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Hints For Homebuilders - What would you like to see?

Posted By:
Joe Norris
Vintage Aircraft Association MemberYoung Eagles Pilot or VolunteerHomebuilder or CraftsmanAirVenture Volunteer
328
Posts
137
#1 Posted: 2/24/2010 16:08:57

In each month's issue of EAA's Sport Aviation magazine you'll find a number of handy "Hints for Homebuilders".  In the EAA spirit of "members helping members" many of these hints are developed from ideas submitted by members or as a response to questions sent in by members.

With this in mind, I invite you to submit your ideas for "HFH" subjects.  Do you have a question on how to do something?  Are you up against a problem on your project that you need some help with?  Do you have a hint of your own you'd like to share?  LET US KNOW!  No question is too basic.  No idea is too simple.  We want to see your personal "tricks" for doing things easier/faster/cheaper, and we want to know what you want to know!

Post your HFH questions and ideas here!!

Thanks,

Joe Norris

EAA Homebuilders Community Manager



Lasciate ogne speranza, voi ch'intrate
Joanne Palmer
Young Eagles Pilot or VolunteerHomebuilder or Craftsman
276
Posts
68
#2 Posted: 2/25/2010 10:04:55

Joe

How about some of these. HFH Projects

 Mechanical: Use of tools

Shrinking and fluting pliers

Dimpling tools, Large throat dimplers, riveters

Rivet squeezers, Rivet Guns, bucking bars

Blind Rivet tools

Cutting tools

Drills, Countersinks, combined drill and countersinks, reamers

Hole Saws, fly cutters, step drills

Abrasive cut-off wheels, polishers, surface finishing disks (how to blend)

Wood tools

Jig saws, jig saw blades

Forming tools (Surform)

Composite tools

Layup rollers, squeegees

Fabric cutters

Small scales and ratio mixers for adhesives

Electrical tools,

Wire connector crimpers/positioners, Connector pin insertion tools

Components Installation and limitations of Specialty fasteners

Blind rivets, blind bolts, blind nuts, nutplates

Hi-lok pins/collars, Lockbolt pins/collars

Dzus fasteners, Camloc fasteners

Click-bond studs, standoffs, nutplates, electrical loom supports

Adhesives & sealants

Firewall sealants

Electrical Connectors

 

 

Don't forget that there are some homebuilders who don't have access to people with experience building aircraft.



Joe Norris
Vintage Aircraft Association MemberYoung Eagles Pilot or VolunteerHomebuilder or CraftsmanAirVenture Volunteer
328
Posts
137
#3 Posted: 2/25/2010 10:53:30

Joanne,

Thanks for the comprehensive list!  Some of these look like good subjects for the magazine while others might be more suited for video Hints For Homebuilders for the website.  Either way, good input!

Thanks again!

Joe



Lasciate ogne speranza, voi ch'intrate
Rick Galati
Homebuilder or Craftsman
22
Posts
8
#4 Posted: 2/25/2010 13:03:42 Modified: 2/25/2010 14:27:25


 

The plans call for 8 equally spaced holes. The easiest way I know how to lay out any number of equally spaced holes on a ROUND tube with reasonable accuracy is using a piece of tape, a marking pen and a fan spacer. If you don't have a fan spacer, a machinist scale will work almost as easily. The pictures should explain the process:.


vqmkhl.jpg

 

 



Rick Galati RV-6A N307R "Darla!" RV-8 N308R EAA Technical Counselor
John Fasching
Homebuilder or Craftsman
2
Posts
0
#5 Posted: 2/25/2010 19:10:39

I would like a fairly in-depth discussion of torque wrench use. Digital, click, and beam types...advantages, accuracy, cost, utility, etc.

 

Thanks



Charlie Becker
Homebuilder or Craftsman
109
Posts
41
#6 Posted: 2/25/2010 19:23:15

John,


We have two Hints for Homebuilder Videos we published on Torque Wrench techniuque.

 

 

 

 


 

 

 




Built Sonex, Own J-3 Cub
Joe Norris
Vintage Aircraft Association MemberYoung Eagles Pilot or VolunteerHomebuilder or CraftsmanAirVenture Volunteer
328
Posts
137
#7 Posted: 2/26/2010 10:05:01

Nice hint Rick!  We'll probably use it!! 

Thanks!

Joe



Lasciate ogne speranza, voi ch'intrate
Henry D Babenco
Homebuilder or Craftsman
1
Post
1
#8 Posted: 2/26/2010 12:51:57

Joe,

How about a series on how to set up a paint gun and blow polyurethane paint, epoxy primer, etc.

 

Dan

 

 



Rick Galati
Homebuilder or Craftsman
22
Posts
8
#9 Posted: 2/27/2010 11:57:36 Modified: 3/1/2010 09:42:45

 
Wing Jack 1.JPG

 

I am hardly the first person to build a wing jack based upon this clever design but here is my example of an inexpensive alternative to buying a brand new wing jack.  Its basic design is adaptable for use on most low wing aircraft. Mine was sized to accommodate most RV's. The best part is that the jack can be assembled in a matter of hours using off-the shelf parts available at most big box stores. 
The basis for the clever design is a 3-ton ram jack available at Harbor Freight. I paid $45 for it on sale. top://tinyurl.com/7eb5ed

The other required items needed to assemble the wing jack brought my total cost up to about $60. Not bad.

