GlaStar Assembly Sequence

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GlaStar assemblyCompiled by Roy Kokenge based on the assembly sequence from the GlaStar Manuals. Builders may use this as a basis for a builder/time log for the FAA.

RUDDER ASSEMBLY

  1. Inspect and Deburr the Parts
  2. Mark the Flange Centerlines
  3. Fabricate Rudder Jig
  4. Mark the Rudder Trailing Edge Line
  5. Install and Mark the Spar Support Board
  6. Fasten the Yoke Weldment to the Spar Support
  7. Join the Forward Spar/Hinge Bracket and the Hinge
  8. Mounting Plate to the Forward Spar
  9. Drill and Cleco the Forward Spar to the Yoke Weldment
  10. Drill and Cleco the Root Rib to the Yoke Weldment
  11. Join the Aft Spar to the Root Rib
  12. Join the Counterweight Rib to the Spars
  13. Slide the Skin into Place
  14. Drill and Cleco the Skin
  15. Drill and Cleco the Forward Skin
  16. Drill Holes for Mounting the Tip Fairing

FINAL RUDDER ASSEMBLY

  1. Disassemble, Clean and Deburr
  2. Dimple the Skin, the Forward Spar and the Tip Rib
  3. Fabricate the Lead Counterweight
  4. Apply Corrosion Protection
  5. Install the Counterweight
  6. Rivet the Rudder Assembly Together
  7. Install the Hinge and the Hinge Shim
  8. Check and Adjust the Rudder Trailing Straighten and Deburr the Parts

HORIZONTAL STABILIZER ASSEMBLY

  1. Straighten and Deburr the Parts
  2. Mark Rivet Lines on the Flanges of the Node Ribs and Spars
  3. Cleco the Main and Nose Ribs to the Forward Spar and Drill
  4. Cleco the Aft Spar to the Main Ribs and Drill the Rivet Holes to Size
  5. Position and Drill the Forward Spar Web Doublers
  6. Position the Right Skin
  7. Drill the Upper Surface Main Rib and Forward Spar Rivet Holes
  8. Drill the Upper Surface Aft Spar Rivet Holes
  9. Realign and Drill the Lower Surface of the Right Skin

ELEVATOR ASSEMBLY

PRELIMINARY ASSEMBLY MAIN STRUCTURE

  1. Straighten and Deburr the Parts
  2. Mark Hole Positions on the Forward Spar/Hinge Doublers
  3. Position and Drill the Doublers
  4. Cut an Angle Template
  5. Cut the Rib/Control Horn Stiffeners
  6. Mark Hole Locations On the Stiffeners
  7. Lay Out the Trim Cable Bracket Reference Lines
  8. Mark the Trim Cable Bracket Hole Locations on Ribs A and B
  9. Position and Drill the Stiffeners
  10. Drill Index Holes in the Attach Angles
  11. Mark and Drill Index Holes in the Control Horns
  12. Finish Drilling the Attach Angles and the Control Horns
  13. Trim the Corners Off the Attach Angles
  14. Cut Out the Trim Cable Bracket Parts
  15. Fabricate the Trim Cable Gates
  16. Notch the Trim Cable Bracket Angles
  17. Drill the Left-Side Rivet Holes in The Bracket Parts
  18. Fabricate the Trim Cable Retainer Clip
  19. Mark Rivet Lines on the Forward Spar and Ribs
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MAIN STRUCTURE

  1. Cleco the Ribs to the Forward Spar
  2. Cleco the Aft Partial Spar to the Inboard Ribs and Drill the Rivet Size
  3. Drill the End Flanges of the Aft Partial Spar
  4. Mark and Cut Out the Tip Rib Notches in the Lower Skins
  5. Position the Lower Right Skin
  6. Drill the Remaining Lower Right-Side Holes in the Spars and Ribs
  7. Mark and Cut the Trim Tab Pushrod Slot in the Lower Left Skin
  8. Position and Drill the Lower Left Skin
  9. Mark and Cut the Trim Tab Pushrod Slot in the Lower Right Skin
  10. Position and Drill the Control Horn Attach Angles
  11. Position and Drill the Right Trim Cable Bracket Angle
  12. Position and Drill the Left Trim Cable Bracket Half
  13. Drill the Right-Side Holes in the Trim Cable Bracket Assembly
  14. Position and Drill the Trim Cable Retainer Clip
  15. Position and Drill the Upper Right Skin
  16. Mark and Cut the Trim Cable Slot in the Upper Left Skin
  17. Position and Drill the Upper Left Skin
  18. Mark the Trim Cable Slot in the Upper Right Skin
  19. Mark Hole Positions on the Tip Ribs
  20. Position and Drill the Tip Ribs
  21. Cut the Trim Cable Slot in the Upper Right Skin
  22. Drill and Dimple the Rivet Holes for the Trim Cable Retainer Clip Nutplates
  23. Trim the Elevator Upper Leading Edge
  24. Clean and Deburr all the Parts
  25. Corrosion-Proof the Elevator Interior
  26. Rivet the Doublers to the Forward Spar
  27. Rivet the Trim Cable Retainer Clip Nutplates to the Rib-Control Horn Stiffeners
  28. Rivet the Trim Cable Bracket Assembly
  29. Rivet the Control Horn Stiffeners and Trim Cable Bracket Assembly to Ribs A and B
  30. Finish Riveting the Control Horn Stiffeners to Ribs A and B
  31. Rivet the Attach Angles to the Control Horns
  32. Rivet the Inboard Ribs to the Aft Partial Spar
  33. Rivet Ribs C and D to the Aft Partial Spar
  34. Rivet the Upper Skins to the Ribs
  35. Rivet the Tip Ribs to the Outermost Ribs
  36. Rivet the Control Horn Assemblies and lower Skins to Ribs A and B
  37. Rivet the lower Skins to the Aft Partial Spar and Ribs
  38. Rivet the Trailing Edge Joggles
  39. Rivet the Forward Spar to the Ribs
  40. Rivet Lower Skins and Control Horn Attach Angles to Forward Spar
  41. Tape the Lightening Holes in the Forward Spar

