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Chapter 1

Page 1.14

REV. 2nd Ed./08-15-06

Introduction to the Lancair ES FastBuild Kit

Plumb bob

A small plumb bob is necessary for

vertical measurements. Multiple plumb

bobs are useful for aligning.

1" Makita belt sander

This belt sander along with an assortment of different grit belts will come in handy before you

finish your kit.

Heat gun

The heat gun can help warm parts you want to bond, straighten a warped part and a lot of other

jobs. It can also destroy parts if you are not careful! The heat gun is a well-used tool in our shop,

not only for heating parts, but for gently heating to cure epoxy, shrinking heat-shrink tubing on

electrical connections, etc.

1.5.C Supplies

Safety glasses or goggles

Wearing eye protection is important when you are working on a composite aircraft. A splash-

resistant goggle works best to prevent dust from entering your eyes and the goggles.

1 mil thick plastic drop cloths

You will need a lot of 1 mil thick drop cloths. You can get them at most hardware stores and

they are great for covering things. You will also use them in the preparation 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 with your kit. There should be enough to complete the project with

a few left over. You will use the depressors as mixing sticks for the epoxy you pump from your

epoxy dispenser.
We also use modified tongue depressors for many tasks. A square-end version is used to spread

micro radii. Also a tapered-end version is used as shims when pre-fitting airplane parts. The

following picture is of a square-end tongue depressor.

Brushes

Brushes are supplied with your kit. You will use these for stippling and soaking up excess resin.

You will need to cut the bristles to half length on some of the brushes. The brushes can be

cleaned in acetone and reused.

2" side paint roller or wallpaper roller

Another simple but handy tool is the roller. We recommend a small 1-1/2" wide paint roller

(without the furry paint sleeve), and a larger 3" wide roller for pushing the air bubbles out from

under laminates. Try sliding a length of PVC tubing onto the paint roller to get a smooth, hard-

Содержание ES

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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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