AIRCRAFT TOOLS

Airplane STC Modifications

2008-01-01T06:01:00.000-08:00

A new website is being developed to connect airplane owners with STC holders. Where most STC listings are cumbersome to locate, this listing is by aircraft model which should make it easy for the owner and operator to locate the exact STC they are looking for. Another feature will allow STC holder's to place a link from the stc-mod site back to their own website and to specific sales information about their produce. This should be a great tool for all owners, operators and for modifiers.

RV TOOL KIT REQUIREMENTS

2007-11-05T09:33:00.000-08:00

RV Builder's often ask if all the tools they need to build their RV airplane are included in the RV Tool Kit. For sheet metal this is true. The RV Builder will also need mechanic tools. The link above provides the basic list of aircraft mechanic tools required to build and maintain an RV airplane.

TracerMarker for Aircraft Sheet Metal Repair

2007-10-25T17:16:00.000-07:00

If you have holes to match locate in aircraft structure you will find that the TracerMarker is the perfect tool for this application. These aircraft hole finders are easy to use. Simply stick the pilot in the existing hole, peel off the cover to expose the self-stick adhesive, and place the new part in the correct location. The TracerMarker will stick to the new part so you can easily mark a perfectly located hole before drilling.

This new aircraft tool saves time and money plus avoids errors in holes being incorrectly located. The low cost TracerMarker should be a product that every aircraft sheet metal mechanic has in their tool box.

Exporting RV Aircraft Tool Kits

2007-10-20T13:00:00.000-07:00

Over the years Isham Inc. has exported many tools to our RV tool kit customers. Generally our shipping cost for an export RV tool kit is 1/3 to 1/4 of the cost compared to standard shipping methods.

In some cases special approvals are required by the importing country. These approvals include US Chamber of Commerce and foreign Embassy approvals for some countries. Whatever the requirements are we will work hard for our customers to obtain the proper approvals to make the importing of our RV tool kit to your country as seamless as possible.

Full details of the RV tool kit can be found at www.PlaneTools.com as well as your ability to obtain a shipping quote for an export kit.

RV Tool Kit Customer Comments

2007-10-17T07:00:00.000-07:00

Isham Inc. believes that RV tool kit customer input is the key to maintaining the best customer service to make sure that the quality, price and customer service is the best in the world. This is why we post customer comments about our aircraft tools and tool kits on the web.

Many of our customers provide us with regular feedback so we can maintain the best RV tool kit available. We look forward to input from our customers and also those who are not our customers. Our goal is to maintain our position as the number one preferred supplier for RV tool kits.

New Aerospace Cost Saving Tools

2007-10-11T09:18:00.000-07:00

A new patented tool provides a significant cost savings to aerospace manufacturers, modification, completion and maintenance centers. The TracerMarker eliminates the need for the planning, design, fabrication, storage and use of shop aids used to locate holes in sheet metal parts.

The TracerMarker is a new hole locating tool that is simple to use to match an existing hole pattern in a part of structure of any aircraft. The steps to match holes are:

1. Place the TracerMarker in the holes that need to be copied.
2. Remove the backing to expose the self-stick adhesive surface.
3. Place the new part into position and press to cause the TracerMarker to adhere to the new part.
4. Remove the new part and tap each TracerMarker with a hammer which causes the marker to create a center punch hole in the new part.
5. Remove the TracerMarkers which reveals the center punch locations for drilling the holes in the new part.

The TracerMarker is available in several standards aerospace diameters. Additionally, the TracerMarker may be special ordered to specific size for unique applications.

This product is currently used by several aircraft modification companies, airlines and some United States Air Force maintenance centers. Studies are underway to make the TracerMarker a roto-bin item by some maintenance and modification facilities. The significant cost savings over the use of shop aids and special tools makes this product a great value for any facility that regularly replaces and repairs aircraft structure.

For more information contact Isham Inc. at www.PlaneTools.com

RV Tool Kit Sales

2007-10-10T07:41:00.000-07:00

RV Tool Kit sales were down about 25% from 2006 attributed to lower sales of Van's Aircraft kits. Isham Inc. sales were consistent with sales of the airplane kits through the third quarter of 2007. In 2006 Isham Inc. exceeded 1/3 of total airplanes sold by Van's on their website tool kit offer at www.PlaneTools.com. The tool kit sales have experienced steady increase in market share due to the higher quality of their tools, completeness of their aircraft tool kit and excellent customer service over competitor tool kits.

Isham Inc. also added new products in 2007, however, continues to focus their main business on the Van's RV airplane. An increase in market share is expected in 2007 over 2006 sales. This is largely because of the tight nit RV aircraft community forums and word-of-mouth recommendations from other RV aircraft builders.

Drill Bit Aircraft Tools

2007-10-08T09:07:00.000-07:00

Aircraft drill bits are normally 6-inches long rather than jobber drills which are 2 - 3-inches. The reason aircraft drill bits are longer is to provide more control when drilling. The longer drill bits allow the operator to flex the bit in order to move it a small amount in any direction. This is important when drilling out rivets. The longer bit is much easier to move the bit to the center of the rivet.