TRIM TAB

  1. Fabricate Trim Tab Zee Ribs, Control Horn and Counterweight Arm
  2. Mark and Drill the Rivet Holes in Webs of the Upper Zee Rib Halves
  3. Mark Reference Lines and Hole Patterns on the Trim Tab Skin
  4. Position and Drill the Upper Zee Rib Halves
  5. Position and Drill the Remaining Trim Tab Ribs
  6. Drill the Trim Tab Counterweight Arm
  7. Position and Drill the Trim Tab Horn and the Lower Zee Ribs
  8. Drill the End Tabs of the Trim Tab Skin
  9. Clean and Deburr the Parts
  10. Corrosion-Proof the Trim Tab Interior

TRIM TAB RIVETING

  1. Rivet the Zee Rib Halves
  2. Rivet the Zee Ribs and the Control Horn to the Lower Surface
  3. Rivet the Trim Tab Ribs to the Upper Surface
  4. Rivet the Remaining Rib/Skin Holes
  5. Rivet the End Tabs of the Trim Tab Skin
  6. Rivet the Counterweight Arm to the Trim Horn

ELEVATOR HINGES

  1. Cut the Elevator and Trim Tab Hinges to Length
  2. Cut and Bend the Hinge Pins
  3. Position the Elevator Hinges and Drill Index Holes
  4. Position Elevator Behind Stabilizer, Align the Hinges on the Aft Spar
  5. Drill Index Holes in the Stabilizer-Side Hinge Halves
  6. Drill the Final Hinge Alignment Holes
  7. Drill the Remaining Holes

TRIM TAB HINGE

  1. Position the Trim Tab Hinge and Drill an Index Hole
  2. Align the Hinge on the Elevator Side and Drill an Index Hole
  3. Drill the Final Alignment Holes
  4. Drill the Remaining Holes

HINGE RIVETING

  1. Rivet the Elevator Hinge Halves to the Stabilizer
  2. Rivet the Elevator-Side Hinge Halves to the Elevator
  3. Rivet the Trim Tab Hinge Half to the Elevator
  4. Rivet the Trim Tab Hinge Half to the Trim Tab

WINGS

FABRICATE THE WING JIG

  1. Fabricate the Jig Framework
  2. Fabricate the Wing Jig Spar Brackets
  3. Install the Inboard Spar Brackets

ASSEMBLE THE WING SPARS

  1. Cut Lightening Holes in the Spars
  2. Drill the Forward Spar Root Doublers
  3. Drill the Forward Spar Strut Beam Doubler
  4. Drill the Aft Spar Root Doublers
  5. Trim and Drill the Aft Spar Strut Beam Doubler
  6. Trim the Ends of the Spars
  7. Apply Corrosion Protection to the Spar Components
  8. Rivet the Spar Assemblies
  9. Ream the Wing Attach Holes
  10. Press In the Wing Attach Bushings
  11. Mark Rivet Lines on the Forward Spar Flanges

MOUNT THE SPARS ON THE JIG

  1. Fasten the Spars in the Jig Brackets
  2. Fabricate the Aft Spar Center Supports

MOUNT THE RIBS AND STRUT BEAM ASSEMBLY TO THE SPARS

  1. Square the Rib Flanges and Mark the Rivet Lines
  2. Reinforce the Root Main Rib
  3. Mount the Ribs to the Spar
  4. Mark the Ribs
  5. Assemble the Strut Beam
  6. Mount the Strut Beam

FIT UP AND DRILL THE WING SKINS

  1. Position, Clamp and Index Drill the Outboard Leading Edge Skin
  2. Position, Clamp and Index Drill Center and Inboard Leading Edge
  3. Finish Drilling the Leading Edge Skins
  4. Deburr the Leading Edge Skins and the Nose Ribs
  5. Position and Drill the Upper Main Skins
  6. Mark and Trim the Leading Edge Skins
  7. Finish Drilling the Upper Main Skins
  8. Position and Drill the Lower Outboard and Center Main Skins
  9. Trim the Aileron Cove Ribs (Early Kits Only)
  10. Install the Lower Center Skin Gusset
  11. Position and Drill the Lower Inboard Main Skin
  12. Drill the Lower Inboard Skin Doubler

INSTALL THE HAT SECTION STIFFENERS, FORWARD SPAR CAP STRIPS AND LOWER CENTER SKIN STIFFENERS

  1. Adjust the Flanges of the Stiffeners
  2. Trim the Stiffener Flanges and Mark Rivet Lines
  3. Position and Drill the Lower Skin Stiffeners
  4. Position and Drill the Upper Skin Stiffeners
  5. Deburr the Skins and Stiffeners
  6. Position and Drill the Forward Spar Cap Strips
  7. Position and Drill the Lower Center Skin Stiffener Channels

