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.

GlaStar right door

GlaStar Door Installation Tips

Door warpage: It sounds like you have encountered a door fit problem which we have encountered on many Glastars as well. What we have...
Low corners on the sides of the instrument panel enhance visibility, but the center column could impede access and reduce leg comfort. Photo: Peter Braswell.

GlaStar Systems Installation Tips

Flap handle detent notches: Trial-fit flap detent notches in the flap actuator lever between the seats prior to chroming. I had to widen my aft-most...
glastar firewall assembly drawing

GlaStar Firewall Template Tip

I started out by using the supplied template to cut out a cardboard firewall. It did not come close to fitting. I started all...
Wing ribs

Making Your Own Ribs

Making ribs is a simple process not requiring more than what is found in a standard wood shop. You will need a oak form...
glastar firewall assembly drawing

GlaStar Firewall Installation Tips

Firewall installation: Install engine and all engine plumbing/wiring prior to installation of firewall. Carefully measure where holes should go, then drill firewall holes, install...
Top deck installation. Photo: Zach Chase/FiberTech Composites

Finish Glass Work Tips

Glassing the top on: When glassing the tail of the top deck to the aft part of the fuselage there is a problem area....

GlaStar Static Port Reverse-Engineered

A number of builders have been wanting to get the exact dimensions for the GlaStar static port that was once available from Stoddard-Hamilton. After...
Keeping fiberglass parts in a hot attic comes with the risk of warping.

Fiberglass Parts Warping in Hot Storage

Glenn Culver sent this tip. I've had a problem with warped GlaStar doors after storing them in a hot location. If I were to do it...

GlaStar Wing Folding

For a taildragger, folding the wing is an accident waiting to happen. Mess up and you will damage the airplane like I did. I...

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...