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.

Fiberglassing Tips

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Working with fiberglass and resin is as much art as it is science. As builders gain confidence and get used to working with fiberglass,...

Flush Riveting Tips

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The GlaStar is not typically built with flush rivets, but some builders are using them anyway. This does not improve aerodynamics, but helps if...

Marking Parts

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The purpose of marking parts is to be able to find it and place it in an assembly where it's supposed to go. Using...
Automatic center-punch

Locating and Center-Punching Holes

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You may have the best tools, but it's knowing how to use them that makes you a craftsman - in this case our members...
Wing ribs

Making Your Own Ribs

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Making ribs is a simple process not requiring more than what is found in a standard wood shop. You will need a oak form...
trimming wing skin

Trimming a Wing Skin in 5 Minutes or Less

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Here is how we trim wing skins at R&D Technical Services. Get your work table ready: Purchase a 1-1/4” x 1-1/4” x 1/8” piece of...
dimpling aluminum sheet

Metalworking Tips

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Deburring rivet holes: A 3" Scotchbrite wheel in a variable speed drill motor does a very fast job of deburring long lines of rivet...
nutplate

Nutplate Installation

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Dimpling nut plates: It can be difficult to dimple the nut plates. One of our A&Ps came up with a trick for not dimpling the...

Picking Up/Unloading Your Kit

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Use of boat trailer for crate pickup: Living approximately 70 miles from the closest Consolidated Freight yard, the cost of a rental truck or...
Nose rib and skin on left GlaStar wing

Rib and Skin Fitting

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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...