Another advantage is that spring type drill stops are easier to install and adjust on the longer bits.

The Isham Inc. RV Aircraft Tool Kit includes the required range of 6-inch aircraft drill bits for building the Van's RV airplane. You may check out the complete tool kit at the link above.

RV Aircraft Tool Kit 1/4-28 Threaded Angle Drill

2007-10-04T20:30:00.000-07:00

About 15% of all RV Tool Kit buyers also purchase the 1/4-28 threaded bit air angle drill. This drill is a very high quality clone of the DOTCO angle drill. The head is about 1-inch deep so with a short drill bit installed one can get into an area with less than 2-inches of space to drill a hole.

The aircraft angle drill also has optional heads including a 45-degree head and an long 90-degree head for other hard to reach places.

This is a great addition to the RV Tool Kit, but many builder's find way to work-around the need for this type of drill. One method is to use the 12-inch extended drill bits and come at the hole from the opposite side.

Visit the RV Aircraft Tool site at www.PlaneTools.com for a full line of aircraft tool kits.

RV Tool Kit for building Van's Aircraft

2007-10-04T02:11:00.000-07:00

The RV tool kit used by Mike on his RV-7 is the Isham full tool kit. Mike has done an excellent write up of the differences between RV tool kit providers and it will be worth your time to study this analysis. The Isham RV tool kit is available at www.PlaneTools.com and includes the DRDT-2 dimpler and the pneumatic squeezer.

In addition to doing a great job on the RV tool kit decision process, Mike has one of the best websites for building the RV-7 airplane. His attention to detail is great and this is probably one of the best websites for a new builder to visit.

For the very best RV tool kit study Mike's analysis and visit the aircraft tool website at www.PlaneTools.com for more information.

Good luck on choosing your RV tool kit.

RV Aircraft Tool Kit Options

2007-09-29T15:52:00.000-07:00

Many RV Aircraft Builder's ask what optional tools are needed to build their airplane. The basic RV Tool Kit includes everything needed. There are some tool kit options that some builders elect to purchase.

Additional squeezer yokes in the Longeron style and 4-inch thin nose (no-hole) yoke will get into more places than only the standard 3-inch yoke. About 20% of builders purchase these additional yokes. Without them the builder can always use the rivet gun and bucking bar for those rivets.

Angle drills that use 1/4-28 threaded drill bits are purchased by about 10% of builders. This drill will get into spaces as small as 2-inches. As an alternative, use the 12-inch extended drill bits and come in from the other side to drill the hole.

RV Quick Build kits require less clecos than the full build kit. About 20% of the builders build the quick build and opt for the reduced number of clecos.

The best way to determine your options is to decide if you want to use the rivet gun and bucking bar more and come up with some other methods to make a few holes by using the extended drill bits.

Good Luck on your RV airplane!

RV Tool Kit Detail Components

2007-09-25T18:28:00.000-07:00

RV tool kits have several options depending upon the RV aircraft model being built and whether the airplane is a quick build or a "slow" build kit.

The basic kit includes the pneumatic squeezer and DRDT-2 dimpler which are considered must have tools.

In the options a builder may select the quick build option which deletes one-half of the clecos.

The RV-10 airplane option adds clecos, a special RV-10 bucking bar and additional squeezer and dimpler die sets.

In the area of air drills a builder may select between the standard 2700 RPM pistol drill or upgrade to a Sioux 1412 3600 RPM palm drill. Another drill that is optional is the 1/4-28 threaded angle drill. This unit is designed to fit in tight areas -- about 2-inches is enough room to drill with the angle drill.

The rivet gun has optional sizes. The 3X is by far the best choice for the RV beginning builder. The 2X gun hits too fast and is too hard to control. The slower blows-per-minute of the 3X rivet gun allows the builder much better control when riveting.

A great way to decide on which options you will need is by talking to other builders or discussing this on the forum at www.vansairforce.net. With many user groups for RV aircraft builders you will find many suggestions for your own unique configuration of your RV tool kit.

Cogsdill Deburring Tools

2007-09-21T23:15:00.000-07:00

Many RV builders ask about the Cogsdill Deburring Tools for 3/32 and 1/8 inch rivet holes in their airplane projects. The RV tool kit does not include these deburring tools. The reason for this is that the rivet holes can be easily over-deburred with these tools. This causes the cleco temporary fasteners not to hold after the rivet hole is countersunk. For a better explanation of this issue see the link in the title of this writing.

Most RV tool kits are based on Van's Aircraft recommendations. Van's often over-emphasizes the deburring of holes on the RV airplanes. The fact is that unless you are building a pressurized aircraft you do not need to worry about having perfect rivet holes. A hole drilled with the appropriate aircraft drill bit and wiped off to remove any burrs is adequate.

