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.
Denso alternator pulley on a Lycoming engine

Denso Alternator Homemade Adaptation

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Swapping a Denso alternator into a Lycoming engine? Here’s how one builder tackled pulley design for optimal reliability.

In Case You Missed It

Seeing the Dream Through

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Having earned a number of homebuilding trophies for his work constructing airplanes, Paul Muhle decides to share his experience with those who aim to win awards-or just look like they could.

Wind Tunnel

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Design process: balance, part 3.

RANS S-19

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When new aircraft from two very different designers, in this case Randy Schlitter and Richard VanGrunsven, surface with considerable similarities, consensus about basic design tenets must be blowing in the wind. Certainly Light Sport regs do constrain performance considerations, but human factors are more up for grabs, and that’s where one or another design can truly shine; by Marc Cook.

Ask the DAR

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Repairman certificate, test-flight areas.