DIMPLE THE SKINS AND COUNTERSINK THE FORWARD SPAR LANGES

  1. Dimple the Wing Skins and the Nose Ribs
  2. Countersink the Forward Spar Ranges
  3. Corrosion-Proof the Parts

AILERON AND FLAP ASSEMBLIES

  1. Straighten and Deburr the Parts
  2. Mark Rivet Lines on the Flanges of the Ribs and Spar
  3. Drill the Hinge and Actuator Bolt Holes in Rib Pairs B and C
  4. Mark and Drill the Counterweight Bolt Holes
  5. Position and Drill the Bolt Nutplates
  6. Dimple the Ribs and Nutplates
  7. Cleco Nose Rib Pairs B and C to the Spar
  8. Mark and Drill the Hinge Brackets
  9. Cleco the Remaining Ribs to the Spar
  10. Drill All the Rib/Spar Rivet Holes to Final Size
  11. Clamp the Spar/Rib Assembly to the Bench
  12. Position the Skin and Drill the Lower-Surface Rivet Holes
  13. Mark Locations for the Inspection Hole Doubler Rivet
  14. Position and Drill the Inspection Hole Doublers
  15. Drill the Inspection Hole Cover Mounting Screw Holes
  16. Mark and Drill the Spar Web/Inspection Hole Doubler Rivet Holes
  17. Position and Drill the Upper Surface of the Skin
  18. Drill the Trailing Edge Joggles
  19. Position and Drill the Inspection Hole Cover Nutplates
  20. Position and Drill the Upper Surface of the Skin
  21. Drill the Trailing Edge Joggles
  22. Position and Drill the Inspection Hole Cover Nutplates
  23. Dimple the Inspection Hole Doublers, Spar, Skin Nutplates
  24. Smooth and Deburr the Parts

RIVETING

  1. Rivet the Hinge and Actuator Bolt Nutplates to the Nose Rib of Pairs B and C
  2. Rivet the Counterweight Bolt Nutplates to the Inboard Counterweight Nose Rib
  3. Rivet the Inspection Hole Cover Nutplates to the Doublers
  4. Rivet Rib Pairs B and C to Their Respective Hinge Brackets
  5. Rivet the Ribs and Inspection Hole Doublers to the Spar
  6. Rivet the Hinge Brackets to the Spars
  7. Rivet the Skin to the Upper Flanges of the Spar and Aft Ribs
  8. Rivet the Skin to the Upper Flanges of the Nose Ribs
  9. Rivet the Skin to the Lower Flanges of the Nose Ribs
  10. Rivet the Inspection Hole Doublers to the Skin
  11. Rivet the Skin and the Aft Inspection Cover Nutplates to the Lower Spar Flange
  12. Rivet the Skin to the Lower Flanges of the Aft Ribs
  13. Rivet the Trailing Edge Joggles
  14. Mark and Cut the Counterweight Arm Slot

FUSELAGE ASSEMBLY

  1. Remove the Mold Lip from the Fuselage Shells
  2. Make the Cutouts for the landing Gear Legs
  3. Lay Up the Shell Attach Fitting Hardpoint Reinforcements
  4. Install the COM Antennae in the Vertical Fin
  5. Install Transponder Antenna in Vertical Fin
  6. Install VOR Antenna in Belly
  7. Prep Sand Fuselage Joggles
  8. Prep and Prime the Steel Parts

FITTING FABRICATION

  1. Cut the Angle Stock to Length for the Shell Attach Fittings
  2. Fabricate the Upper Shell Attach Fittings
  3. Fabricate the lower Shell Attach Fittings
  4. Fabricate the Aft Shell Attach Fittings
  5. Fabricate the Forward Shell Attach Fittings

EXTERNAL STRUCTURE

  1. Press Bushings into the Wing Pivot Jugs on the Cage
  2. Install the Wing Pivots
  3. Fasten the Alignment Jigs to the Fuselage ShelIs
  4. Mount and Rough-Fit the Shells on the Cage
  5. Tape the Shells Together and Set the Wing-Root Dihedral Angle
  6. Drill the Holes for the Cage Floor Hardpoints
  7. Finish the Floor Attach Tab Hardpoints
  8. Fasten the Shells to the Cage Floor
  9. Fasten the Shells to the Cage Side Attach Tabs
  10. Lay Up the Belly Seam
  11. Mark the Fuselage Centerline
  12. Plumb the Vertical Fin
  13. Lay up the Dorsal Seam
  14. Secure the Final Two Cage Tabs
  15. Position and Drill the Upper Shell Attach Fittings
  16. Position and Drill the Lower Shell Attach Fittings
  17. Position and Drill the Aft Shell Attach Fittings
  18. Corrosion-Proof the Shell Attach Fittings
  19. Install the Upper, Lower and Aft Shell Attach Fittings
  20. Install the Forward Shell Attach Fittings

