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General| Brand | Sequoia Aircraft Corporation |
|---|---|
| Model | F.8L Falco |
| Category | Aircrafts |
| Language | English |
Introduction to the Falco project and the experience of building the aircraft.
Guidance on initiating the Falco building process, studying plans, and overcoming initial overwhelm.
Advice on discussing the Falco project with family and managing time commitments.
Advice on setting up a suitable workspace for building the Falco, considering location and equipment.
Decision-making advice on whether to build wood parts from scratch or purchase kits, considering time and cost.
Importance of establishing high-quality workmanship standards early in the Falco construction process.
Discussion on the risks and potential pitfalls of making modifications to the Falco design during construction.
Recommendation to visit existing Falco builders for practical insights and photographic documentation.
Emphasizes the importance of planning and ordering tools and materials in advance to maintain project momentum.
Advice on finding help and joining organizations like the EAA for support and resources.
Guidance on how to ask questions and seek assistance from the manufacturer during the build.
Details regarding the agreement and restrictions on the transfer or resale of Falco plans.
Introduction to production drawings and how they define aircraft parts for manufacturing.
Explanation of European projection used in Falco drawings and how to interpret different views of a part.
Understanding sectional views and hatching techniques used in technical drawings to show internal structure.
Explanation of metric and imperial measurements used in Falco plans and conversion methods.
Definition of reference planes (Water Lines, Butt Lines) and Stations used for locating parts in aircraft drawings.
Information on the standard ±0.1mm tolerance for dimensions and when specific tolerances are provided.
Guidance on interpreting dimensions on drawings, emphasizing that dimensions take precedence over scaling.
Explanation of common drafting notations like (ref) and N.B., and abbreviations used in drawings.
Description of different line weights and types (hidden, dimension, centerline) used in technical drawings.
Explanation of symbols used in drawings, such as those indicating grain direction and surface finish.
Importance of posting and incorporating revisions to Falco plans to ensure accuracy and safety.
Advice on seeking assistance from experienced individuals or engineers when encountering difficulties with drawings.
Guidance on locating part drawings and installation details using the plans index and installation drawings.
Clarification that Falco plans take precedence over the construction manual in case of contradictions.
Importance of locating the shop close to home for convenience and family integration.
Considerations for shop size, including vertical clearance, to accommodate the airplane's assembly.
Recommendations for adequate lighting in the workshop, favoring fluorescent lighting and portable lights.
Importance of maintaining appropriate temperature for glue curing and general working conditions.
Awareness of humidity's effect on wood and its potential impact on aircraft construction.
Planning for the removal of the completed airplane from the shop, especially considering size limitations.
Overview of essential tools for building the Falco and the importance of selecting appropriate quality.
Discussion of necessary measuring devices, including rulers, calipers, and drafting tools.
Emphasis on the need for a wide variety of clamps and suggestions for types and potential homemade options.
Essential drilling equipment, including hand drills and drill presses, and recommendations for quality.
Importance of a band saw, especially for metal parts, and options for wood-only cutting.
Consideration of a table saw if all wood parts are made, with a preference for radial arm saws.
Versatility of a radial arm saw, particularly for scarfing plywood, and features to look for.
Recommendation for a specific type of coping saw for detailed work.
Essential tool for final fitting of wood pieces, with emphasis on adjustable tables.
Discussion on creating scarf joints for plywood and spruce, and methods for building jigs.
Essential for painting and pneumatic tools; sizing considerations for spray gun requirements.
Highly recommended tool for skinning the Falco, facilitating quick and secure attachment of parts.
Alternative for builders without an air compressor, using U-shaped staples.
Tool recommended for easily removing small staples.
Useful, though not essential, tool for scooping wood, more powerful than a Dremel.
Handy tool for sanding, with the 'Sand-Cat' model noted for its versatility and ease of use.
Specialized sanding tools coated with carbide grit, effective for spruce and plywood.
Simple tools made from wood and sandpaper for sanding in awkward places.
Option for builders to save money by making their own power tools from kits.
Router bit useful for cutting plywood edges cleanly after gluing.
Tool for accessing screws in tight quarters, particularly useful for electrical kits.
Handy tool for skinning the airplane, essential for ensuring proper wood moisture content.
A necessary tool for engine spark plugs, with recommendations to consult local FBO for type.
Essential items for working with glue, including disposable gloves and mixing containers.
Explanation of the FAA's role in aircraft certification and inspection of experimental, amateur-built aircraft.
Historical context and regulatory requirements for homebuilt aircraft, emphasizing the 'education and enjoyment' justification.
Procedure for notifying the nearest FAA office before starting construction and scheduling inspections.
Overview of the chapter, focusing on parts included in kits and metalworking background.