Deburring does not mean having round and smooth holes, only removing burrs -- if you do not understand what a burr is, consider it a hang-nail inside of the rivet hole. If you don't have any of these "hang nails" then don't deburr. Your airplane will look highly professional and you will be glad your clecos all held in place after you dimpled your parts.

Performance of Sioux Air Tool Products

2007-09-20T19:13:00.000-07:00

We have handled Sioux air tools for several years now. The most popular is the Sioux 1412 palm air drill. About 20-percent of RV aircraft builders purchase this drill. Over the past 3-years there have been two drills, that we are aware of, returned to Sioux Service Centers for warranty work. One drill had a defective body casting. The second has a leak when the drill is off.

Sioux rivet guns are a different story. In the past 3-years we have had very few satisfied customers. The Sioux rivet gun seems to always leak air when connected to an air supply. The Service Centers and the Sioux factory have been unable (or unwilling) to correct these defective rivet guns. We stopped carrying the Sioux rivet gun because the lower cost import rivet gun is just as impressive for riveting and has very few problems. About the only thing I can say that is positive about the Sioux rivet gun is that it has a nice red powder coat finish.

When you purchase air tools for your project you may want to do some research to make sure you are getting a good durable product.

New Hole Marking Tools Save Time & Money

2007-09-17T15:36:00.000-07:00

The TracerMarker is a unique new design that replaces traditional aircraft tool hole locating methods. A big advantage is that these new markers eliminate the need to design and develop special locating tools. This saves the cost of design and manufacturing of shop aids to build tools for modification and maintenance applications.

The TracerMarker sticks to the existing part locating holes, the new part is placed on top and the markers stick to the new part. A slight tap with a hammer marks the center of each hole for drilling.

Another big advantage over traditional hole locating tools is that the TracerMarker does not require any additional space for the mechanic to mark the holes. If the actual part will fit in the space it is a simple task to place the TracerMarkers into position and place the new part over the markers for an exact fit.

This tool will soon become a roto-bin item in most major manufacturing, modification and repair centers of jet aircraft. It is being used by the military in modifications and maintenance of aircraft. The TracerMarker has proven its worth in many general aviation and commercial aircraft repair and modification applications.

The next time you need aircraft tools to locate holes in a part or assembly try the TracerMarker. You will be very pleased with the accuracy and will benefit from the cost savings in time and money.

Builder Support for Van's RV Aircraft

2007-09-14T20:12:00.000-07:00

Probably the best resource for building an RV aircraft is VansAirforce.net. The forums are great for folks just thinking about building or for those in any stage of aircraft construction. Every model, every part and every step of each building process is well documented. This is the place to ask questions and get answers from those who have "been there and done that." The same is true for deciding which aircraft tool kit you want to purchase. Make sure to search for "isham" to get the posts on the Isham Inc. RV tool kit from www.PlaneTools.com

Isham Inc. PlaneTools.com Blog

2007-09-13T18:47:00.000-07:00

I need to be more disciplined about writing to the blog. This can be a great tool to discuss and explain technical aspects of aircraft tools. In the past we have included many of the steps for using tools on the Van's RV aircraft build and assembly processes. We have answered many questions and shared ideas on how to use our tools and which tools work the best for specific applications. We will try to do a better job in keeping this blog up to date in the future.

What are Springback or Spring Back Dimple Dies?

2006-11-07T02:55:00.000-08:00

Many aircraft builders ask what the difference is between a Springback and regular dimple die. The concept behind springback dies are that the aluminum is slightly "canned" in the opposite direction of the dimple (about 1-1/2 degrees) which allows the aluminum to "Spring back" into a flat sheet around the dimple. A regular dimple die will leave a slight can around the dimple, in the same direction as the dimple. Springback dimple dies were developed by the Aluminum Company of America in 1942 under contract for the National Advisory Committee for Aeronautics. Since that time there are a few tool companies that have the illusion that they invented the springback dimple dies, or that they have improved upon them. We have measured and tested all of them. The bottom line is that the spring back dimple dies work on 1/8" or larger diameter countersink holes, and all of them work the same with no noticeable difference in the finished product. However, technique of dimpling also affects the finished dimple and canned effect. On 3/32" rivets we find that a standard die works as well as the spring back dimple die. Many will argue these points, but they will also say that they invented this 1942 tool. The best dimpled hole is one that is dimpled a second time with the actual rivet that will fill the hole and a dimpling block -- see my May 2, 2006 previous post on this subject.