INTERNAL STRUCTURE

  1. Mark the Fuselage Waterline
  2. Cut Out the Vertical Fin Rib
  3. Rough-Cut the Foam Core for Bulkhead B and Cut and
  4. Bevel the Center Hole
  5. Lay Up and Trim the Bulkhead B Laminate
  6. Lay Up and Trim the Laminate for Bulkheads C, D and E
  7. Level the Fuselage Longitudinally
  8. Install Bulkhead B
  9. Trim the Vertical Fin Spar
  10. Press In the Upper Rudder Hinge Bushing
  11. Temporarily Mount the Lower Rudder Hinge on the Rudder Yoke
  12. Temporarily Mount the Upper Rudder Hinge on the Vertical Fin Spar
  13. Temporarily Join the Upper Hinge Halves
  14. Sand the Tops of the Vertical Fin Shells
  15. “Hang” the Rudder Assembly from the Tops of the Vertical Fin Shells
  16. Drill Index Holes Through the Flanges of the Vertical Fin Spar
  17. Center the Rudder Between the Fin Shells
  18. Mark the Lower Hinge Location on the Fin Spar
  19. Position and Install Bulkhead C
  20. Drill the Lower Rudder Hinge Mounting Holes in the Vertical Fin Spar and Bulkhead C
  21. Position and Drill Nutplates for the Upper Hinge
  22. Bed the Vertical Fin Spar Between the Fin Shells
  23. Mark and Drill the Vertical Fin Spar Rivet Holes
  24. Corrosion-Proof the Vertical Fin Spar and the Rudder Hinge Halves
  25. Rivet the Upper Rudder Hinge Nutplates to the Vertical Fin Spar
  26. Bolt the Lower Rudder Hinge and the Fin Spar to Bulkhead C
  27. Rivet the Vertical Fin Spar to the Fin Shells
  28. Install the Vertical Fin Rib
  29. Bolt the Upper Rudder Hinge to the Vertical Fin Spar
  30. Finish the Trailing Edges of the Fin and Fit the Rudder
  31. Fabricate the Rudder Stop Plate
  32. Fasten the Stop Plate to the Rudder Yoke
  33. Adjust the Rudder Travel
  34. Install the Stop Plate Pads
  35. Drill Holes for the Tailwheel Steering Cable Bushings
  36. Rivet the Rudder Stop to the Rudder Yoke
  37. Install the Tailwheel Steering Bushings
  38. Cut an Inspection Hole in the Lower Aft Fuselage
  39. Fill inspection Hole in Lower Aft Fuselage (Not Needed)
  40. Trim, Position and Drill the Lower Elevator Bellcrank Bracket
  41. Position and Drill the Upper Elevator Bellcrank Bracket
  42. Drill the Elevator Bell Crank Assembly
  43. Corrosion-Proof the Elevator Bellcrank Assembly and Brackets
  44. Rivet the Elevator Bellcrank Assembly
  45. Install the Elevator Bellcrank/Bracket Assembly
  46. Position and Install Bulkhead D
  47. Position and Drill the Horizontal Stabilizer Forward Attach Bracket
  48. Laminate the Aft Attach Flange for the Forward lnter-Bulkhead Shearweb
  49. Position and Drill the Forward Attach Angles for the Forward Shearweb
  50. Cut Out the Forward Shearweb
  51. Laminate the Side Attach Flanges for the Forward Shearweb
  52. Drill the Bolt Holes Along the Sides of the Forward Shearweb
  53. Deburr and Corrosion-Proof the Forward Shearweb and Attach Angles
  54. Install the Forward Shearweb Forward Attach Angles
  55. Install the Horizontal Stabilizer Forward Attach Bracket
  56. Rough-Cut the Fuselage Shells to Fit the Horizontal Stabilizer
  57. Position Bulkhead E
  58. Install Bulkhead E
  59. Drill the Horizontal Stabilizer Aft Attach Bracket Bolt Holes
  60. Install the Stabilizer Mounting Nutplates
  61. Laminate Attach Flanges for the Aft Inter-Bulkhead Shearweb
  62. Cut and Install the Aft Inter-Bulkhead Shearweb
  63. Lay Up and Trim the Bulkhead A Laminate
  64. Install Bulkhead A
  65. Install the Fuselage Struts

SYSTEMS INSTALLATION

RUDDER CONTROL ASSEMBLIES INSTALLATION CONTROL

  1. Reinforce the Rudder Control Mounting Area of the Fuselage Shell
  2. Fabricate the Rudder Control Support Brackets
  3. Mount the Rudder Controls
  4. Fabricate the Rudder Pedals
  5. Fabricate the Rudder Pedal Brackets
  6. Assemble the Rudder Pedals
  7. Mount the Rudder Pedals on the Rudder Control Weldments
  8. Fabricate the Brake Master Cylinder Mounting Brackets
  9. Install the Brake Master Cylinders

CONTROL STICK ASSEMBLY INSTALLATION

  1. Assemble the Elevator/Aileron Control
  2. Install the Control Yoke Assembly

FLAP HANDLE ASSEMBLY INSTALLATION

  1. Assemble the Flap Handle
  2. Install the Flap Handle

FUSELAGE CONTROL SYSTEM PULLEYS INSTALLATION

  1. Install the Forward Pulleys
  2. Install the Lower Forward Aileron Pulleys
  3. Install the Lower Aft Forward Pulleys
  4. Install the Center Flap Pulleys
  5. Install the Lower Outboard Flap Pulleys
  6. Install the Upper Crossover Pulleys
  7. Fabricate and Install the Bulkhead A Pulley Brackets
  8. Install the Cable Fairleads

