Table of Contents
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Chapter 1 Introduction to the Lancair ES FastBuild Kit
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.2 Recommended Reading and Background Information . . . . . . 1.2
1.3 The Manuals, Blueprints and the ES CD. . . . . . . . . . . . . . . . . 1.3
1.3.A Manual Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.3.B Blueprints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.3.C The ES CD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.4 Setting up your Shop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.4.A Shop Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.4.B Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.4.C Cutting and Layup Tables . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1.4.D Making a Useful Jack Stand . . . . . . . . . . . . . . . . . . . . . . 1.7
1.5 Shop Tools and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
1.5.A Basic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
1.5.B Specialized Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
1.5.C Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
1.1
Introduction
The purpose of this chapter is to familiarize you with the use of this manual, the general
philosophy behind its layout, how to set up your shop and what supplies you will need. You
should also read the recommended books to familiarize yourself with glassworking if you are a
newcomer to fiberglass construction techniques.
Always refer to the Glossary on page G.1 for definitions of unfamiliar terms.
Chapter 1
ES
Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756
Page 1.1
REV. 2nd Ed./08-15-06
Introduction to the Lancair ES FastBuild Kit
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Summary of Contents for Lancair ES
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Page 1: Table Of Contents
1.3.C The ES CD ........1.4... -
Page 2: Recommended Reading And Background Information
Moldless Composite Sandwich Homebuilt Aircraft Construction by Burt Rutan EAA Aviation Foundation Though the hot-wire shaping technique covered by this book is not used on the Lancair, this book has a great deal of other excellent, basic fiberglass construction information. Highly... -
Page 3: The Manuals, Blueprints And The Es Cd
Revisions Chapter Organization Occasionally revisions to the manuals may be necessary. Updates are posted on the Lancair web page. When updates are available, you need to immediately replace all outdated pages with the Each assembly chapter is organized in the same sequence. -
Page 4: B Blueprints
A list of blueprints for the ES Super Fastbuild Kit are included at the beginning of the Parts List section of each chapter. The lists contain only the blueprints that are provided after the completion of the two week builder assist program. -
Page 5: Setting Up Your Shop
The ideal shop temperature is between 68° and 78°F. Chapter 1 Page 1.5 REV. 2nd Ed./08-15-06 Introduction to the Lancair ES FastBuild Kit Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756... -
Page 6: C Cutting And Layup Tables
Simply flip the plastic sheet over and use the other side. Chapter 1 Page 1.6 REV. 2nd Ed./08-15-06 Introduction to the Lancair ES FastBuild Kit Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756... -
Page 7: D Making A Useful Jack Stand
5. Glue soft padding on the top of the 8” x 8” piece of plywood. 6. Insert the Jack port on the jack stand. Chapter 1 Page 1.7 REV. 2nd Ed./08-15-06 Introduction to the Lancair ES FastBuild Kit Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756... -
Page 8: Shop Tools And Supplies
Dull blades create rough edges and create more sanding/smoothing work later in the building process. We use carbide-tipped blades exclusively for the composite cutting. Chapter 1 Page 1.8 REV. 2nd Ed./08-15-06 Introduction to the Lancair ES FastBuild Kit Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756... - Page 9 Buy several of these. Chapter 1 Page 1.9 REV. 2nd Ed./08-15-06 Introduction to the Lancair ES FastBuild Kit Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756...
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Page 10: B Specialized Tools
They should only be used to remove small amounts of material. This ensures a long life for the reamer and a superior finish to the hole. Chapter 1 Page 1.10 REV. 2nd Ed./08-15-06 Introduction to the Lancair ES FastBuild Kit Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756... - Page 11 Otherwise the volatiles in the epoxy can evaporate out and cause faulty curing or no curing at all. Chapter 1 Page 1.11 REV. 2nd Ed./08-15-06 Introduction to the Lancair ES FastBuild Kit Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756...
- Page 12 Clecos are a sheet metal Chapter 1 Page 1.12 REV. 2nd Ed./08-15-06 Introduction to the Lancair ES FastBuild Kit Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756...
- Page 13 We also recommend dying the water with food coloring to make the water level in the tube easier to read. Chapter 1 Page 1.13 REV. 2nd Ed./08-15-06 Introduction to the Lancair ES FastBuild Kit Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756...
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Page 14: C Supplies
Try sliding a length of PVC tubing onto the paint roller to get a smooth, hard- Chapter 1 Page 1.14 REV. 2nd Ed./08-15-06 Introduction to the Lancair ES FastBuild Kit Lancair International Inc., Represented by Neico Aviation Inc., Copyright 2008 Redmond, OR 97756... - Page 15 These epoxies are not interchangeable. The instructions in this manual will specify which epoxy to use. Always follow the instructions. Make sure you use Lancair approved products. Most epoxies have a manufacturer's recommended shelf life of typically one year. In some cases this is quite conservative.
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