RV Tool Kits

2006-10-28T14:41:00.000-07:00

Many new builder's ask if they need a full tool kit or if it is wise to only get an empennage tool kit to start with. I think that most RV builder's will agree that the tool list on Van's website really does not contain all of the tools needed for the empennage or the full airplane. It's a good start, but many other tools are needed to build the airplane. Most full tool kits provide the necessary tools for the sheet metal work, but many other tools are available to make the building process easier and to do a better quality job on the finished product. When a builder is considering the empennage kit rather than a full tool kit the things to keep in mind are: 1. Do you plan to build the full airplane or are you only building the empennage to see if you are really ready to tackle the airplane. If so, you may want to consider the empennage kit. If you are committed to the whole airplane then start with the full tool kit. 2. Buying the kit piece-meal will most likely cost more money in the long run. Shipping is expensive, often as much as the tool itself if it is a small purchase. These costs will add up and could significantly increase the total cost of the tools. 3. Most full kits are assembled in a way that gives the best price available and gives you a set of matching tools. I believe this is the best way to go if you are committed to building the airplane. Thanks, Glenna

The Best Drill for aluminum sheet metal

2006-10-12T23:02:00.000-07:00

What is best in an air drill for aluminum work on an airplane? #1 Speed, #2 User friendly, #3 comfort, #4 quiet, #5 reversible. For aluminum 2000+ RPM is needed. A drill that is user friendly will accept the drill and accessory sizes you need to use and will be easy to change bits/tools. A keyless chuck is the best way to accommodate this. A drill should be comfortable in your hand. A drill should be quiet. Some air drills like the Sioux palm drill are very quiet. Many builders are going to high speed battery operated drills which are also quiet. Reversible -- well, I threw it in but have never owned one myself. That's why it's at the end of the list. I've never seen a worn out reversing trigger on a used drill.

Building the Van's RV Aircraft

2006-10-08T20:11:00.000-07:00

If you are considering building a homebuilt airplane then look carefully at a Van's RV aircraft. Some things to consider. Van's has more kits produced and more flying airplanes than any other homebuilt. Accident history of homebuilt aircraft is important to research and understand. Only an aircraft mechanical or performance failure may be reason to shy away from certain aircraft. Most of the Van's aircraft that have been involved in accidents have been the result of pilot error or builder error. Van's aircraft are very high performance and require the right level of pilot experience. If you build one don't fly it yourself unless you have actual stick time in another Van's aircraft or with an experienced RV pilot in your local area. Avoid builder errors by checking and double checking every decision you make at www.vansairforce.net. Other builders will be glad to help you avoid any problems. If something doesn't seem quite right then ask before you build or install that part. Use the very best tools from www.planetools.com so that you can be sure the parts and assemblies you use on your airplane will be right. Take time to do every job correctly. Rework if you need to. This will help you avoid any mistakes during the building process. Ask a fellow EAA RV expert to assist you by reviewing your work and helping guide you in the building process. This is invaluable in that it will help you avoid costly mistakes and rework. In the end you will have a fantastic performing airplane that will take you just about anywhere you want to travel. HAVE FUN. Thanks, Glenna RV8A N220LS (In to tools!).

How long should a rivet be before driving or squeezing?

2006-05-08T21:21:00.000-07:00

Several builders and customers of aircraft tools have asked how long a rivet should be before they drive or squeeze the rivet. The simple answer is the shank of the rivet should stick out 1-1/2 times the shank diameter before driving. There is a link to a mil-spec above that has the exact measurements in Table 3. If you follow the 1-1/2 times the shank diameter rule you will always be pretty close. Hope this helps those of you who may not have heard this before. Glenna

Dimpling Block - Setting Perfect AN426 Rivets

2006-05-02T07:47:00.000-07:00

I have had several questions on the earlier explaination of making a dimpling block to set AN426 rivets. A couple of photos have been added to this link to show what the dimpling block looks like and how it is used to set near perfect rivets. This process will set the rivet in the skin before actually driving the rivet. The result is that the rivet and skins will fit nicely together. When the rivet is actually driven this will produce the best quality flush rivet.

Pneumatic Rivet Squeezer Set-up

2006-04-29T08:30:00.000-07:00

The set up of a pneumatic rivet squeezer is different for riveting and dimpling.

For riveting -- Always start with a gap when the squeezer is fully activated. The initial gap should be the skin thickness plus the length of the "finished" rivet. Once the rivet is squeezed if the butt of the rivet is squeezed too little add shims or fine adjust until the butt of the rivet is the correct size. It is better to have the rivet squeezed too little than to over-squeeze.

For dimpling -- The dimple dies should touch each other without any gap. The male die should be in the fixed part of the yoke and the female in the set holder that moves when the squeezer is activated. When dimpling, place the aluminum over the male set holder and trip the squeezer trigger very fast and at full throttle. This will "slap" the dies together to create a nice crisp dimple.

Caution -- Pneumatic squeezers have enough power to spring a yoke. Most yokes spring a little during dimpling and riveting, but do not operate a squeezer with less than zero clearance in the yoke as this may permanently bend the yoke.

Deburring Rivet Holes

2006-01-19T20:38:00.000-08:00

A lot of discussion centers around deburring of rivet holes. After drilling and installing hundreds of thousands, if not a million rivets I can say with some authority you do not need to deburr rivet holes in .020 or .032 aluminum. What is left in the hole is not a burr, but is actually a chip left over from the drilling operation. You can easily remove chips by disassembling the parts, putting on a pair of gloves and lightly running your hand across the drilled sheets. What must be avoided is removing the aluminum material. The holes should be crisp and clean, not deburred by removing material. If you do have an occasional burr (a piece that you cannot remove by rubbing) you can remove it by taking a countersink bit and lightly turning it by hand to remove the burr.