Details on the primary aluminum alloy (2024) used, its tempers, and acceptable substitutions.
Information on steel alloys used, primarily 4130 steel, and its conditions (annealed, normalized, heat treated).
Discussion of bronze alloys used for bearings and bushings, including SAE 660 and aluminum-bronze.
Importance of cadmium plating for steel and bronze parts and exceptions where plating should not be done.
Conformity requirements for welding, suggesting TIG equipment and specific welding rod recommendations.
Specification of general tolerances for dimensions given in millimeters.
Guidance on using drill sizes versus reamed holes and the use of letter/number drills.
Function of bronze bushings in hinges for clearances, low friction, and adjustability.
Methods for fabricating hinges from extrusions or sheet aluminum, including bend radius considerations.
Specification of bearings used for control systems, recommending Heim LSS-4 over earlier Southwest Product Co. bearings.
Warning about difficulties in making the nose gear fork from annealed material due to cracking.
Instructions for jigging and fitting landing gear mount components.
Advice on making landing gear legs, including welding considerations and turning bearing surfaces.
Overview of corrosion protection for aluminum, bronze, and steel parts, referencing relevant publications.
Detailed steps for applying Alodine conversion coating to aluminum parts for corrosion protection and paint adhesion.
Standard protection for steel and aluminum parts, offering sacrificial pigments but limited adhesion.
Discussion of polyurethane paints for superior metal protection, emphasizing ease of use and durability.
Painting recommendations for steel parts, including options like zinc chromate and polyurethane paints.
Caution against painting parts subject to wear, like bushings and landing gear legs, to avoid friction.
Warning against plating welded parts due to potential acid trapping and weakening of the weld.
Importance of using Sitka spruce for spar caps and general aircraft construction due to its strength and weight.
Mention of other woods used, like Douglas fir for main wing spar fittings and beech for aileron balance weights.
Specifications for birch plywood, including metric sizes, and the importance of sanding its hard surface.
Explanation of how wood moisture content is affected by humidity and temperature, and its impact on dimensions.
Recommendations for adhesives, favoring Aerolite 306 for its gap-filling and ease of use.
Detailed instructions for using Aerolite 306, including mixing, working life, and application methods.
Information on Penacolite G-1131 resorcinol adhesive, noting its durability and use for high-strength joints.
Discussion of plastic resin glues like Weldwood, noting their gap-filling limitations and non-adherence to birch plywood.
Advantages and limitations of epoxy glues, including heat sensitivity and potential health hazards.
Importance of testing glue batches using test blocks to ensure joint strength and reliability.
Objective of covering wood surfaces with a coating to prevent moisture absorption, focusing on interior surfaces.
Primary objectives for interior and exterior finishes: protection against moisture and weathering.
How protective finishes retard moisture passage, maintaining uniform moisture distribution and avoiding internal stresses.
Summary of suggested procedures from ANC-19, including effective coatings like aluminum enamel and varnishes.
Discussion of polyurethane and epoxy paints, their durability, and moisture-excluding characteristics.
Methods for coating interior airplane surfaces, often inaccessible after plywood covering is glued.
Critical areas for moisture collection, emphasizing the need to bed fittings to exclude moisture.
Overview of basic techniques used in building the Falco, including methods found helpful by builders.
Importance of scarf joints for wood structure, emphasizing accurate machining and slope requirements.
Methods for scarfing plywood and spruce, including using a drum sander on a radial arm saw or other equipment.
Importance of allowing wood to dry after gluing to prevent warping and ensure full joint strength.
Technique for beveling plywood edges where they butt against skins to avoid stress and wavy surfaces.
Use of nails or staples for clamping during gluing, with advice on size, penetration, and removal.
Methods for bending wood and plywood, including soaking, heating, and using jigs or steam irons.
Common methods for clamping ribs to spars and other components, including rubber bands and custom clamps.
Guidance on drilling holes in wood and metal, including procedures for pilot holes and combined wood/metal drilling.
Considerations for bolt tightness in wood structures, avoiding crushing the wood while ensuring secure joints.
Importance of drain and vent holes for preventing moisture buildup in closed compartments and ensuring drainage.
Emphasis on making ribs to correct dimensions, accounting for paper expansion and tolerance build-up.
Requirements for jigs to ensure accurate contours and dimensions during rib construction.
Step-by-step process for making ribs, including sanding, trimming, and checking contours.
Specific instructions for building wing ribs, including references to horizontal reference lines and chord lines.
Discussion of male and female molds for fuselage frames and the use of headless nails or blocks for support.
Process for making fuselage frame laminations, including mold preparation and glue application.
Comparison of open and closed laminations and techniques for making them easier.
