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Old 12-21-2004 | 11:42 AM
  #6  
John_E
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Joined: Nov 2004
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From: Virginias Beach, VA
Default RE: Kit Building..

1. Read the instructions fully and if you don't understand something get clarification before you start.

2. Make sure you have all the pieces accounted for before you start. I just built a GP 60 size J-3 Cub and some of the instructions were wrong on part sizes and cutting. I at least had enough knowledge to be able to correct for their error. They had me cut the main spar 2 inches off on each side. This is because the instructions had been written with 42 inch spars in mind. someone else in the parts list made the spars only 40 inches because that is all that was needed. I was able to make a brace that joined the spars better than original. Would not have wanted to have that happen o a first kit though.

3. Make sure you use the specified glues where they tell you. 30 minute Epoxy when stated not 5 or 10. longer setting epoxies have more flex strength than fast epoxies. Fast epoxies can be more brittle. Also use slow, medium, and fast CA as specified. Get some CA debonder and CA accelerator. Both can be essential.

4. Take your time, measure two or three times then cut or shape. A good metal (Steel) ruler with fine accurate measuring marks will also make a good cutting guide. A long metal yard stick is also useful for longer straight cuts. Wood rulers and yardsticks flex too much and you can cut into them too easily.

5. Razor tools are sharp but dull razor tools cut YOU more. If a tool is dull you tend to put more pressure or force to make the cut, when that happens a slip is more likely to happen and that's when you can get hurt real bad. Sharp tools use less force and give you more control. The bulk pack of #11 Xacto blades is a real bargain and allows you to keep a sharp edge when you want it , Put old used blades in a soda can or old bottle before throwing out. I must have used at least 10 - 12 blades in making my Cub.

6. Don't throw anything away unless you really know it is useless until the plane is complete. I find the excess wood is very useful in repairing planes. You did decide to build a kit so you can improve your repair skills didn't you? Those scraps from die cut / laser cut parts and cut offs can make all sorts of repairs.

7. If you want to keep your plans in great shape go to Kinkos or Office Max and make a working copy of the plans that you cut up, build on and generally destroy if need be. You can always make another set from the the originals later. Cost me $15 for two full sheets to be reproduced . Had to fold the drawings as the machine could only copy up to 36 inches wide but any length. Also tape wax paper over your building set of drawings to keep the glue from sticking to the plans and the wax will generally release the wood from the wax paper at least once.

8. A good straight and level building board that you can also pin into. (get building T pins also) I found a 3/4!QUOT! melamine board with dense foam insulation or ceiling tile glued on to it works great.

9. Take your time and enjoy. It's therapeutic and a hobby after all.