Who uses a C-Frame to rivet?

2005-12-08T19:29:00.000-08:00

An "old timer" asked me why he needed a C-Frame to rivet? I could not give him a straight answer -- because you don't. Anyone that works in aircraft sheet metal knows that flush rivets are best driven with a rivet gun, flush rivet set and bucking bar. The only place a C-Frame riveter could be used is for back-riveting -- and only then if the person doing the riveting is not capable of holding a rivet gun with a back-rivet set straight up and down.

Anyone that can rivet with a rivet gun will be able to do back-riveting without a C-Frame. This "back-to-basics" approach will provide the nicest quality and will be faster than using a tool that really is not required.

My point, in case you are wondering, is that you can use a DRDT-2 dimpler for all of your dimpling and you don't need to worry if you do not have a conventional C-Frame for riveting -- because you don't need it -- and you don't want it. You will do a better job without it! But, for someone that sells aircraft tools, if you want it you can still buy it. We have several collecting dust on our shelves!

Dimpling Aircraft Tools

2005-11-18T22:08:00.000-08:00

The facts are that no matter what dimple die you use for dimpling 02Thin skin you will not get a professional dimpled rivet unless you finish the dimpling process when you set the rivet.

Everyone selling tools has the best dimple dies on the market! Some suppliers claim to have developed and hold the secret to the perfect springback dimple die after years of fine tuning. I don't know if they are dazzling you with their genius or baffling you with BS. What I do know is that the "perfect" 100-degree springback dimple die was perfected in 1942. Everyone that builds springback dimple dies today uses the original 1942 design with very little difference.

I constantly hear and read that dimples are too deep or too shallow and the dimple die is generally blamed for this. The real problem isn't the dimple die, it's the process for installing countersunk rivets.

In order to do a professional job you will need to start with the dimple die to make the initial dimple. This is done by impact or pressure on the dimple die set using a DRDT-2 dimpler, C-Frame dimpling tool, hand squeezer or pneumatic squeezer. After the dimple is formed in the skins, stringers, ribs, bulkheads and all parts for assembly you will need to go to the next step.

Lightly debur the holes. Very lightly so you don't actually cut any metal away, only knock off the rough burrs. After deburring cleco the parts together and your ready for the next step.

Make a tool. Yes, that's right. Make a dimple set block. Make this by drilling a hole and countersinking it to match your rivet head depth in a scrap piece of steel or bucking bar. Next, use the dimple set block.

Install a rivet in the skin, place the dimple set block on the back side and lightly drive the rivet into the dimple set block. This will "set" the aluminum and the rivet tight and flush. When you do this it only take two or three taps with the rivet gun at low throttle.

Next drive the rivet using a standard bucking bar and you will have the perfect countersunk rivet.

This is a lot more work than would be required if you had the "perfect" springback dimple die. Unfortunately, many claim to have improved upon the springback dimple die developed in 1942 by NACA. Few, if any, have come up with a new unique design for a tool that installs a rivet into aluminum sheet that hasen't changed since 1942. Drive your flush rivets using the dimple set block and you won't need to spend hours trying to figure out who makes the best 1942 springback dimple die or why your flush rivets just don't set right in the dimple.

Happy building!

Rivet Gun & Bucking Bar versus Squeezer

2005-11-17T00:26:00.000-08:00

What is wrong with a good ole' bucking bar and rivet gun? I continuously hear about problems builders are having with hand squeezers, pneumatic squeezers and C-Frame riveters and think it is time to talk about getting back to the basics -- 101 Riveting!

Have you ever walked through an airplane factory? Listen. . . hear that. . . sounds like rivet guns pounding away. There is a reason that Cessna, Piper, Raytheon, Boeing and others use rivet guns and bucking bars -- quality. A rivet installed this way gives the strongest, tightest and best rivet. What amazes me is that it is also the easiest when one considers how many rivets installed with a hand squeezer must be drilled out and re-installed.

In a major production facility you will find automated rivet machines -- but these are no comparison to a hand squeezer many kit builders use. The only application you will find a hand squeezer use for in a production factory is where absolutely no other tool will reach. There are instances where production facilities use pneumatic squeezers, but when a rivet gun and bucking bar will fit it is the preferred method.

Try this -- instead of trying to use a hand squeezer or pneumatic squeezer to build your airplane use a rivet gun and bucking bar. If you absolutely cannot get these into an area and the squeezer will do the job then use it. You will find that you have very few bad rivets and you won't have to spend a lot of time trying to figure out what you are doing wrong on a tool that really should have very little use when you build your airplane!

I expect Rosie the Riveter would tell you "If it ain't broke, don't fix it." After all, Rosie could have built a B-17 with the basic sheet metal kit like the one linked in the title above.

Quality of Aircraft Tools for Homebuilt Aircraft

2005-11-14T22:22:00.000-08:00

I want to share some thoughts on the quality of homebuilt aircraft tool kits.

There have been several suppliers over the years that have entrenched their names in the minds of builders. These aircraft builders have become the experts that new kit builders rely upon for advise. This is particularly true in the Van's RV Aircraft world. For many of these former builders there is no alternative to the tool kits and tools they used when building their RV airplane.

This could be true if the older aircraft tool suppliers were the only ones that offered their own branded product. The fact is that the old tool suppliers, for the most part, sell the same exact tools as the new suppliers. Each aircraft tool company may have a specialty item or two, but there are only a few manufacturers of rivet guns, pneumatic drills, rivet squeezers, dimple dies, tin snips and most other tools contained in the tool kit.

Occassionally a new product comes along that is a big hit with RV builders. This is the case for the ExperimentalAero DRDT-2 Dimpler (see the web link in the title above). This new dash 2 dimpler makes professional quality dimples consistently. The DRDT-2 has a reasonable price tag and is in very high demand by RV aircraft builders. I have seen several posts on the RV web spots where former builders just cannot see how this tool can replace their conventional hammer operated C-Frame riveter and dimpler.

The piece of the puzzle the experienced builders are missing is competition. In a competitive market a company provides an equal or better product at a lower price. The way they do this is by having a lower cost. This can be by quantity purchases, lower overhead, lower operating cost and other factors that improve their competitive position.

A new competitor will also offer quick delivery and service after the sale if a customer has a problem. In a tough market like Van's RV aircraf tools it is critical for a company to offer service beyond the sale. RV builder's talk a lot! With over 8,000 RV aircraft kits out there they have websites devoted to people building RV aircraft.

When a homebuilt aircraft kit builder is looking for a quality aircraft tool kit look carefully at the price and the tools provided in the kit. RV builders are finding that they get the same or better quality at a lower price by looking at the latest tool kit options, versus the old companies.

03/31/2005 Rivet Sets for Aircraft Sheet Metal Work

2005-03-31T19:04:00.000-08:00

Rivet sets for rivet guns are available in many sizes and shapes. The most common are .401 shank (the shank size diameter that goes into the rivet gun) and a 3 or 3-1/2” length. A standard combination set includes an AN470-3-3 (3” long and 3/32 diameter rivet), AN470-3-4 (4/32 or 1/8” diameter rivet), AN470-3-5 (5/32” diameter rivet) and AN470-3-6 (6/32 or 3/16” diameter rivet) and a flush set, generally 1” diameter.

Other .401 sets are available in longer versions, mostly 5” or 7” and also in offsets or double offsets to get into tight spaces.

Rivet sets are also available for hand and pneumatic squeezers. Most popular sizes have a 3/16” diameter shank or 0.187 diameter.

Rivet Tools for Sheet Metal Airplanes

2005-03-18T19:32:00.000-08:00

Several riveting tools may be necessary for your sheet metal project. In addition to the obvious rivet gun you will need bucking bars, rivet sets, clecos with pliers, rivet squeezer equipment and possibly pop-rivet tools. I will discuss each of these in more depth in future writings. For this session I will concentrate on the pneumatic or air rivet gun.

Rivet guns are different than “air hammers” in that a rivet gun is metered differently to hit harder and slower plus they normally have a “teasing” trigger or a variable trigger. The “teasing” action is necessary to allow the “setting” or lightly tapping of the rivet before it is driven. This technique is done by holding the bucking bar off to the edge of the rivet butt and teasing the rivet to set it properly in the hole. Once set, the rivet is driven with full throttle and with the bucking bar directly on the butt of the rivet. Do not practice on real airplane parts. Practice on plenty of scrap until you are familiar with the operation.

Rivet guns are available in many sizes starting with the OY or “Stubby” which is a special gun designed for very tight spots and requires special short shank rivet sets. Next is the 1X which is the shortest gun that uses standard aviation rivet sets (.401 shanks). From there they move up in sizes of 2X, 3X, 4X, 5X, 7X and 9X. Each has a larger rivet capability. For most general aviation applications the 3X or 4X will work the best.

Files for Aircraft Sheet Metal Work

2005-03-06T14:34:00.000-08:00

A variety of files will be needed for your project. A general purpose file set with coarse, smooth, flat, curved and round files will be handy for most pieces that you will need to cut or shape. A file card will be a useful addition in order to clean your files after use. The one unique file you will need is a Vixen file which is a very coarse file for de-burring long pieces of aluminum. Other than the Vixen, a general purpose set should do everything you need.

Summary of Drilling Tools for your Homebuilt

2005-03-05T05:07:00.000-08:00

This list summarizes the drill and drilling accessories you will require and those optional items that you may find worth investing in for your homebuilt aircraft project. This list is based upon Van’s RV Aircraft but should apply to any sheet metal construction airplane.

