Countersink Bits - Watch out for this

Deburr Tool Extension
If your project includes aluminum ribs like the RV series, you will want an extension for your deburring tool. It definitely improves the hole (pun intended) deburring experience.
Click this link for more details:
http://websites.expercraft.com/rzbill/index.php?q=log_entry&log_id=6651

Deburr Bits
I improved my deburring by using a threaded drill bit in the deburr handle.
More details are here: Click on the link.
http://websites.expercraft.com/rzbill/index.php?q=log_entry&log_id=6652

Wing Cradle vs the wallet
If you save the crates your wing kit comes in, you can build most (if not all) of the wing cradle described in Van's plans. I used the crate lumber plus a couple of partial sheets of plywood and particle board I had laying around. Given a little more industrious use of the crate lumber, I could have gotten by without the spare plywood/particle board.
Click on the link below to see pictures of my cradle:
http://websites.expercraft.com/rzbill/index.php?q=log_entry&log_id=6642

Leading Edge to Tank Splice Plate fixture (W-423)
On the second wing I drilled, I figured out a nice way to hold all the W-423 splice plate parts in alignment prior to drilling. It is a tricky operation because there are three parts that have to be held in alignment without cleco's prior to drilling. No special stuff to make, just an application of tools and scrap you probably have already.
See the method here:
http://websites.expercraft.com/rzbill/index.php?q=log_entry&log_id=6648

Proseal Balance
Here is how I built my balance. I think it works well enough to share my idea.
http://websites.expercraft.com/rzbill/index.php?q=log_entry&log_id=7706

Windowed inspection panels
I made some inspection covers with clear windows that can be used during preflight. See them here:
http://websites.expercraft.com/rzbill/index.php?q=log_entry&log_id=8233

 
 

Drill and Set storage plus a roll around tool table
I took a scrap of hardwood and drilled "one size over" (meaning #30 hole for a #40 bit) for all the commonly used drills and rivet sets. Very handy. You can see I have multiple #30's for instance. A bare one, a drill stopped one, and a threaded one.

Another handy thing is an item I stole from my wife. Its an ancient metal roll around table she had in her college apartment. Well, it serves to hold my clecos, rivet squeezer, bucking bars and rivet trays.

ExperCraft is supported by these quality vendors: