In order to build a plane, a guy needs a decent workshop. We've all heard about the guys who tried to build a plane in an apartment or a basement. I don't need to tell you how difficult that would be! My last airplane project was done in a spacious T-hangar with lots of room to work. It's amazing how much you can get done when you have lots of space to move around, and lots of work tables and storage. Unfortunately I don't have access to a hangar anymore so I have to make due with a 2 car garage. Can a plane be built in a two car garage? You bet! I measured my garage and discovered that the entire plane will fit inside with the wings on and a couple of feet to spare.
One of the most important things that you will need as a builder of fine aircraft is a decent set of work tables. Pictured below is the famous EAA workbench.
The plans call for enough material to build 2 complete benches which are 5' x 2' and they are designed to be modular. They can be grouped together in various ways depending on what you are working on at the moment, and they have a storage shelf underneath. My 2 benches cost just under $100 using material from the local builder's supply. The plans are very clear and there is a material list included. The plans actually tell you how to cut your lumber for the most efficient use of material. You can find the plans absolutely free at:
A FEW WORDS ABOUT WELDING........
In addition to good workbenches you will also need the following items:
+ Drill Press + Die Grinder + Chop Saw
+ Circular saw + Dremel Tool + Welder
+ Bench Grinder + Jig/Scroll Saw + Electric drill
+ Air Compressor + Lots of light + Safety Equipment
The LITTLE TOOT is constructed primarily of 4130 chrome-moly steel tubing. The question is not "Should I weld?" because YOU WILL BE welding! Rather, the question is "How will I weld?". There are really only two ways which are acceptable for aircraft welding:
+ TIG (Tungsten Inert Gas)
+ GAS (Oxygen Acetylene)
TIG is an electric arc welding process which uses a tungsten tip for long life, but the primary feature of TIG is that the welding zone is flooded with an inert gas such as Argon which will not burn. The gas flooding forces the oxygen out of the weld zone and prevents oxidation of the weld.
GAS welding does not rely an an electric arc to melt the steel, but rather an intensely hot flame tip composed of a blend of Oxygen and Acetylene gases. Properly balanced, all of the oxygen is burned up and it won't oxidize the steel. Gas welding is the old school way of welding, and the old airplanes were all welded up this way. It works just as well today as it did back in the good old days.
There are those who swear by TIG and say it is the only way to go. This is simply not true! All of the old Pipers, Aeroncas, and such were welded with gas and they still are airworthy after so many years. TIG welds look nice and clean, but the problem is that they have stress locked into the weld which will leave the weld brittle, which may cause cracks in the future. You must go back with a Gas torch and reheat the TIG welds to relieve the stress (called normalizing). If you buy a TIG welder, you will still need to buy a Gas welding outfit! TIG outfits are very expensive compared to the Gas outfits, so for me it makes sense to weld with gas. With practice you can make very good looking welds with gas that are perfectly airworthy.
What about aluminum, you say? Yes, it is possible to gas weld aluminum! It is not as easy as welding steel, but with the correct torch settings, technique, and alloy you will be able make nice welds in aluminum.
