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Workshop

My workshop and some of the 'tools of the trade'

Unlike the kit builders, plans builder need to invest in various tools to make their lives easier (and in some cases the tools are essential for making certain parts). Rather than regarding this extra cost as a burden, I regard these tools as an investment which I can use for many of my other 'construction' activities.Some of the tools such as the bending brake and the press have been constructed using fairly easily obtainable materials, and the plans for both are available from Zenair or through Zenair News.

Bench Drill

Left - My bench mounted drill - essential for using the fly cutter for cutting the lightening holes. This drill goes down to 190 rpm which is just about right for using the fly cutter.

Press

Right - My first attempt at a press (made according to the plans in Zenair News) used with a bottle jack to form the flanges of the lightening holes amongst other things.

Bending brake

Right - A bandsaw has been essential for cutting the thicker sections of aluminium. Here I am using it to cut the leg off some extrusion so that I can use it for the wing spar doubler.

Flanging dies

Left - A picture of the bending brake that I made using the Zenair plans. It took me a weekend to build and has been well worth the time spent constructing it.

Band saw

Left - I was fortunate to get these dies machined for me for the cost of a crate of beer!