Required Tools:
• Pneumatic Air Drill, minimum 2,600 RPM
• Standard Length #40, #30, #21 and #10 Drill Bits
• 12” Long #40 and #30 Bits
• Countersink Cage with #40, #30, and #6, #8 and #10 Screw bits
• Hole De-burring bit

Optional Tools:
• Drill Press, bench type of floor stand type
• ¼-28 Threaded Air Angle Drill and Bit Set, minimum 2,000 RPM
• Air Swivels for all Air Tools
• Drill Bit Stops, Spring Type
• Full Set of Wire Gauge Drill Bits
• Wire Drill Gauge for Checking Bit & Countersink Sizes
• Battery Drill for de-burring
• Hand Speed De-burring Tool
• Drill Hole Guide Set
• Hole Saw Set for Instrument Panel
• Plexiglass Drill Bits

Aircraft Drill Accessories

2005-02-24T19:32:00.000-08:00

Key accessories for aircraft drilling include drill bits, countersink cage, countersink bits, drill guides, drill stops, and a de-burring bit.

Standard wire gauge drill bits are #40 (3/32”), #30 (1/8”), #21 and #10. These bits will drill the holes for most standard aircraft fasteners. It is recommended to have a full set of 60 wire gauge drill bits just to have the exact size needed for any critical holes you may need to drill. Generally 3” to 6” drill bits are standard for most drilling applications. Occasionally you may find a need for a 12” long bit in the #40 and #30 sizes for hard to access areas. On ¼-28 threaded bits for the angle drill the #40 and #30 are generally the sizes needed. You will find that spring type drill stops are great to keep from damaging your skin and parts – you won’t need to worry about the drill chuck marking the aluminum.

A countersink cage with 1,000th adjustment increments is perfect. Ball-bearing types are preferred. You will need 100-degree (aircraft standard) countersink bits with pilots that match the drill bits in #40, #30, #21 and #10 sizes. Countersink bits need to run at a high-speed in order to cut a clean neat countersink. Adjust the countersink using a piece of scrap metal and test the fastener fit to get it as flush as possible before countersinking you airplane skins.
Drill guides are needed if you have holes that need to be perfectly straight. These are generally plastic guides with a metal collet that matches the drill bit diameter. Rest the guide on your part and drill straight through.

A de-burring bit will make it easy to remove burrs from the holes (although I prefer the hand type speed de-burring tool that uses the countersink bit to de-burr. See the link above.

Pneumatic Angle Drill Aircraft Tools

2005-02-21T19:39:00.000-08:00

Quite often you will find that you need to drill in an area of your airplane that does not have enough room for a pistol type drill and bit. In this case the air angle drill is the answer. The angle drill normally requires less than 2” of space, depending upon the length of the drill bit. Drill bits have a ¼-28 threaded adaptor that screws into the drill chuck. Bits are available in all standard aircraft wire gauge sizes. I would recommend a drill that is over 2,000 RPM which will provide the best speed for drilling aluminum or composites. I would also recommend an air swivel which will keep the air hose from binding during the drilling operation. See the link above for a photo of the angle drill.

Pneumatic Drills for Aircraft Fabrication

2005-02-20T18:07:00.000-08:00

For aluminum sheet metal a high-speed air drill will cut through the aluminum the easiest. The high-speed drills range from good quality economical models to high quality drills like the Sioux drill. These both have teasing triggers – a trigger that will allow you to operate the air drill at a slow speed until the bit starts grabbing the aluminum, the full throttle to complete the hole.

For steel you will need a low RPM air drill from 400 to about 650 RPM range. This will allow you to drill a neat and controlled hole in harder metals without burning up the drill bit.

Aircraft Tools for Drilling

2005-02-19T10:07:00.000-08:00

There are a wide range of drilling tools required for building a Van’s RV aircraft or any other experimental homebuilt airplane. These include a tabletop or stand-mounted drill press, air drill and battery powered drill. Also, you may need a variety of drill bits, countersinks, de-burring bits and other miscellaneous items like drill guides, hole saws, etc.

The drill press is needed for making small parts of wood, plexiglass, aluminum, steel or any other material you are using. The drill press allows accurate drilling of straight holes for torque tubes, control sticks, rudder pedals, bearing mounts and many other items. It is also an excellent tool to use for drilling and cutting out an instrument panel or a switch panel. For the panels it is recommended you use metal hole saws rather than a fly cutter on the larger holes. This will provide a much better cut out and these are safe to use. Place a piece of scrap wood under the part you are cutting or drilling to provide a good clean cut all the way through the panel.

An air drill for most aluminum applications needs to be fast. The faster the drill the easier it will be to drill holes for rivets and other fasteners. Minimum should be 2,600 RPM and you may easily go up to 6,000 RPM.

A battery drill is great for de-burring.

I will discuss drilling in more detail in future writings.

