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...
clunis-anti-ice-pitot

Pitot System Tips

Heated pitot drain: I installed the system per the plans. The drain valve in a push-to-drain device. It is mounted just below the left-rear...

GlaStar Elevator Stop Plate Installation Tips

DON'T do it like the manual says! The drawings show the stop plate mounted below the elevator bellcrank with the spacer pack modified to...
eyedropper for resin promoter

Properly Promoting Resin

The resin that we currently use in both the Glasair and the GlaStar is Dow Derakane 411-45. This resin is shipped from Stoddard-Hamilton in...
GlaStar - drilling the flap skin doublers

GlaStar Aileron and Flap Installation Tips

Whilst many have been at Oshkosh enjoying themselves, I have been doing likewise checking out my first wing in preparation for riveting on the...
GlaStar elevator construction start

Elevator Building Tips for the GlaStar and Sportsman

Keeping twist out of the aft elevator partial spar: There is a discontinuity between the aft edges of the elevator respective to each end...
Glastar baggage door latch mechanism

GlaStar Baggage Door Installation Tip

The pull rivets end up so close to the door seal flange that the only pull rivet tool I have found to work resides...
Lempicke header tank

Tom Lempicke’s Aluminum Fuel Header Tank for the GlaStar

This tip was submitted by Tom Lempicke. Modifications to the fuel system can lead to serious consequences, so be sure you know exactly what...
Preparing the gel coat. Photo: Zach Chase

GlaStar Fuselage Finish Tips

Exterior screws: countersink screw heads deep enough to fill flush with a couple thin layers of glass. Makes for a smooth surface. - Jim Londo Exterior...
Zach Chase window installation videos

New Window Installation Videos by Zach Chase

Zach Chase of Fibertech Composites has been the go-to man when it comes to assembling the Glastar and Sportsman airplanes. His one day of...