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Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756

Chapter 1

Page  1.2

REV. 2nd Ed./08-15-06

Introduction to the Lancair ES FastBuild Kit

ES

1.2  Recommended Reading and Background Information

This manual provides detailed step-by-step instructions for assembling the Lancair ES Kit. 

Hands-on experience with fiberglass construction techniques and various hand tools is assumed. 

If you do not have this background knowledge, we recommend that you study the following 

texts.

Composite Materials Practice Kit

This kit contains various materials with which to practice and develop your fiberglass 

construction technique. It also contains a copy of Burt Rutan's 

Moldless Composite 

Sandwich Homebuilt Aircraft Construction

 book described below. This kit is recommended 

for all newcomers to fiberglass construction and is a good refresher for everyone else.

Moldless Composite Sandwich Homebuilt Aircraft Construction

 by Burt Rutan

Though the hot-wire shaping technique covered by this book is not used on the Lancair, this 

book has a great deal of other excellent, basic fiberglass construction information. Highly 

recommended.

Building Rutan Composites

 Video tape by Burt Rutan

Although it covers some techniques not used on the Lancair, it shows you how the experts 

handle fiberglass construction. Highly recommended.

Composite Construction for Homebuilt Aircraft

 by Jack Lambie

This book is an additional source of useful construction information and goes into the theory 

of aircraft design as well. Jack's Chapter 9, 

Safety in Working With Composite Construction

is particularly worth reading. This book would be a useful addition to the above.

Kitplane Construction

 by Ron Wenttaja

This is a resourceful book with information on metal, wood, and composites.

The above publications, practice kit and video tape are available from:

Aircraft Spruce and Specialty Company
Address:

225 Airport Circle

 

Corona, CA 91720

Toll-free order line:

(877) 477-7823

Customer service:

(800) 861-3192

Fax:

(909) 372-0555

Email:

[email protected] 

The following recommended books largely describe aspects of aircraft construction other than 

working with fiberglass:

Firewall Forward

 by Tony Bingelis

This book is filled with vital information about engine installation. You'll need this when 

you're getting ready to install the engine.

The Sportplane Builder

 by Tony Bingelis

This book has useful information on aircraft construction in general such as electrical 

systems, instrumentation and fuel systems. The chapter entitled 

You and the FAA

 gives 

important information on the procedures that you will need to follow during construction in 

order to get your homebuilt's airworthiness certificate.

These two books can be obtained from:

EAA Aviation Foundation
Address:

Whittman Airfield

 

Oshkosh, WI 59403-3065

Phone:

(920) 426-4800

Internet:

www.eaa.org

Summary of Contents for ES

Page 1: ...ead the recommended books to familiarize yourself with glassworking if you are a newcomer to fiberglass construction techniques Always refer to the Glossary on page G 1 for definitions of unfamiliar terms 1 1 Introduction 1 1 1 2 Recommended Reading and Background Information 1 2 1 3 The Manuals Blueprints and the ES CD 1 3 1 3 A Manual Layout 1 3 1 3 B Blueprints 1 4 1 3 C The ES CD 1 4 1 4 Setti...

Page 2: ...tion Highly recommended Composite Construction for Homebuilt Aircraft by Jack Lambie This book is an additional source of useful construction information and goes into the theory of aircraft design as well Jack s Chapter 9 Safety in Working With Composite Construction is particularly worth reading This book would be a useful addition to the above Kitplane Construction by Ron Wenttaja This is a res...

Page 3: ...nization Each assembly chapter is organized in the same sequence 1 Introduction Briefly describes the work that will be completed in this chapter and special construction requirements and if a pre fit is necessary 2 Parts List Provides a complete list of the parts used in the construction procedures in the chapter Parts lists may not match a kit A parts list can include all or part of a kit plus o...

Page 4: ... version of the manual that you can view or print from your computer In addition the CD manual provides the following Includes color photographs of various construction processes and specific assembly techniques Ability to search the entire manual for a specific word or phrase Includes a linked table of contents and index All drawings and photographs are organized in a slideshow presentation in th...