RUDDER CONTROL CABLES INSTALLATION

  1. Install the Forward Rudder Cables
  2. Complete the Rudder Cable Installation

ELEVATOR PUSHROD AND CONTROL CABLES INSTALLATION

  1. Fabricate the Elevator Pushrod
  2. Install the Elevator Pushrod
  3. Install the Elevator Control Cables

MOUNTING THE WINGS TO THE FUSELAGE

  1. Install the Inboard Wing Strut Fittings
  2. Mark the Bolt Centerlines on the Strut Attach Arm and the Wing Strut
  3. Trim the Openings in the Wing Root Areas of the Fuselage Shells
  4. Mount the Wings to the Fuselage
  5. Set the Dihedral Angle of the Wings
  6. Remove Twist from the Wings
  7. Mark the Wing Struts for Drilling
  8. Drill the Outboard Ends of the Wine Struts
  9. Trim the Outboard End of the Strut (Optional)
  10. Bolt the Wing Strut to the Wing

MOUNTING THE FLAPS TO THE WINGS

  1. Mount the Flaps to the Flap Tracks
  2. Install the Flap Pushrod

MOUNTING THE AILERONS TO THE WING

  1. Mount the Ailerons to the Aileron Hinges
  2. Install the Aileron Pushrod and Cable Attach Tabs

FLAP CONTROL CABLES INSTALLATION

  1. Fabricate the Inboard Cable Guide
  2. Adjust the Flao Deployment Cable
  3. Route the Flap Retraction Cable
  4. Complete the Flap Cables

AILERON CONTROL CABLES INSTALLATION

  1. Fabricate the Aileron Cable Guides
  2. Route the Aileron Control Cables
  3. Adjust the Aileron Travel and Set the Control Stops
  4. Secure the Aileron Cable Guides to the Wing Structure

CONTROL CABLE RETAINERS FABRICATION AND INSTALLATION

  1. Install Cotter Pin Cable Retainers
  2. Fabricate and Install Control Cable Pulley Guard Straps

PRELIMINARY FUEL TANK INSTALLATION

  1. Apply Anti-Chafe Tape to the Hat Section Stiffeners in the Fuel Tank Bays
  2. Test Fit the Fuel Tank
  3. Drill a Hole in the Lower Wing Skin for the Sump Drain Boss
  4. Test Fit the Upper-Surface Hat Sections
  5. Install “Bumpers” Around the Perimeter of the Tank
  6. Make a Cutout in the Root Rib for the Fuel Gauge Mounting Flange
  7. Drill Holes in the Root Rib for the Main and Return Fuel Line Bosses
  8. Cut a Hole in the Upper Wind Skin for the Filler Neck
  9. Drill the Inspection Hole Doublers
  10. Corrosion-Proof the Doublers and Rivet the Nutplates to them
  11. Install the Pitot Tube
  12. Install the Fuel Vent Line (Standard Fuel Tanks Only)
  13. Install the Wing Light Wiring (Optional)
  14. Install the Wing Pitot Line

MAIN GEAR INSTALLATION

  1. Support and Level the Fuselage
  2. Insert and Position the Gear Legs
  3. Drill and Bolt the Main Gear Legs

MAIN GEAR WHEEL AND BRAKE INSTALLATION

  1. Fabricate the Wheel Pant Backing Plates
  2. Install the Brake Mounting Flanges on the Axles
  3. Install the Brake Torgue Plate and Wheel Pant Backing Plate on the Brake Mounting Flange
  4. Mount the Tubes and Tires on the Main Wheel
  5. Instail the Outboard Wheel Pant Nutplates on the Axle Nuts
  6. Mount the Wheels on the Axles
  7. Mount the Brake Calipers

NOSE GEAR INSTALLATION (OPTIONAL)

  1. Position the Nose Gear Trunnions
  2. Cut the Nose GearSlot in the Fuselage Floor
  3. Position and Drill the Nose Gear Leg
  4. Bolt the Trunnions and Gear Leg in Place
  5. Position and Drill the Forward Wheel Pant Mounting Nutplates
  6. Fabricate the Aft Nose Wheel Pant Mounting Brackets
  7. Position the Aft Nose Wheel Pant Mounting Bracket and Drill the Screw Holes
  8. Corrosion-Proof the Remaining Nose Gear Components
  9. Rivet the Nutplates to the Forward Wheel Pant Mounting Brackets
  10. Screw the Aft Wheel Pant Mounting Brackets to the Fork Arms
  11. Mount the Fork on the Axle
  12. Drill the Axle Nut Coffer Pin Hole and Secure the Nut
  13. Mount the Tube and tire on the Nose Wheel
  14. Install the Nose Wheel in the Fork

TAILWHEEL INSTALLATION (OPTIONAL)

  1. Fabricate the Forward Spring Attach Bracket
  2. Install the Forward Spring Attach Bracket
  3. Drill the Forward Spring Attach Bolt Hole
  4. Fabricate the Forward Sprind Block
  5. Apply DBM Reinforcment to the Aft Fuselage
  6. Stack the Tailwheel Springs
  7. Bolt the Springs in Place
  8. Drill Aft Spring Attach Brackets
  9. Fabricate the Aft Spring Block
  10. Install the Spring Blocks and Attach Brackets
  11. Install the Aft Spring Block Retainer Screw
  12. Re-Install the Springs
  13. Install the Tailwheel Assembly
  14. Install the Steering Cables

