Building Metal Airplanes Index

Introduction

1. Materials

1.1 Aluminum

1.1.1 Non-Heat Treatable Alloys

1.1.2 Heat Treatable Alloys

1.2 Steel

1.2.1 Heat Treatments

1.2.2 Strength

1.3 Effect of Temperature

2. Measuring and Marking

3. Fasteners

3.1 Rivets

3.2 Bolts

3.3 Threads

3.4 Pipe Threads

4. Drilling

4.1 Edge Distance

4.2 Bearing Strength

5. Cutting Metal

6. Corrosion Protection

7. Fatigue

8. Welding

8.1 Definition of Soldering and Brazing

8.2 Preparation

8.3 TIG Welding

8.4 Torch Welding

8.5 Welding Practice

8.6 Testing the Welds

8.7 Filler Materials

8.8 Welding Aluminum

8.9 Welding Steel

8.10 Welding Engine Mounts

8.11 Other Tube Structures

8.12 Slip Joints

8.13 T-Joints

8.14 Cluster Joints

9. Welded Aluminum Fuel Tanks

10. Bonding Metal

11. Bending

12. Forming Metal

12.1 Basic Forming Operations

12.2 Tools

12.3 Forms

12.4 Annealing

13. Using a Lathe

13.1 Turning

13.2 Facing

14. Machining

15. Riveting

15.1 Drilling out Rivets

15.2 Example of Skinning a Fuselage

15.3 Blind Rivets

15.4 Assembly

16. Repairs

16.1 Assessing Damage

16.2 Scratches, Dents and small Cracks

16.3 Corroded Sheet Metal

16.4 Damaged Holes

16.5 Repair of Tube Structures

17. Systems Integration

17.1 Fluid Carrying Lines and Tubes

17.2 Wires and Clamps

17.3 Ventilation

17.4 Access Panels

17.5 Sealing Integral Fuel Tanks

References

Appendix A:

List of Useful Tools for Building a Sheet Metal Airplane

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