Page 5: ...for your shop floor should be approximately 20 ft by 30 feet This will accommodate the building of your Lancair Figure 1 4 B 1provides an overview of the ES dimensions Since the wings are pre fit to the wing fairings and then removed for the remainder of the building process it is not necessary to have a shop that will accommodate the finished dimensions with the wings on You can temporarily move ...

Page 6: ...oll Mount the pipe through two plywood supports nailed to the sides of your table Figure 1 4 C 1 Fiberglass cutting table The cutting surface should be a hard plastic such as an 1 8 thick high density polyethylene HDPE Some home supply stores have similar sheets of this material called tileboards for use as shower liners Also check a plastic supply store After you have been using the cutting surfa...

Page 7: ...ing checking the weight and balance In addition the ES fuselage bottom may have optional jackpoints Steps 1 Cut two pieces of plywood one 8 x 8 and the other 4 x 4 2 Glue the two pieces of plywood together with the 4 x 4 centered on the larger piece 3 Drill a 1 deep and 3 8 diameter hole in the center of the 4 x 4 piece 4 Install the JP 325 jack point in the hole 5 Glue soft padding on the top of ...

Page 8: ...Tools Saber saw jig saw This saw is very handy for cutting out large or complex shapes from prepreg material You can use a manual saw but it won t be fun Always have plenty of sharp blades and change them often Dull blades create rough edges and create more sanding smoothing work later in the building process We use carbide tipped blades exclusively for the composite cutting Electric or cordless d...

Page 9: ... other parts in exactly the proper position Vise grip clamps These are useful for forcing pieces together Never use these on any fiberglass prepreg or carbon composite parts They grip with enough force to do great damage to these parts which may not be visible to the naked eye Buy several of these C clamps Buy an assortment of these and three or four in each size Again use caution when applying th...

Page 10: ... used to turn a tap for the cutting of screw threads They should only be used to remove small amounts of material This ensures a long life for the reamer and a superior finish to the hole 1 5 B Specialized Tools We refer to the following tools as specialized shop tools because it makes it a little easier to overlook their higher price tags Again the tools listed are not mandatory for your shop but...

Page 11: ...h the Dremel If these bits are available get one of each You can make a holder for the bits out of a piece of 2x4 with drilled holes for holding the bits Epoxy pump Sticky Stuff dispenser An epoxy pump pays for itself in saved epoxy With every pump of the handle you will receive the proper amount of resin and hardener without needing to weigh or measure With practice you ll know the proper number ...

Page 12: ...nd Cleco pliers are available from aircraft supply stores or catalogs ours included Digital level A digital level has an LCD readout instead of a bubble On some digital levels the center pops out to become a small six inch level that s extremely handy for measuring control surface throws seat back angles firewall angles engine thrust lines etc all with an accuracy of 1 10th of a degree KCI carries...

Page 13: ...t action for deburring holes and radii The curved blade automatically follows all contours Surveyor transit If you like gadgets this one is fun although a water level will work just as well for less money A surveyor transit can save you an hour or two in setup time and is usually available for rent from surveyor construction suppliers It is like the water level because it still takes two people to...

Page 14: ...aration of BID tapes and other fiberglass layups Thinner drop clothes are not as easy to handle and thicker ones are too hard to work Paper towels Buy paper towels by the case if you have the storage space Always keep at least three or four rolls on hand You ll be using paper towels for cleaning up drips as well as using them for absorbing excess resin Tongue depressors We supply tongue depressors...

Page 15: ...ld carry this item Cardboard We recommend using cardboard for rib or web templates Create cardboard templates to use as a pattern for prepreg Cotton flox Cotton flox is finely chopped cotton fibers which appear nearly as fine as micro balloons The difference is that flox is structurally stronger than micro when combined with epoxy Epoxy During aircraft assembly two types of epoxy are used Structur...

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