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 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...
GlaStar window installation

GlaStar and Sportsman Window Installation Tips

Installing the Windows: A friend suggested a new way of locating the plexiglass panes in the windows and doors of the Glastar. Window with...
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...

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...
GlaStar wing in its jig

GlaStar Wing Assembly Tips

Positioning the leading edge wing skins: In positioning the leading edge wing skins, I found it easier to start by clamping one edge in...
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...
aluminum sheet

Aluminum Skin Protective Plastic

While building and storing the various pieces of your GlaStar it is advisable to leave the white protective coating on the skin sections as...
Nose rib and skin on left GlaStar wing

Rib and Skin Fitting

Skin/rib fitting: I'm sharing my experience with horizontal stabilizer skinning, for the benefit of anyone else who's having trouble pulling the skin far enough...

GlaStar Tail Wheel Fitting Tip

For those of you using the tail wheel option, having just attempted to fit this, be aware that the instructions in the manual, Steps 90...
GlaStar pulley

GlaStar Control Cable & Control Stick Installation Tips

Pulley spacers: Cut spacers (from 3/8" tubing) to put in between the pulley guards(and over the AN3-17 bolt) on the front pulley group. For...