Scratch Building Basics For Metal Aircraft

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Part# 13-04185


Explaining basics of rib forms Forming rib in vise Forming rib tip in vise Cutting horn from thick stock Forming the nose radius Examine spring back contour Demo of sanding block Forming rib on bench Scotch-brite power deburring Completed set of rudder parts Transferring pattern to metal Homemade edge marking tool Band saw for rib forms Demonstrating air shears Mounting form block Solid riveting tool Fluting pliers Creating the nose skin Bending in the brake Almost complete nose skin Creating lightening holes Scoring knife for sheet cuts Completed tip rib Reviewing the plans

What planned adventure in life can top that of building your own airplane from scratch – -- using just raw materials, common tools and a set of plans?

It requires a builder with special skills, knowledge, and an attitude complete with persistence and imagination. Not all of us are cut out for a project like this… although most of us can appreciate the rewards that will result!

The purpose of this video presentation is to expose you to the world of building a metal plane from plans, demonstrated by one of the most considerate pair of builders you will find anywhere. You will witness the type of skills, materials, tools and commitment that is required to accomplish this feat. These two gentlemen, Mark Townsend and David Barth (owners of Can-Zac Aviation Ltd the Canadian distributor for Zenith Aircraft Company) donated their time and expertise in making this video so that we could share their passion for this hobby.

This 2 disk DVD video (over 3.5 hrs runtime) is divided into the following chapters for easy navigation:

From Plans to Form Blocks
Creating Cutting Blocks and Form Blocks
Producing the Metal Rib Blanks
Deburring and Polishing Techniques
Forming Ribs
Fabricating the Rudder Spar
Fabricating the Rudder Horn
Fabricating the Rudder Skins
Creating a Full Size Wing Rib
Tips, Tricks and Techniques

Mark and David take you thru each step of the process required to create the components needed to build a Zenith rudder. A rudder was chosen because it contains nearly all of the components that are needed to complete the remaining parts of an airframe: ribs, spar, skin, control horns, etc. The presentation begins with just raw materials and common tools. By the conclusion of the 2 DVD set, you will have witnessed all of the internal rudder components completed and will now be at the point that kit builders start their rudder project - ready to assemble these components into a finished rudder. This next step of rudder assembly is detailed in the companion DVD video from HomebuiltHELP entitled Metalworking101.

Details of the fabrication process are explained and demonstrated - such as: how to translate blueprint plans to a form block drawing, cutting, sanding and finishing the form blocks using common tools; choice of form materials (plywood, MDF, particle board, hardwoods, etc); tools for cutting aluminum sheet, (power shears, hand shears, scoring knife), forming rib blanks around form blocks (how many hammers can be used!), fluting techniques for curved edges, cutting lightening holes, various methods for deburring and polishing, sheet metal bending using a home made brake, and much more. Both Mark and Dave spend equal amounts of time explaining these operations and expend just the right amount of humor to make this truly fun to watch.

Watching Scratch Building Basics for Metal Aircraft is an excellent way to determine if building a homebuilt aircraft from scratch is right for you... you will obtain a full understanding of the trials, tribulations, joys and successes that this type of building process entails. Many builders have attempted this journey without fully understanding the challenges - and waste time and money when things don't go as planned. This video presentation takes the mystery out of this journey! Whether you are just curious what goes on in garages around the world - or if you are serious about getting started building your own plane from scratch - you can't watch these guys at work and not learn something that might change the way you think about the process and people that build their own planes from scratch! This affordable 2 disk DVD video is approximately 3.5 hours in length and is divided into 10 video chapters to make navigation and review of desired sections fast and easy. The DVD set includes web links to plans for building your own sheet metal brake and other tools used in this video (you can print the plans on your own printer). A great resource if you are really serious about starting your own project at home.



Please note, Pilotshop's personnel are not certified aircraft mechanics and can only provide general support and ideas, which should not be relied upon or implemented in lieu of consulting an A&P or other qualified technician. Pilotshop assumes no responsibility or liability for any issue or problem which may arise from any repair, modification or other work done from this knowledge base. Any product eligibility information provided here is based on general application guides and we recommend always referring to your specific aircraft parts manual, the parts manufacturer or consulting with a qualified mechanic.

Q: What is the resolution of the DVD Video?

Standard resolution. It is not 4K.