BRAKE SYSTEM PLUMBING

  1. Install the Fittings in the Caliper Assemblies
  2. Install the Fittings in the Master Cylinders
  3. Route the Brake Lines from the Calipers to the Master Cylinders
  4. Route the Brake Lines from the Master Cylinders to the Reservoir

FUSELAGE FUEL SYSTEM PLUMBING

  1. Reinforce the Drain Valve Mounting Area
  2. Drill the Drain Valve Holes in the Fuselage Floor
  3. Install the Drain Valve
  4. Route the Fuel Line From the Left Wing to the Drain Valve
  5. Route the Fuel Line From the Right Wing to the Drain Valve
  6. Route the Fuel Line from the Union Tee to the Shut-Off Valve

MANUAL ELEVATOR TRIM SYSTEM INSTALLATION (OPTIONAL)

  1. Drill the Trim Cable Holes in the Bulkheads
  2. Route the Trim Cable Through the Fuselage
  3. Fabricate the Trim Gear Box Brackets
  4. Temporarily Mount the Gear Box on the Cage
  5. Secure the Trim Cable to the Airframe Between the Gear Box and Bulkhead B
  6. Install the Terminal Hardware on the Aft End of the Cable

MISCELLANEOUS FUSELAGE PLUMBING AND WIRING

  1. Route the Fuselage Pitot Line
  2. Install the Static Ports and Lines
  3. Route the Fuselage Nav/Strobe Light Wiring
  4. Route the COM Antenna Cable Forward from the Vertical Fin
  5. Route the VOR Antenna Cable Forward from the Vertical Fin
  6. Route the Battery Cables
  7. Install the ELT and Remote Switch Wiring
  8. Install the Transponder and/or DME Antennas and Cables

FIREWALL INSTALLATION

  1. Fabricate and Install the Instrument Panel Angle Brackets
  2. Fabricate the Firewall Components
  3. Fit the Firewall to the Fuselage
  4. Drill the Engine Mount Bolt and Attach Tab Holes
  5. Rivet the Firewall Assemb/y Together
  6. Fasten the Firewall Assembly to the Fuselage
  7. Install the Brake Reservoir

FIREWALL FORWARD

  1. Install Everything Forward of the Firewall

INTERIOR INSTALLATION

  1. Cut Out the Bulkhead A Close-Out
  2. Drill the Close-Out and Install the Mounting Nutplates
  3. Install the Baggage Shelf (Optional)
  4. Fit the Aft Control Cable Cover
  5. Fabricate and Drill Aft Attach Angles for the Aft Control Cable Cover
  6. Install Mounting Tabs for the Aft Control Cable Cover
  7. Assemble the Aft Control Cable Cover
  8. Fit the Forward Control Cable Cover Halves
  9. Join the Forward Control Cable Cover Halves
  10. Fit the Floorboards
  11. Fit the Seat Pans
  12. Fabricate the Seat Track Slider Angles
  13. Fabricate the Seat-Back Adjustment locking Pins
  14. Cut and Rivet the Seat Back Rest (First-Run Seats)
  15. Mount the Seat Tracks on the Cage
  16. Bolt the Seat Back to the Seat Base
  17. Fasten the Seat Assemblies to the Tracks
  18. Drill the Seat-Back Adjustment Holes
  19. Assemb/e the locking Pins
  20. Install the Control Sticks
  21. Install the Cabin Air Vents (Optional)

FUSELAGE FAIRING INSTALLATION

  1. Mark the Centerlines of the Horizontal Stabilizer Strakes on the Fuselage
  2. Fit the Strake Halves to the Fuselage and Stabilizer and Tape Them Together
  3. Seam the Strake Halves Together
  4. Cut Out the Strake Ribs
  5. Install the Strake Ribs
  6. Adjust the Strakes and Mark Their Outlines on theFuse/age
  7. Prep the Fuselage and the Strakes for Bonding
  8. Bond the Strakes to the Fuselage
  9. Fair the Strake Ranges into the Fuselage
  10. Prep the Strakes and Fuselage/Strake Junctions for Painting
  11. Apply Anti-Chafe Protection to the Horizontal Stabilizer
  12. Placard the Strakes
  13. Trim the Rudder Base Fairing to Fit
  14. Drill the Rudder Base Fairing
  15. Install the Nutplates and Rivnuts for the Rudder Base Fairing
  16. Fit and Drill the Tailcone
  17. Seam the Rudder Tip Fairing Together (Fiberglass Only)
  18. Secure the Tip Fairing to the Rudder

