Ted's Aircraft Shop

Essential and Useful Tools, page 5

HVLP Touch Up Gun	Harbor Freight	Used off high pressure air from air compressor; surprisingly useful
Air drill	Avery Tools	For Drilling Rivet Holes
Die Grinder	Harbor Freight	Handheld grinder for trimming metal edges
90 degree Die Grinder	Harbor Freight	Handheld grinder for hard-to-reach edges
Air Reciprocating Saw	Harbor Freight	Will cut off metal (and fingers)
3X Rivet Gun	Avery Tools	Only way to set rivets
Air blow gun	Harbor Freight	For cleaning metal fragments off workbenches

 

 

 

 

 

 

 

 

 

4. Fixtures and Jigs

 

I build a surprising number of fixtures, jigs, holders, and guides out of wood.  Wood is easier to work than metal, readily available, and I have the wood working tools already in my shop.  Many of these devices were suggested in the Cub Clues newsletters or the EAA Sport Aviation articles over the years.  One of the best examples is a “spar spreader” used when building up the wings.  When every rib is in place on the spars, suddenly it becomes impossible to put the drag struts into place.  The space is just too tight.  But with the ingenuity of another builder and his design, I have a spar spreader that will separate the wing spars just enough to get the drag struts into place. 

I built special use sawhorses, several kinds.  I built rotary wing stands.  I borrowed a couple of welded units for the fuselage.  But for the wings, I built my own out of 4x4 lumber, 2x4s, plywood, and bolts. 

 

I built jigs for Piper rib repair.  They held the ribs in place while removing and replacing bent or cracked rib frame pieces.  The result was a set of wings with no deviations in part size.  (You might be surprised at the sloppiness of some repairs, and it pays to check.) 

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