Tips and Tricks  For Aircraft Homebuilders, by Sonja Englert

Tips and Tricks
For Aircraft Homebuilders

by Sonja Englert

ISBN:
0975298488
Copyright Date:
2009
Pages:
130
Binding:
Paperback
Dimensions:
11.0" x 8.5"
Weight:
1.1lbs
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Benefit from the experiments and years of accumulated knowledge from others.

Aircraft homebuilders are sharing their secrets to success. Many homebuilders have discovered ways to build a part quicker, for less money or with better quality while working on their project. Many of them are eager to share what they have learned with other builders and help them avoid mistakes. This book is a collection of the experiences of many builders. No matter what type of airplane you are building or what materials it is made from, there are a lot of useful tips on these pages. They cover the range from setting up a shop, tools and jigs to assembling the structure, systems installation, customizations, finishing and flight testing, many of them with step-by-step instructions.


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TABLE OF CONTENTS:

  • GETTING STARTED
    • Planning the Work
    • Building Time
    • Get Advice Early
    • Understand the Concept of Your Kit
  • SHOP AND TOOLS
    • Heating the Shop
    • Air Compressor
    • Vacuum Pump for Free
    • Machine Set Up
    • Magnets as Clamps
    • Clamping Small Parts in a Vise
    • Scale in a Bag
    • Procedure to Sharpen Scissors
    • Spiral Tubing Cutters
    • Drill Press
    • Depth Stop for Drill Press
    • Considerations for a Fuselage Turning Jig
    • Wing Turning Jig
    • Cutting Large H
    • Protection of Power Chords
    • Flat Surface
    • Dust Removal Table
    • Weights
    • Level the Wings
    • Bicycle Spokes
    • Table as a Jig
    • Wing Jig
    • Drilling and Supporting Large Pieces
    • Creating an Airfoil Template
    • Wing Cradle
    • Storage of Control Surfaces
    • Straight Lines
    • Breathing Protection during Spray Painting
  • WORKING WITH COMPOSITES
    • Riveting Thin Composite
    • Composite Skins and Metal Fasteners
    • Finishing Composite Airplanes
    • Cutting Fabric
    • Composite Access Door
    • Resin and Hardener Dispersal
    • Containers for Mixing Resin
    • Resin Brushes
    • Working with Narrow Strips of Fabric
    • Layup at Lower Temperatures
    • Spreading Resin
    • Carbon Fiber and Corrosion
    • Composite Tubes
    • Fillets
    • Composite Landing Gear Leg Root Fairings
    • Poor Manís Vacuum Bagging
    • Reducing Gaps
    • Bonding Nutplates
    • Bonding Aluminum
    • Bonding Bushing
    • Inserting Tubes Through Ribs
    • Clay as Tooling Material
    • Control Surface Actuator Horn Fairing
    • Sanding Wings
    • Finishing the Bottom of the Fuselage
    • Drilling Composites
    • Composite Fittings
    • Hardpoints and Bolts in Sandwich Structure
    • Making a Mold for a Wheel Pant
  • WORKING WITH METAL
    • Cutting Straight Edges from Large Sheets
    • Bending Wing Skins
    • Jewelers Saw
    • Avoiding Scratches
    • Form Blocks Materials
    • Forming Ribs
    • Cutting Large Holes in Small Parts
    • Bending U-Shaped Brackets
    • Bending Trailing Edges
    • Deburring Sharp Edges
    • Dimpling
    • Clecos
    • Countersinking
    • Drill and Hole Tolerances
    • Drilling Rivet Holes
    • Compromised Edge Distance
    • Riveting Tips
    • Back Riveting
    • Aligning Ribs
    • Skinning a Wing
    • Skin Lap Joints
    • Nutplate Installation
    • Flanging the Lightening Holes
    • Drill Template
    • Radius Template
    • Cutting Tubes
    • Support for Tube
    • Tube Bending
    • Tube Notching
    • Chamfer a Bolt
    • Part Marking
  • WELDING
    • Edges
    • Welding Stainless Steel with a Torch