GEAR FAIRING INSTALLATION

  1. Prep Sand the Wheel Pant Halves
  2. Cut Out the Wheel Pant Bulkheads
  3. Seam the Pant Halves Together
  4. Fit and Install the Wheel Pant Bulkhead
  5. Drill the Outboard Mounting Screw Hole and Install Foam Spacer
  6. Make the Brake Caliper Cutout
  7. Install the Inboard Foam Spacers
  8. Drill the MountingScrew Holes
  9. Trim the Tire Cutout as Necessary
  10. Sand and Fill the Whell Pant Seam
  11. Cut Out, Bend and Fit the Main Gear Leg Fairings
  12. Install Piano Hinge Along the Trailing Edges
  13. Install the Main Gear Leg Fairings
  14. Prep Send the Nose Wheel Pant Halves (Tricycle Gear)
  15. Reinforce the Mating Edge of the Left Wheel Pant Half
  16. Mark and Drill the Screw Holes in the Wheel Pant Halves
  17. Intall the Nutplates on the Right Wheel Pant Half (Tricycle Gear)
  18. Drill the Forward Mounting Screw Hole in the Right-Hand Pant Half(Tricycle Gear)
  19. Drill the Aft Mounting Screw Hole in the Right-Hand Pant Half (Tricycle Gear)
  20. Install the Nutplates on the Right-Hand Aft Mounting Bracket (Tricycle Gear)
  21. Reinforce and Countersink the Right-Hand Mounting Screw Holes (Tricycle Gear)
  22. Fit and Install the Left-Hand Pant Half (Tricycle Gear)
  23. Reinforce the Trailing Edges of the Nose Gear Leg Fairing Halves (Tricycle Gear)
  24. Install Piano Hinge Along the Trailing Edges of the Fairing Halves (Tricycle Gear)
  25. Reinforce the Mounting Hole Locations in the Fairing Halves (Tricycle Gear)
  26. Seam the Fairing Halves Together (Tricycle Gear)
  27. Fabricate the Fairing Mounting Brackets (Tricycle Gear)
  28. Fit and Install the Nose Gear Led Fairing (Tricycle Gear)

FINAL WING ASSEMBLY

  1. Cleco the Upper-Surface Hat Section Stiffeners to the Spars
  2. Connect the Fuel Tank Vent Lines and Secure Them to the Hat Sections
  3. Drill the Flap Track Rib Rivet Holes
  4. Rivet the Upper Wing Skins
  5. Install the Fuel Tank and Rivet the Root Ribs to the Spars and Skins
  6. Install the Filler Necks and Fuel Caps
  7. Connect the Fuel Tank Vent Lines to the Tanks
  8. Rivet the Inspect/on Hole Doublers to the Wing
  9. Cut the Cove Skins to Length
  10. Fit the Trailing Edge Doublers
  11. Fit and Drill the Cove Skins
  12. Rivet the Cove Skins and Trailing Edge Doublers
  13. Install the Main Fuel Line F/flings and Hose
  14. Install a Plug in the Fuel Return Line Boss (Except the Continental)
  15. Install the Fuel Tank Sump Drain Valve
  16. Cut Out the Components of the Delta Wing
  17. Bend the Outboard Delta Wings
  18. Bend the Inboard Delta Wings Supports
  19. Drill the Delta Wing Caps and lipper Support Tabs
  20. Position the Supports on the Airframe and Drill the Lower Tabs
  21. Corrosion-Proof the Delta Wing Components
  22. Prepare the Wing-Root Areas of the Fuselage Shell for Final Wing Installation
  23. Install the Wings on the Fuselage
  24. Complete the Fuel Tank Vent Line Installation at the Wingtip
  25. Complete the Wing-to-Fuse/age Fuel System Connections
  26. Seam the Wingtip Fairing Halves Together
  27. Trim the Wingtip Fairings to Clear the Ailerons
  28. Install the Fairing Mounting Nutplates
  29. Bond the Trailing Edges of the Fairings Together

DOOR INSTALLATION

  1. Mark Reference Lines on the Fuselage Shell and Cabin Door
  2. Fit the Door to the Cutout and Temporarily Secure It in Place
  3. Assemble the Hinges
  4. Position and Drill the Hinges
  5. Install the Forward Hinge Halves
  6. Install the Door Seal
  7. Fabricate the Door Latches and Dogs
  8. Install Shoes on the Ends of the Latches (Optional)
  9. Install the Latches on the Cage
  10. Fabricate the Door Latch Pushrods
  11. Install the Latch Pushrods
  12. Bend the Door Dogs
  13. Install the Dogs on the Doors
  14. Drill the Exterior Door Handle
  15. Install the Forward Over-Center Spring
  16. Final-Adjust the Latches
  17. Install the Exterior Door Handle and Interior Knob
  18. Install the Cabin Door Locks (Optional)
  19. Final-Fit the Cabin Doors
  20. Trim the Baggage Door Hinge
  21. Position and Drill the Fuselage-Side Baggage Door Hinge

TOP DECK INSTALLATION

  1. Adjust the Fit of the Fuselage Shell to the Wing
  2. Cut Slot in the Top Deck for the Fuselage Lifting Eyes
  3. Fit the Top Deck to the Fuselage
  4. Drill Holes for Securing the Top Deck to the Cage
  5. Fit the Aft End of the Top Deck to the Fuselage Shell Flange
  6. Bond the Top Deck to the Fuse/age Shell
  7. Install the Upper Aft Shell Attach Fittings
  8. Trim the Wing-Fold Hatch Mounting Flanges
  9. Secure the Fuselage Strut Fittings to the Fuselage Shell
  10. Fit the Upper Wing-Fold Hatch Halves to the Mounting Flanges
  11. Trim the Lower Wing-Fold Hatch Halves
  12. Fit the Lower Wing-Fold Hatch Halves to the Fuselage
  13. Drill the Fastener Holes for the Hatches and Mark the Halves for Final Trimming
  14. Bond The Upper and Lower Hatch Halves Together
  15. Adjust the Lower Hatch Flange as Needed
  16. Install the Hatch Mounting Nutplates
  17. Install Weather-Stripping and Mount the Hatches
  18. Install GPS Antenna (Optional)
  19. Install the Wing-Fold Drain Pan (Optional)