My local HF had the 3-ton jack in stock. I then swung by Home Depot to pick up a
 2'X2'X3/4" piece of plywood, two 3-1/2" band clamps and one 10' stick of 1/2" electric conduit.    I also used aircraft quality screws, bolts, nuts and washers I had on hand.
My variation features a spare tie down ring that I cut up and turned down to size by chucking it to a spinning cordless drill, grinding to size on my Grizzly 12" bench sander and finally polishing it on a scotch brite wheel. I then hollowed out the concave "socket" surface on the top of the jack finishing with a rotary ball file. A significant amount of material was removed.  I'm guessing a lot of pressure is concentrated into that small area of the jack so to guard against the (somewhat remote?) possibility of the surface ever failing under load, I plugged the hole in the side of the jack located directly underneath. I used steel dowel stock to plug the hole, secured in place with JB Weld. For handle stowage, I used a couple of 1/2" electrical conduit clamp brackets and even threaded a small block of wood to stow the ball when not in use. Not bad for a few hours work on a bitterly cold weekend.


Wing Jack 2.JPG

 

 



Rick Galati RV-6A N307R "Darla!" RV-8 N308R EAA Technical Counselor
Jeff Point
Vintage Aircraft Association MemberYoung Eagles Pilot or VolunteerHomebuilder or CraftsmanAirVenture Volunteer
94
Posts
65
#10 Posted: 2/28/2010 03:14:25

Joe,

On another thread we had a small discussion about using the Tubemiter program for notching tubes for clusters.  I find Tubemiter very useful, and it is a good high-tech application of an old-fashioned technique.

This thread has some discussion about it (see post #6 in particular.)

http://www.oshkosh365.org/ok365_DiscussionBoardTopic.aspx?id=1235&boardid=147&forumid=178&topicid=3725



Bill Morse
Homebuilder or Craftsman
2
Posts
1
#11 Posted: 3/4/2010 05:11:14

Morning Joe:

 

I am finishing a Sonerai IIL and am reworking the fuselage tubing.  My gas welds are not as nice as TIG welds. I am interested in seeing examples of good gas welds, especially at tubing intersections.   Also, what is the best way to remove and replace a plate or tang welded to tubing.  I am working with 4130 at this time.

 

I'd like to make an air/oil separator in aluminum and would like to see good welds with this material as well.

 

Thanks,

 

Bill



wmcfi
Don Williams
Homebuilder or Craftsman
1
Post
0
#12 Posted: 3/4/2010 22:08:11

I'd like to see a vid on making d-sub connectors; the different types of pins, crimpers, and wire sizes accomodated.

 

Don



Jeff Boyd
Homebuilder or Craftsman
3
Posts
0
#13 Posted: 3/4/2010 23:59:57

More composite info. There is a lot not covered, resins, fiberglass types and when to use, different materials joined with composites, vacume bagging, recognizing problems in layups etc....



David Lewis
7
Posts
1
#14 Posted: 3/5/2010 02:25:41

How about a section with a series of videos explaining flight test parameters and methods.

Another series might address cabin treatments and upholstery.

And finally, how about a series on prep and painting your aircraft.

David Lewis

RV-7A Empennage & Wings



Mark Williams
1
Post
0
#15 Posted: 3/5/2010 08:47:59

I would like to see Hints for precision drilling of replacement spars.  The most critical area is strut attachments and butt attachment. 

 

Thanks

 

Mark Williams



John Little
Homebuilder or Craftsman
1
Post
2
#16 Posted: 3/5/2010 09:37:29

Hey Friends!

I know it has been addressed before, but aligning and installing DZUS fasteners is still very challenging. Maybe you can make it look easy for us!  Thanks!  John L



Roger Wibbels
1
Post
0
#17 Posted: 3/5/2010 10:35:50

I would like to see some basic aircraft wiring for those of us who are electrically challenged.


Roger Wibbels

Atwater, Ca.



Joe Norris
Vintage Aircraft Association MemberYoung Eagles Pilot or VolunteerHomebuilder or CraftsmanAirVenture Volunteer
328
Posts
137
#18 Posted: 3/5/2010 14:59:23

Thanks for all the good ideas.  Keep them coming!  We continue to work on new video clips as well as printed hints in Sport Aviation, so the more ideas the better!

Cheers!

Joe

 



Lasciate ogne speranza, voi ch'intrate
Richard Williams
3
Posts
2
#19 Posted: 3/6/2010 09:25:59

Joe,

We haven't seen anything on metal shaping. Let's start with simple fairings and work up to cowls! Any beginner use of shrinker/stretcher, english wheel and planishing hammer would be great.



Bob Shumaker
Homebuilder or Craftsman
1
Post
0
#20 Posted: 3/6/2010 10:55:35

Joe:

HFH is a great resource and is greatly appreciated.  Here are some topics I'd like to see addressed, even though some of them may not fit the HFH short format:

-magneto maintenance

-engine timing

-repairing metal prop nicks

-changing a tire/tube

-brake puck replacement

-painting

Many thanks,

Bob Shumaker

Glasair II-RG



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