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.

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 wingtip fairing installation

Wingtip Installation Tip

There is a conflict in the wing tip construction as per the Manual (Rev C) Section VI Wing assembly, Fig 43 p.103 instructs you...

Sportsman Transfer Pump Filters

I installed fuel filters between my tip tanks and Facet transfer pumps after one pump failed due to FOD. Facet specifies a 74 micron filter...

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...

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...
dimpling aluminum sheet

Metalworking Tips

Deburring rivet holes: A 3" Scotchbrite wheel in a variable speed drill motor does a very fast job of deburring long lines of rivet...
Additional inspection cover for GlaStar aux fuel tank fitting

GlaStar Auxiliary Fuel Tank Tips

Extra inspection hole: I installed an extra inspection hole, located at the connection of aux tank to fuel line. I obtained the parts (doubler...

Keeping Oil Temperatures Low

Sorting out the oil temperature issues and CHT temperature spread was a bit of a challenge. Extended climbs during Sydney summers had to be...
Gap sealing tape

Scotch Electrical Tape for Sealing Gaps

I change the gear every float season so for sealing the gap between the gear leg and the fuselage I used a general purpose...

Riveting the GlaStar Top Skins

Riveting on the top skins: I used saw horses, carefully set up, to support the wings instead of putting them back in the wing...