Other General Purpose Cutting Tools

2005-02-17T19:03:00.000-08:00

The band saw is a fantastic cutting tool – just make sure to have the appropriate blade for the type of material being cut. I use the band saw for wood, plexiglass, aluminum and some steel. It is great for cutting small parts or jigs from wood. For plexiglass and metals you will need a fine tooth blade. For hard metals like steel you will want to run the blade at a very slow speed.

Air grinders are really a must have tool. For the most useful set you will want a straight and a 90 degree head angle grinder that turns around 12,000 RPM. Generally the 12,000 will give the most torque (power) for grinding, sanding, polishing, and de-burring. Get a high-quality grinder as the cheap ones do not have the torque needed.

Razor blades or utility knives are good for everything from opening boxes to cutting and scraping all kinds of items.

A hacksaw is a required item which works great for almost every material you will need to cut. Have extra blades on hand.

Cutting Tools for Aircraft Tubing

2005-02-16T19:26:00.000-08:00

Most projects include some amount of 4130 steel tubing. One of the most economical methods to cut tubing is the hacksaw. A bench grinder may be used to curve the edges to mate for welding. If you have a lot of tubing work there are regular tubing jigs available that will drill and cut the tubing at different angles in one operation. This is one of the fastest ways to cut and prepare the steel tubing for welding. Another economical method, which I generally use, is a fiber blade steel cutoff saw. I finish the end using an air grinder to mate the surfaces before welding.

Cutting Tools for Aircraft Composites

2005-02-14T18:55:00.000-08:00

If your project includes composite materials, which most do, you will benefit from some special cutting tools. Fiberglass is relatively easy to cut and trim. Tougher composites can be cut using the same tools but you will need extra blades, cutters and wheels. I have found that the easiest method to cut composite materials is using a grinder type air saw with a 2” saw blade. The high speed saw cuts through most composites very fast. Other options include a fine tooth jig saw or band saw, however this method may delaminate the edge of the material being cut. Another good method is to route the cut. You may do this using a high-speed router, preferably an air router, and a router guide. For materials other than fiberglass it is a good idea to check with the material manufacturer to see what cutter and cutter speed will work the best for that material. In most cases you can sand the edges with fine wet/dry sand paper to smooth and finish the cut.

Cutting Tools for Aluminum Aircraft Sheet Metal

2005-02-13T17:20:00.000-08:00

This is one area where high-quality tools are very important. Cheap tin snips will tend to dull quickly and cause the aluminum to roll rather than to shear clean when cutting. Another important consideration is ease of cutting. Regular tin snips require your hand to be right between the two sharp edges of the aluminum being cut. Good offset aviation tin snips will allow the hand to be above the sharp aluminum and may avoid getting a hand cut. Another benefit of the offset tin snips is that they are easier to get a lot of leverage when cutting. The tin snips come in straight, left and right cut. Use them exactly as they are labeled. Yellow handle straight snips for cutting straight pieces, red handled left snips for cutting curves to the left, and green handled right snips for cutting curves to the right. In judging the quality of tin snips based upon retaining sharpness and ease of use I would rate them as follows: #1 Klein Tools Offset Tin Snips, #2 Klein Tools Straight Tin Snips and #3 WISS Brand Aviation Tin Snips.

For very large and flat sheet metal parts, such as a wing skin panels, you may want to locate someone with a foot shear or power shear which will provide a very quick and clean straight cut.

Marking Tools for Aircraft Sheet Aluminum

2005-02-12T15:42:00.000-08:00

Van's RV Aircraft kit is the basis for my writing but the same principles apply to all experimental homebuilt aircraft whether you are building a rag-wing or sheet metal airplane.

Obviously, the first step will be to mark the sheet metal for cutting and bending. For simple straight cuts and bends a rule and a permanent parts marking pen are the essentials.

On more complex parts you may try a method that I learned in a silver-smith class. Use a paper copy of your drawing and a bottle of rubber cement. Simply coat the back of the paper and the part with a thin layer of rubber cement, allow to dry thoroughly. This will bond much like contact cement when you stick the paper and metal together. After the part is cut the paper and rubber are easy to remove.

Introduction to Aircraft Tools

2005-02-12T11:51:00.000-08:00

Building an airplane is a monumental task. You will undoubtedly develop a passion for really nice tools. The right tools will make your Van's RV aircraft or any other homebuilt project go much smoother, faster, and the quality of your project will be GREAT!

In my writings I will attempt to explain the tools needed for specific tasks, compare the quality of different brands, and try to answer any questions you may wish to send to me. I am intimately familiar with Klein Tools, Snap-On Tools, and almost every air tool brand including DOTCO, Chicago Pneumatic, Cooper and others.

I also have a pretty good network of tool users including RV and T-51 aircraft builders, general aviation and commercial large get mechanics. My friends and myself are using tools everyday and I will be happy to pool our collective knowledge to find an answer to any question you may have about aircraft tools, their use, quality, maintenance or repair.

Bookmark the page and come back often to check out the tips I will include as I write. GOOD LUCK on your aircraft project!

Brad