Advice on longeron cutouts and ensuring consistent alignment of frame components.
Methods for drawing and creating the curved fuselage frames, including graphical and mathematical approaches.
Instructions for building spar jigs and holding parts in position for gluing.
Importance of plywood grain direction in spars for resisting buckling and achieving strength.
Requirements for plywood scarf joints on spars, including slope ratios and placement.
Specifications for spar cap joints, emphasizing 15 to 1 scarf joints for maximum strength.
Methods for shaping the ends of spars to the required curvature.
Technique for making spars from a single assembly and resawing for two spars.
Instructions for making aileron and flap spars as one piece for easier alignment.
Specific guidance on bending the lower spar cap of the forward wing spar.
Detailed instructions for making the main wing spar, emphasizing careful work and jig use.
Installation of the primary VHF communications antenna (ferrite foil) in the vertical fin.
Installation of the secondary VHF communications antenna in the left wing.
Installation of the VHF navigation antenna in the right wing, similar to COM antenna installation.
Installation of the marker beacon antenna in the bottom aft section of the fuselage.
Installation of the transponder antenna in the right wing, including ground plane and radiating rod placement.
Installation of the DME antenna, identical to the transponder antenna, except it is in the left wing.
Information on installing the ADF antenna, typically a combined sense-loop antenna inside the fuselage.
Guidelines for routing antenna coaxial cables and maintaining separation from high-voltage strobe light wires.
Notes on metalized paint, metallic enamels, and their potential effect on internal antenna performance.
Details on internal antennas for Loran navigation systems and considerations for Falco installation.
Explanation of the ground plane's purpose for Loran antennas and methods for its installation.
Importance of grounding all large metal parts to one of the three negative bus bars for noise suppression.
Discussion of potential noise sources affecting Loran reception and strategies for suppression.
Step-by-step guide for assembling BNC connectors onto coaxial cables.
List of components required for installing navigation and strobe lights.
Location of electrical equipment installed in the Falco to understand wire routing.
Detailed routing instructions for electrical wire bundles through the aircraft structure.
List of kits required for assembling the tail group.
Fundamental principles of assembly order and the diversity of correct procedures for builders.
Overview of different assembly methods for the tail group, favoring the vertical assembly approach.
Highlights changes from earlier drawings for tail group assembly, including plywood skinning and hinge locations.
Specific notes on installing hinges, including bolt length, channel-nuts, and screw types.
Checklist of preparatory steps before starting the main assembly of the tail group components.
Instructions for preparing the main fin spar, including reviewing drawings and varnishing interior surfaces.
Steps for preparing the forward fin spar, including modifications to older drawings and installing spruce blocks.
Instructions for preparing the rudder spar, including noting changes to spruce block length.
Steps for preparing the main stabilizer spar, including adding spruce blocks and installing hardware.
Instructions for preparing the forward stabilizer spar, including drawing centerlines and drilling holes.
Steps for preparing the elevator spar, including installing plywood pads and drilling holes for control cable.
General instructions for preparing all tail group ribs, including drawing centerlines and drilling holes.
Instructions for cutting plywood skins for the tail group components.
Detailed steps for installing elevator hinges, including reaming bushings and aligning with the stabilizer spar.
Procedure for installing rudder hinges, including temporary installation of parts for alignment.
Steps for installing the elevator balance weight assembly, including spacer preparation and alignment.
Instructions for assembling the elevator, including fitting leading edge ribs and strips.
Guidance on installing stabilizer ribs and spars, emphasizing alignment and proper spacing.
Notes on installing ribs in the fin and rudder, and considerations for longeron notching.
Steps for assembling the rudder, including installing leading edge ribs and strips.
Process for installing trailing edge ribs, emphasizing alignment and fitting to the trailing edge strip.
Instructions for skinning the rudder, including fitting and gluing leading and trailing edge skins.
Notes related to fin and rudder assembly, including antenna installation and spar preparation.
Methods for assembling the fin, including jig setup and spar alignment.
List of kits required for assembling the ailerons and flaps.
Detailed steps for installing hinges on the aileron and flap spars, including alignment and channel-nut installation.
Instructions for assembling the aileron and flap units, including fitting skins and spars.
List of kits required for the preliminary assembly of the wing.
List of additional materials needed for wing assembly, including spruce pieces and tapered reamers.
Instructions for drilling and installing spar fittings, including those for rudder cables and antenna.
Steps for integrating fuselage frame No. 4 with the main wing spar, including cutouts and alignment.
Procedure for attaching fuselage frame No. 3 to the forward wing spar, including exhaust port framing.
Detailed steps for assembling the landing gear retraction gearbox, emphasizing gear alignment and lubrication.
Instructions for trial fitting and assembling the main landing gear components.
