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.

aileron cove

GlaStar Cove Ribs and Skins Tips

Aileron cove rib: We found that when installing the left wing aileron cove the lower wing skin is about 3/8" too short to give...
GlaStar fuselage bonding process

GlaStar Fuselage Bonding Tips

Joining the fuselage halves: In addition to taping the belly and dorsal seam as per manual, I screwed tongue depressors (one #4 x 3/8...
Sportsman top deck. Photo: Zach Chase, Fibertech Composites

GlaStar Top Deck Installation Tips

Lifting eye slots: when laying out the dimensions for the lifting eye slots in the top deck, be sure to make an inside measurement...
GlaStar strake in position. Photo: Zach Chase, Fibertech Composites

GlaStar Strake Installation Tip

I tooled these myself off of Jim Londo's GlaStar but the incidence was later changed. It is a real struggle to get these to fit...
Confirm clearance before cutting the GlaStar cabin air inlet opening.

GlaStar Cabin Air Inlet Position Tip

I don't remember the dimension called for but they need to be a whole 1" lower than called for in the instructions. I ended...
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...

GlaStar Wing Angle of Incidence Tips

When to align wing angle of incidence: We have worked on 20+ Glastar projects, and this problem constantly arises. I can not stress strongly...
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....
Wiring through the nose ribs. Photo: Russ Beers.

Planning for Wiring Runs in the Wings

Tips are great when you read them before you go down the wrong path. Here are a few that could save you some headache...
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...