmin's autopilot system, the G-Diya has a wingspan of 9.54 meters, a length of 23.5 feet (7.175 meters), and a height of 8 feet (2.45 meters).

"The kits were rather excellent on their own and were designed for an amateur to build with a reasonable amount of skills. Most of the structure is riveted together, but there were fiberglass components that had to be cut to the right shape. Those elements were challenging because it's part science, part art. In aviation, they say that if it looks good, it flies well," says Ashok.

Ashok says that he outsourced some elements of the avionics in the aircraft. "I found a company in the US to build the harness and the panel for me, and they shipped it over. I just had to install it on the aircraft and test the same. Also, I leaned in on the experience of a few others who are more familiar with the safety aspects of the build. You also pick up many skills on the way - everything is about utilizing the information available," he says.

The UK Civil Aviation Authority monitored Ashok's work - he could proceed to the next phase only after inspection and approval.

The flight permit was issued in May 2022, Ashok has taken his family on a few trips to the UK. In June, Ashok and his other pilot friends flew across Europe, visiting France, Germany, Austria, and the Czech Republic. "The UK has a lot of airfields and airstrips, and we're very excited to travel further. Other places on the list would be Disneyland Paris and the highlands in Scotland," says Ashok.

The perils of aviation

Avionics aside, Ashok states that time management and the need for a large workspace were the most challenging aspects of the project. Nevertheless, he says that a homebuilt aircraft can mitigate some of the general risks in aviation. "I'd trained in an old Cessna which was built in the 1970s. There were several instances wherein I'd felt that it wasn't safe for myself, let alone my family. I knew that I'd feel more comfortable in flying an aircraft that I've built myself," he says.

Of late, several celebrities have come under fire for racking up the most CO2 emissions this year using their private jets. It does seem like Ashok has taken it into account.

"If I was undertaking my travels in a Cessna which is a legacy aircraft, I'd be burning 40 liters of leaded fuel in an hour. The Rotax 915 uses unleaded fuel and is more efficient than traditional engines. Compared to a traditional aircraft, the Rotax is a lot more fuel-efficient. There is a small carbon footprint, I agree, and in an ideal world, we would love to reduce it and perhaps switch to electric. But, ultimately, any form of energy will leave a footprint," says Ashok.

Though he plans to jet-set into the world, Ashok already has his eyes on another aviation project, a two-seater aircraft that is more affordable than G-Diya.