Engine Plumbing

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Many of you may not be familiar with proper engine plumbing techniques. The beauty of home-building is to do it your own way, reducing...
Sportsman window installed with Silpruf. Photo: Randi Ernst.

GlaStar and Sportsman Window Installation

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Mask off the front and back of the window to approx. 1.5" of the edge. (Blue 3M 2" tape) Trim perimeter of window to fit...
Additional inspection cover for GlaStar aux fuel tank fitting

GlaStar Auxiliary Fuel Tank Tips

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

Adding Inspection Holes to the GlaStar or Sportsman Wing

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Cutting inspection plate holes: Here is one way to cut (perhaps scribe is a better choice of words) a nice inspection circle in your...
aileron cove

GlaStar Cove Ribs and Skins Tips

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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

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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

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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

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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

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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

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The pull rivets end up so close to the door seal flange that the only pull rivet tool I have found to work resides...