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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.

Baffles Reduce Cylinder Temperatures

Mods

Paul Sather’s Neat GlaStar Innovations

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 Bulkhead Installation Tips

Bulkhead layups: On my last trip to Germany, I purchased special brushes designed for painting behind radiators. They are about 18" long with the...

GlaStar Door Installation Tips

Door warpage: It sounds like you have encountered a door fit problem which we have encountered on many Glastars as well. What we have...

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...

GlaStar Firewall Template Tip

I started out by using the supplied template to cut out a cardboard firewall. It did not come close to fitting. I started all...

GlaStar Fuselage Assembly Tips

Step 27: If your kit includes the upper shell attach fittings pre-made with all holes predrilled, as mine did, when doing the final installation,...

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...

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...

General Tips for GlaStar Fuselage Construction

Bicycle hooks: Don't use bicycle hooks to hold up the fuselage cage! When you put some weight on them, they will straighten out and...

GlaStar Rudder Installation Tips

Marking the rudder spar rivet line: When I set the rivet line on the spar, I ran a taut string under the top and...

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The Glasair Aircraft Owners Association is the one must-join association for Glasair, GlaStar, Sportsman 2+2, Merlin, and OMF Symphony builders, owners, pilots, and enthusiasts. If you’re currently building, flying—or dreaming of building and flying one—this is the place for you! We are not affiliated with Glasair Aviation, LLC., but we maintain a great working relationship. Our members can be found worldwide.

Disclaimer: This website contains information submitted by our members about building their airplanes. Some methods they employ may differ from the factory instructions. Builders are advised that they are responsible for their own construction methods and should check with the factory if any of the information included on this website differs from the factory manuals. The Glasair Aircraft Owners Association has not checked the accuracy or safety of any information included on these web pages and any users of this information do so completely at their own risk.