Best Tips for a New Builder

NDflyer

NDflyer

Companion QB #19
As I get close to picking up my Companion kit and bringing it home, I am reading through and looking for best ways to get started and advice for avoiding the big mistakes. I thought it would be nice to have a thread compiled of the best advice from the people who have been there before. The ones who made some mistakes when they were inexperienced and can help us learn.

So what are your best tips you learned while building? Things like "I would never do ___ without doing ___ first," or "I should have bought this tool right from the start." Could be anything, all advice appreciated!
 
I felt overwhelmed when I got my kit. Start by organizing the kit stuff. For me, everything fit into one of three types of containers....A fishing luer size orgainzer box, a shoe box, or a tub. That worked well. Also, as you sort out all the parts, understand what each part is. Your putting away the Elevator Trim Tab Pushrod, not "some bent rod". Part identification might require a set of Plans, I hope each kit comes with a set of plans...if not I get a set. I used the plans for way more than just part ID.
 
Same deal with parts as tools- cry once. Get a variety of an-3 & -4 bolts and a sheet of each common aluminum thickness (025”, 030”, 050”) and some steel (tank straps, extra tabs). It’s frustrating waiting on an order to arrive to finish some step. And it’ll keep temptation to use hardware store hardware to a minimum.

There’s a lot of gray area in airplane building - that caught me very much off guard. I expected a clear “right way” and set myself into a spin a few times so far when it’s not.

Good organization is worth some investment. I started in a 1-1/2 bay garage on one wing, it worked but was tight and I had to have things put away but also accessible. Inventoried all the hardware into harbor freight parts trays and it’s saved so much time along the way. I didn’t inventory all the other parts until last month when I finally had a hangar to myself, that omission caused me some headaches over the last year. Still trying to improve my system for organizing references, but it’s starting to come together. Jared’s flow chart was a great place to start for me. There are so many different sources and innovative things different builders come up with that I want to use as my best practice, it can get overwhelming fast.

It’s a really good kit and I’m sure getting better, but definitely not an RV kind of deal with idiot proof instructions. There’s plenty left for you to make, buy, and figure out. It won’t get you to a complete and fit out airplane, understand that up front and it’ll save you frustration.

I started a look ahead list of tasks and parts on a big whiteboard. Helps me have more productive time when I’m in the shop.
 
Great information everyone.

Buy quality tools, especially an angle drill. I am looking at the Nova from Pan American as well as the Sioux.

Inventory and organize with intention. This one is going to be a challenge. I will be in a non heated T hangar until December. But I will be organizing and planning more than building during this time period I suppose.

Have plenty of hardware on hand. I have a lot to learn about sourcing hardware. Just understanding what an- bolts I need for example.
 
I second the organized labeled hardware containers . Disorganization is the enemy of progress. Also try to have multiple efforts going at once so if you run into a bottleneck (have to order parts etc) in one area, you can shift over to the other and keep moving, If you get sick of doing nutplates (I counted 1022) work on a flap or tubing routing….Try to accomplish something every time you walk into your hangar or shop. You will invariably run into questions in one area…. make progress in another while contemplating solutions.
 
Talking about buying once and crying once, I have never found a better right angle drill than the current snap-on. We probably have 5-6 in the shop now and they are used every_single_day. With the high rpm I dare say they can drill a nicer hole than my standard dewalt drills.

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500AGL said:
Talking about buying once and crying once, I have never found a better right angle drill than the current snap-on. We probably have 5-6 in the shop now and they are used every_single_day. With the high rpm I dare say they can drill a nicer hole than my standard dewalt drills.
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Dang, crying for sure. Looks like about an $800 investment with 1 batter and charger. I can guess your answer, but do you think it is that much better the the Nova series from Pan American? https://www.panamericantool.com/novar-standard-motors.html
Not having to drag around the air hose would be nice though.
 
NDflyer said:
Dang, crying for sure. Looks like about an $800 investment with 1 batter and charger. I can guess your answer, but do you think it is that much better the the Nova series from Pan American? https://www.panamericantool.com/novar-standard-motors.html
Not having to drag around the air hose would be nice though.
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Looking at the snap on store I think they are $389/121/78 - so maybe 588 total off the truck?

Snap-on Store

shop.snapon.com shop.snapon.com

Snap-on Store

shop.snapon.com shop.snapon.com

Snap-on Store

shop.snapon.com shop.snapon.com
 
Drill bit tip.

You need every size drill bit. But you need 5-10 VASTLY more than the rest. You need #30 and #41 vastly more than the rest.
I have drill bit templates to size every drill bit next to the bits. Go ahead and buy one big, high quality drill bit set with a case. Transition it to mini drawer storage at you discretion.

I have a cheap homemade vertical "mini-rack" of 1/4, 3/16, 10, 12, .......up to 30 and 41. It sits right under the drill bit template. Most of the rest are in a "drawer" storage. You can put multiple sizes in each drawer, just label them. You can put a 35, 19, 5/16, 1/2 in one drawer. Spruce and McMaster sell quality individual bits, including specialty bits.

I do the same with bolts. I put #3 bolts with #5. and #4 with number 6. Same length in each drawer. It WAY cuts down on the number of drawers you need.

I put washers and nuts simllar. And I put the correct size cotter pin in the same drawer as the castellated nut.

When I say "drawer" storage, I mean mini storage drawers. Maybe 12 X 18" with 25-30 drawers.

I am the most unorganized person I know. I think I balanced my check book once, maybe in the 80's.

But building an airplane, I got a bit better. Not the checkbook, of course.
 
You will not avoid a big mistake because the first mistake you make, no matter how small, will seem like the end of the world.

When you do make a mistake, don't rush to try and fix it. You will not be in the right state of mind. Give yourself some time to calm down. Do some research, check the forums, make a phone call, etc.

There is almost nothing you can screw up that can't be fixed.
 
Attached is a spreadsheet I made that has a tab for interactive inventory. It's not perfect as there are a couple double entries but it will get you 98% there. Thanks @jaredyates for updating the excel upload.

All the build information is so disjointned. I spend way more time thinking and figuring than building. I uploaded all the reference build manuals and links to a project in an LLM so they can help me find the right source page for the thing I’m working on and point out disagreements.

I’ve probably spend $2-3k on tools and parts so far and I thought I had a decently equipped shop to start but this is my first plane build.
 

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The excel file attachment problem is not an intentional policy. I think I have adjusted it just now, please try again. If it doesn't work, please let me know.
 
Updated this spreadsheet to include the main kit inventory and not just the spruce drop ship. There are still errors direct from Bearhawk where they are shipping the wrong items or missing items per their hardware callout. Quite a few typos in the new wing build manual as well.
 

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