    • Techniques for Welding Aluminum Alloys
  • WORKING WITH WOOD
    • Staples and Nails
    • Deburring Wood
    • Bonding Parts
    • Bonding a Facesheet to a Truss
    • Varnish
    • Wood Truss on Table
    • Wood Gussets
    • Wood Glue
    • Cutting Thick Blocks of Wood
    • Plywood
    • Holding Gussets and Ribs in Place
    • Clamps
    • Bending Plywood Leading Edges
  • FLIGHT CONTROLS
    • Balancing Control Surfaces
    • Control Surface Leading Edge
    • Lightweight Rudder Cables
    • Flight Control Linear Bearings
    • Sealing Control Rod Penetrations
    • Estimate Control Surface Mass Balance Weight Increment due to Paint
    • Flight Control System Stiffness
    • Flight Control System Bearings
    • Control System Functional Check
    • Cable Retainers for Pulleys
    • Control Cable Fairlead
    • Simple Cable-actuated Trim Tab
    • Casting Lead Counterweights
    • Internal Mass Balance
  • ELECTRICAL SYSTEMS
    • Electrical Grounding
    • Wire Splicing Method
    • Ground Power Connection
    • How to Lace a Wiring Harness
    • Marker Beacon, Transponder and NAV Antennas
    • Internal COM Antennas
    • Tuning a COM Antenna
    • Making a Balun for a Half-Wave Dipole Antenna
    • Electrical System Redundancy
    • Solar Panels
    • Radio Noise
    • Strobe Lights
    • Cutouts in Wingtips for Lights
    • Installations of Landing Lights
  • OTHER SYSTEMS
    • Assistance With Systems Design
    • Ergonomic Rudder Pedal Design
    • Brakes Tubing Installation
    • Brake Actuation
    • Adjustable Rudder Pedals
    • Fuel Pickup in a Tank
    • Fuel Tank Material
    • Grounded Fuel Filler Ring
    • Fuel Cap Retainer
    • Fuel Tank Vents
    • Slosh Box Shape
    • Fuel Gauge Calibration
    • Wheel Pants
    • Low Drag Tie Downs
  • ASSEMBLY
    • Torque Witness Stripes
    • Torque Wrenches
    • Temporary Assembly
    • Sliding Washers into Hard to Reach Places
    • Labels
    • Leveling the Plane
    • Wing Incidence
    • Final Assembly Check
    • Threading the Frayed End
    • Door Gaskets
    • Vent Holes and Drain Holes
    • Slip Ring Brushes
    • Sizing Access Holes
    • Piano Hinges
    • Camlocks
    • Hinged Instrument Panel
    • Storage Space
    • Trim to Fit
    • Duplicating Parts
    • Locating Blind Holes
    • Inserting Bolts in Tight Spaces
    • Drill Guide
    • Easy Paint for Small Parts
    • Powder Coating
    • Primer for Aluminum Parts
    • Changing Tires
  • FABRIC COVERING
    • Rib Lacing
    • Avoid Fraying Fabric
    • Avoiding Glue Stains and Wrinkles
    • New Fabric Covering Material
  • POWERPLANT
    • Protection of the Inside of the Cowling
    • Spinner Installation
    • Composite Baffling
    • Installation of Baffle Seals
    • Oil Access Doors
    • The Hidden Hinge
    • Securing Cable Ends
    • Oil Cooler Door
    • Firewall Insulation
    • Ensuring Your Fuel System is Alcohol-Proof
    • Two-Stroke Engine Operation
    • Manual Mixture Control for Two-Stroke Engines
    • Synchronizing Carburetors
  • CANOPIES
    • Blowing Bubble Canopies
    • Cutting and Drilling Canopies or Windshields
    • Storage of Acrylic and Removal of Protective Coating
    • Canopy Repair
    • Bonding Canopies
  • PREPARING FOR FLIGHT
    • Estimate the Weight Paint Adds to an Airplane
    • Structural Load Tests
    • Final Assembly
    • Airplane Weight and Balance
    • Increasing the Range of a Scale
    • Jacking Points
    • Carbon Monoxide
    • Flight Characteristics and Performance
    • Reducing Pitch Sensitivity
    • Wedges on Control Surface Trailing Edges
    • Wing Root Fairing
    • Improvement of Airflow in Stalls at the Wing Root
    • Improving Directional Stability
    • Gear Leg Fairings
    • Wing Leading Edges

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