INSTRUMENT PANEL INSTALLATION

  1. Cut Out and Fit the Instrument Panel
  2. Lay Out the Panel and Make the Instrument Cutout
  3. Fabricate and Rivet the Panel Bow
  4. Drill the Lower Mounting Screw Holes
  5. Install Mounting Angles at the Ends of the Panel
  6. Fabricate and Install the Panel Braces
  7. Fit the Glare Shield and lnstall Its Mounting Tabs
  8. Drill Fastener Holes in the Aft Edge of the Glare Shield
  9. Mount the Instruments and Avionics In the Panel
  10. Install the Panel in the Cabin for the Final Time
  11. Plumb the Pressure Instruments
  12. Wire the Panel

WINDOW INSTALLATION

  1. Fit the Window to Its Mounting Flange
  2. Mask and Prep the Mating Surfaces of the Mounting Flange and Window
  3. Paint the Bonding Surface of the Window
  4. Bond the Window to Its Mounting Flange
  5. Caulk the Gaps Around the Window

CONTROL SURFACE BALANCING AND FAIRING INSTALLATION

  1. Install the Aileron Counterweights
  2. Adjust the Aileron Counterweights
  3. Determine the Size of the Elevator Trim Tab Counterweight
  4. Cut and Install the Trim Tab Counterweight
  5. Install the Trim Tab on the Elevator
  6. Cut Out the Horizontal Stabilizer and Elevator Tip Fairing (Fiberglass)
  7. Install the Horizontal Stabilizer Tip Fairings
  8. Install the Elevator Tip Fairings
  9. Install the Fairing Close-Outs (Fiberglass Fairings Only)
  10. Calcu/ata the Size of the Elevator Counterweight
  11. Cut and Install the Elevator Counterweights
  12. Finish the Tip Fairings (Fiberglass Fairings Only)
  13. Fabricate and Install Hinge-Pin Retainers on the Elevator and Trim Tab

FINAL CONTROL SYSTEM RIGGING

  1. Fabricate the Crossover Cable Guide
  2. Install the Crossover Cable Guide
  3. Safety the Rudder Cable Turnbuckles
  4. Verify the Elevator Travel
  5. Fabricate and Install the Elevator Control Stop
  6. Tension and Safety the Elevator Control Cables
  7. Eliminate Flap Cable Contact with the Fuselage Cage
  8. Tension and Safety the ,Aileron Control Cables
  9. Tension the Tailwheel Steering Cables

MISSCELLANEOUS FINAL ASSEMBLY DETAILS

  1. Install the Fuel Gauges or Fuel Gauge Sender Units
  2. Install the Inboard Delta Wings
  3. Install the Outboard Delta Wings
  4. Fabricate Cover for the Lower Aft Inspection Hole
  5. Set the Trim Tab Travel Stops (Manual Trim Only)
  6. Install the VOR Antenna (Optional)
  7. Set Trim Tab Travel Stops (Manual Trim Only)
  8. Install the Seat Belts and Shoulder Harnesses

SYSTEMS CHECK-OUT

  1. Inspect the Control System
  2. Inspect the Landing Gear, Wheels and Brake System
  3. Bleed the Brakes
  4. “Burn-In” the Brake Linings
  5. Inspect and Flush the Fuel System
  6. Inspect the Pitot/Static System
  7. Inspect the Electrical System
  8. Check the Function of the Avionics and Certify as Required
  9. Swing the Compass
  10. Post a Compass Correction Card
  11. Inspect the Powerplant

FASTENER INSPECTION AND SAFTEYING

  1. Inspect the Fuse/age Structure
  2. Inspect the Fuse/age Systems
  3. Inspect the Main Landing Gear
  4. Inspect the Nose Gear (Tricycle Gear Only)
  5. Inspect the Tailwheel Installation (Taildraggers Only)
  6. Inspect the Wing Structure
  7. Inspect the Empennage Structure
  8. Inspect the Rudder Control System
  9. Inspect the Elevator Control System
  10. Inspect the Aileron Control System
  11. Inspect the Flap Control System
  12. Inspect the Manual trim System (Manual Trim Only)
  13. Secure and Inspect the Cabin Interior
  14. Secure and Inspect the Fairings and Inspection Hole Covers

WEIGHT AND BALANCE

  1. General Definitions
  2. Generic GlaStar Weight and Balance Data
  3. Determine the Stations of the Landing Gear
  4. Weigh the Aircraft
  5. Calculate the Station of the Empty Weight
  6. Perform the CG Limit Check
  7. FORWARD LIMIT CHECK
  8. REARWARD LIMIT CHECK
  9. MOVING THE BATTERY
  10. Install the Battery Tray
  11. Complete the Final Weight and Balance Statement

GO FLY!

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Omar Filipovic is president of the Glasair Aircraft Owners Association as well as the chief tinkerer and content editor for this website. He is also the web editor for Kitplanes Magazine. Omar is building a GlaStar in Portland, Oregon.