Home GlaStar & Sportsman How to & Builder Tips

How to & Builder Tips

Ever wonder how to make a certain part with fiberglass or sheet metal? Or fix an oil leak? These tips can guide you and reduce the amount of head-scratching.

Muffler shroud

Easy Muffler Shroud

This is an easy way to make a mold for a muffler shroud layup. I pegged a board which I clamped to the table of...

Water Seal

Water leaks and noise have been things I’ve wanted to solve for a long time. Once my Sportsman was painted, I taped some simple...

GlaStar Boost Pump Installation

The old hands at aircraft building in my area impressed upon me that it was necessary to mount a boost pump, if using one,...
Superior XP-400 piston. Top two are compression rings and the bottom is the oil control ring.

Engine Break-in

Break-in of an engine refers primarily to the initial phase of operation in which the piston rings will "seat" against the cylinder walls. Run-in refers...
McFarlane Vernier Assist Controls

Vernier-Assist Throttle Control

I struggled with the ACS throttle control cable on N11YM for the first 82 hours. I had two issues: The throttle control was too...

California Custom Metal Polish PIREP

California Custom makes two products of interest to some of us crazy enough to think we want polished aluminum surfaces on our GlaStar or...
Rigging jig used to hold the right control stick in a vertical orientation.

Sportsman Aileron Rigging Process Improvement

During the process of final-rigging of the ailerons in our early-model Sportsman it became abundantly clear that a very small number of improvements to...

Wrap School

I have found that wrapping the airplane can be quite frustrating but I’m learning a lot. I've been testing 3M 1080 wrap and the Avery...

Switching from Hartzell Blended Airfoil to a Trailblazer Propeller

I changed the propeller on my Sportsman from a 74” Hartzell Blended Airfoil (HC-C2YR-1BFP/F7497) to 76” Trailblazer composite (HC-C2YR-1NX/NG8301-7X1). These are my learnings and first...

Assembling Sportsman Flaps Without Helpers

I didn't have any helpers like the manual warns for bending and drilling the top skins for the flaps since they are 10 feet...