Process for installing and fitting grease fittings into main landing gear bushings.
Steps for preparing wing ribs, including drawing chord lines and installing blocks for wiring and tubes.
Instructions for cutting plywood sheets for various sections of the wing skin.
List of kits required for wing assembly.
Detailed instructions for constructing and setting up the wing assembly jig.
Step-by-step process for assembling the wing structure, including frame and spar integration.
Instructions for applying plywood skins to the wing structure, including fitting, scarfing, and gluing.
List of kits required for preliminary fuselage assembly.
List of additional materials needed for fuselage assembly, including firewall and insulation.
Methods for installing cowling supports, recommending installation before fuselage skinning.
Steps for assembling the nose gear, including checking bushings and drilling for grease fittings.
Procedure for trial fitting and assembling the main landing gear components.
Installation of engine mount lugs and the nose gear assembly onto the engine mount.
Steps for reaming bushings and installing rudder pedals onto torque tubes.
Instructions for priming and installing fuel tank band mounts.
Guidance on cutting the firewall to match fuselage frame No. 1 and installing insulation.
Detailed instructions for preparing and assembling fuselage frame No. 1, including blocking and cutouts.
Steps for preparing fuselage frame No. 2, including cutting inside face and drilling holes.
Instructions for preparing fuselage frame No. 7, including longeron and stringer cutouts.
Steps for preparing fuselage frame No. 8, including drawing centerlines and drilling bolt holes.
Considerations for battery types and installation of the battery box components.
Details on constructing the exhaust port framing using spruce and plywood for noise and heat insulation.
Installation of the nose gear screwjack support, including bearing and retainer assembly.
Overview of the fuselage assembly process, emphasizing the use of a jig and the structure's increasing stiffness.
Detailed steps for assembling the fuselage on a jig, including supporting various components and ensuring alignment.
Instructions for fitting and gluing components of the nose gear bay walls and supports.
List of kits required for the third part of fuselage assembly.
Installation of heavier wires and preliminary work on the bottom forward fuselage skin.
Installation of fuel tank supports and framing for the aft top fuselage section.
Steps for installing wood blocks and hanger straps for the forward fuel tank.
List of suppliers for woodworking tools, including moisture meters, clamps, and power tools.
Suppliers for general tools, metalworking equipment, and measuring instruments.
Sources for specialized aircraft tools, including mail order suppliers.
Suppliers for aircraft hardware, materials like spruce, plywood, and epoxy.
Information on suppliers for aircraft engines and accessories.
Recommended books on aircraft woodwork, including ANC-18, ANC-19, and Tony Bingelis's works.
Books by Tony Bingelis covering homebuilt aircraft construction methods.
Comprehensive guide on glue and clamping techniques with numerous illustrations.
Book covering wood bending techniques applicable to aircraft work.
Excellent reference book on glues for wood, covering resorcinol and other adhesives.
Additional books on aircraft woodwork, including military specifications and builder guides.
A 1930s text on aircraft gluing, providing historical context for adhesive techniques.
A helpful book for Falco builders interested in wood aircraft construction, with photos and details.
EAA collection of articles on wood aircraft construction, some suggesting questionable practices.
Essential FAA handbooks for aircraft construction and maintenance.
Other general books on aircraft systems like hydraulics, instruments, and engines.
Guide to FAA requirements and procedures for custom-built sport aircraft.
Manual on the use of various woodworking tools like band saws, planers, and table saws.
Helpful hints and shortcuts from EAA books, though some shortcuts are not recommended for Falco.
Introductory primers on hand tools for basic woodworking tasks.
A manual covering metalworking techniques, useful for understanding metal component fabrication.
Books on aircraft design principles, safety, and homebuilt aircraft construction.
An extensive college text on aircraft structural design, requiring calculus knowledge.
College-level text on designing fiberglass and composite structures.
Classic work on aerodynamic drag, recommended for those interested in the subject.
The definitive book on airfoils, providing essential information for understanding wing design.
Paint color codes and names for the Venezia and Palermo paint schemes.
Paint color codes and names for the Modena, Torino, and Maranello paint schemes.
Paint color codes and names for the San Marino and Monza paint schemes.
Reprint of Ciba-Geigy instruction sheet for Aerolite 306 adhesive and GB Hardeners.
Information on Penacolite G-1131, a two-component resorcinol-formaldehyde resin adhesive.
Notes on cleaning equipment, contact between hardener and resin, and wood moisture content for Aerolite 306.
Description, government specifications, and industry standards met by Penacolite Adhesive G-1131.
List of specifications and standards that Penacolite Adhesive G-1131 meets.
Information on Aerodux 500 adhesives, including properties, instructions for use, and mixing proportions.
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