When possible I pre-polish skins, like this Onex vertical tail skin, through Nuvite grade C prior to assembly. Polishing tools

Taking a Shine To 6061-T6 – Part 2

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Cutting the initial shine with NuShine II F9 is key to a polished finish. Here's how to master the pad, pressure, speed, and polish for gleaming results.
oil cooler shutter

Oil Cooler Shutter

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Ditch the duct tape— an adjustable fix for oil coolers.
cad for the home shop

CAD for the Home Shop

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Explore how EAA members use Solid Edge and 3D printing to design, model, and build aircraft parts—affordably and efficiently with modern CAD tools.
custom engine mount

Building a Custom Engine Mount

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How a custom engine mount for the SR-1 was CNC’d, stress-tested, and welded for strength, weight savings, and tight packaging.
Polishing leads to a shiny airplane. Sonex in flight

Taking a Shine To 6061-T6 – Part 1

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Polishing aluminum transforms gray metal into a mirror finish—cheap, timeless, and endlessly messy but deeply rewarding.
ballast

Cable Ties For Ballast

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Cable ties will become brittle over time and can break. Having weights come loose during flight, especially near the control system, could really ruin your day. 

Starkey’s Custom Spark Plug Adapter Lock Wrench

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Make spark plug changes easier with a custom spark plug wrench for auto plug adapters on aircraft engines.
wire insulation - crimp terminals

A History of Aircraft Wiring Insulation

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Discover the evolution of aircraft wiring insulation—from rubber and cotton to nylon, PVC, and Tefzel—and learn practical tricks for wiring your homebuilt.
custom heat exchanger

Custom Heat Exchanger Fabrication

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Designing and fabricating custom radiator and intercooler systems with packaging challenges.
oil filter testing

Oil Filter Testing

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Some aviation oil filters fall short of efficiency standards, but still protect engines—barely. Understand what yours really does.

In Case You Missed It

Ask the DAR

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Electric motors, major repairs, combining parts from several kits, using completed wings.

MGL Infinity Singles

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MGL Avionics/Stratomaster has cut a nice swath through the EFIS and discrete-electronic-instrument world. The company’s ALT-1, from its Infinity Singles line, makes a good, low-cost backup altimeter with a surprising list of features. By Marc Cook.

Ask the DAR

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What's the difference between the FAAs SLSA (Special Light Sport Aircraft) and ELSA (Experimental Light Sport Aircraft) designation? DAR Mel Asberry clears it up.

Where Do Airplane Parts Come From?

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Building your own replacement kit parts, which is no different than scratch-building from plans, may save you money and time.