Metal Magic Video Series

Whether you're a novice or an experienced builder, our host Paul Dye, a multi-time builder and former NASA Flight Director shows you how to perform essential metal-working tasks and the tools to use for any airplane with metal components.

This series is sponsored by Aircraft Spruce.

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Metal Magic: Making Square Instrument Holes In Aluminum

You've built most of your airplane, now it's time for cutting the instrument panel blank. KITPLANES editor at large Paul Dye shows you how...
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Metal Magic: Learning To Love the Step Drill

KITPLANES editor at large Paul Dye explains the best times to use the so-called step drill (also called a UniBit) for drilling larger holes...
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Metal Magic: Laying Out Lines of Rivets

In this episode Paul Dye explains how to lay out lines of rivets on a workpiece—a simple task you'll be doing many times throughout...
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Metal Magic: Cutting and Shaping Angle Aluminum

In another segment of KITPLANES' Metal Magic series, editor at large Paul Dye shows you how to accurately cut and artfully shape even large...
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Metal Magic: How To Back Rivet

Master aircraft builder Paul Dye demonstrates how to "back rivet" metal for a clean, consistent look, and offers suggestions to avoid common mistakes. This series...
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Metal Magic: Installing Nutplates

Every screw needs a place to go, and for many metal airplanes, that's into a nutplate. KITPLANES editor at large Paul Dye shows you...
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Metal Magic: Blind Rivet Techniques

Paul Dye discusses blind or pull rivets—and why they're not just like hardware-store "pop" rivets.
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Metal Magic: Removing Bad Rivets

How to properly remove bad or damaged rivets. You'll probably do this a lot over the course of an airplane project!
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Metal Magic: Driving and Squeezing Countersunk Rivets

Paul Dye explains how to both drive and squeeze flush rivets and offers handy tips to getting good, repeatable results.
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Metal Magic: Dimpling and Countersinking

Before you can start driving countersunk rivets, you need to know how to dimple or countersink aluminum.