| I want to take an opportunity at the beginning of | | | | deserve some careful consideration from the |
| this article to interject a few words of caution and | | | | beginning. Hold off on the engine purchase until you |
| insight to aircraft building in general. It is likely that the | | | | are ready for it, but knowing what engine you plan |
| person who wants to build with wood already sees | | | | to use will only help in the building process. Some |
| the monetary advantages. There are still many pitfalls | | | | designs actually require different placement of |
| to watch out for that need careful consideration | | | | structural components that hinge on the weight of |
| before spending money. You will find that wood | | | | the engine. |
| construction has many variables. There are as many | | | | A full size set of drawings are an absolute must for |
| opinions as there are designs when it comes to | | | | those of us who are not Master Draftsmen. Can you |
| construction techniques. Opinions are great for | | | | imagine trying to make matching and accurate full |
| consideration, but you must remember that this | | | | size patterns of 13-foot wings based upon sketches |
| aircraft when completed will be registered with the | | | | done on 8.5 x 11 inch sheets of paper? Unless you |
| FAA as (your name followed by the kit manufacturer | | | | are incredibly talented and visionary, I would put this |
| and model.) You are the builder and you need to be | | | | high on the list of requirements. On the other hand, |
| satisfied with the kit manufacturer's engineering, or | | | | full-scale prints may not be necessary if you are |
| change it to suit yourself. It is quite likely that the | | | | purchasing a quick build kit that has the larger length |
| manufacturer's engineer has used approved and | | | | pieces precut and the cut lines etched on the |
| accepted FAA practices, but it always good to ask | | | | plywood. There are slight problems with any way |
| up front so you know what you getting into. | | | | you do it and manufacturers all have their own way |
| Whatever changes you make will still need to be | | | | of getting you accurate measurements. If you get |
| acceptable by the FAA inspector or an FAA | | | | full-scale drawings for patterns and jigs, make sure to |
| Designated Airworthiness Representative who will be | | | | keep them in a climate-controlled environment to |
| signing off on the airworthiness of your completed | | | | keep them from shrinking and expanding with |
| project. | | | | humidity. |
| It is likely that you already have some idea in your | | | | A very clear and concise set of instructions will |
| mind of what your plane looks like. Choices you make | | | | generally keep you from getting ahead of yourself. |
| now need focus on increasing the possibility of | | | | Take time to read all of the literature before |
| completing the project. Beyond the fact that you are | | | | uncrating the kit. Chances are the information will be |
| planning to build with wood are the basic decisions on | | | | rather abstract, so read it again if you need to. I |
| utility. Are you looking for a single place or a | | | | understand that some manufacturers will send the |
| two-place model? Do you prefer high or low wings? | | | | literature out to you ahead of time for opportunity |
| Are you interested in a sleek speedy wing or a | | | | to comprehend it. When your boxes arrive, you will |
| high-lift wing requiring shorter take-off and landing | | | | need to carefully inventory, inspect and mark what |
| distances? What engine will you be using? Should an | | | | you have received. While it is important to know |
| amphibious model be considered? Will you want floats | | | | what you have, it is also important to keep track of |
| in the future? Do you prefer a tail dragger or tri-cycle | | | | those things you will not need for a few months. |
| gear? A huge problem will likely develop if you change | | | | Most kits have a bill of materials to help you |
| your mind half way through the project. | | | | complete this step. Inform the manufacturer of any |
| Purchasing a partial kit does not help to keep you on | | | | damaged or missing parts as soon as possible. |
| task and contributes to lack of vision. Building from | | | | The fast build kits certainly take less time, but you |
| plans without the benefit of any kit at all only makes | | | | will miss a lot of the fun in doing the detail work. The |
| your effort that much more complicated and time | | | | money you saved by not purchasing the fast build kit |
| consuming. "Scratch building" may be a good option | | | | will manifest itself at the very beginning. Depending |
| for your second plane, but certainly not for a first | | | | upon the kit manufacturer, you will likely find yourself |
| time builder. You may save money over the cost of | | | | cutting and gluing little pieces of wood together from |
| a kit, but the actual cost in materials alone (plus | | | | the start. Making a jig and gluing together ribs can be |
| multiple shipping costs) may not be that attractive | | | | very enjoyable and satisfying, at least for a while. |
| when you consider locating and using your own parts | | | | There is always the possibility of making more than |
| and materials. There are countless examples of | | | | one jig to speed the process up, and there is such a |
| partially completed and abandoned aircraft projects in | | | | thing as needing something else to do on a cold |
| garages, basements, hangers and utility sheds | | | | winter night. |
| throughout the world. Years of searching leads me to | | | | One thing you will immediately become very familiar |
| believe that much of it is due to builders purchasing | | | | with is making test glue joints. During the build |
| partial kits or "plans only" designs. A partial kit can | | | | process, you will occasionally take a couple pieces of |
| become a huge obstacle, especially for the first time | | | | the wood you have been working with and glue |
| builder. At the end of the day, you will find that easy | | | | them together in the same fashion, just as you have |
| access to as many of the materials and as much | | | | been gluing parts together for the airplane. After the |
| information possible will only increase your | | | | glue is set, you will need to pull and tug on the joint. |
| commitment and your focus on finishing the project. | | | | A good glue joint will remain in tack while the wood |
| If you need to cut back, I suggest it be limited to | | | | on either side of it will break. Extremely cautious |
| purchasing nothing less than the entire kit. Choosing | | | | people tend to make test glue joints with every |
| not to get the fast build form of your kit will still | | | | batch of adhesive mixed up while some simply make |
| supply you with enough materials and information to | | | | one test joint every hour or so. Others are satisfied |
| keep you working without interruption until the | | | | with once a day. You are the person who will be |
| airplane shows promise of having a day when there | | | | depending upon the structure to remain in one piece, |
| will be air under the tires. | | | | so test your work. FAA Inspectors can ask for |
| Another major consideration is the weight and | | | | evidence of test glue joints, so you may want to |
| performance characteristics of your engine. Power | | | | save a few and take some pictures along the way. |
| plant choices can be overwhelming and certainly | | | | |