Glasair kits Are Builder Friendly

It has been said that building your own airplane is not a big job, just a bunch of little ones. Glasair kits are not only complete, but they give you a head start on many of those little jobs... where time savings count. Many small parts and subsystems are already pre-fabricated. They're ready for installation.

Lots of thought and time spent listening to our builders has resulted in a customized builder-friendly kit that expedites your journey to the flightline. Oh, there's work to do, but it's the kind of effort that leads to progress, not frustration. So much has been done for you by Glasair Aviation to take all the frustration out of the building process and make it go by fast.

A Pleasure To Assemble

Redefining high caliber and completeness in an aircraft kit...

The Glasair III Aircraft kit is one of the most complete and comprehensive in the industry. The Glasair III includes virtually everything you need to complete the airframe, including cowling and engine mount. You supply the powerplant, propeller, upholstery, paint, instruments, avionics and electrical system. You don't have to spend your time sourcing hardware, resin, cables, or other materials that are standard in our kits. It's all there. And comprehensive assembly manuals will lead you step by step through the building process, quickly and easily.

Much has been written in the homebuilt aircraft industry about "fast build" kits. Glasair kits go together fast. Just travel to any airshow throughout the world and count the number of Glasairs on the flightline. People who have shopped around and compared the Glasair with other kits have discovered that the precision fit of Glasair parts, the degree of completion of small parts or subsystems and the attention to details in the assembly process make the Glasair kits truly fast to build. Go ahead, compare the fittings for the landing gear with those in other kits, take a look at any of the parts made from steel or aluminum, examine the welded assemblies, look at what has to be done to the control system... Glasair kits, like the finished products, are designed for speed.

Your aircraft is assembled from preformed composite shells. This process assures accuracy and virtually eliminates the need for any complex jigging fixtures. Fabrication is very much like putting together a big model airplane kit.

The resin used on the Glasair is a special type of vinylester resin that has a maximum heat distortion temperature of 300 degrees F that significantly exceeds that of commonly used oven-cured 250 degree pre-pregs. Vinylester resins offer a number of advantages and benefits over epoxy-based systems. Some of these benefits include: superior secondary bonding characteristics, avoidance of skin sensitivity problems, longevity and reliability. With care, the Glasair will last as long as, or longer, than an aliminum airframe. Composites do not corrode like metals.

All welding is factory finsihed and protective coated. All Glasair fabricated metal components are already machined or formed and are coated per military or aerospace specifications for maximum corrosion resistance.

The Fuselage

The fuselage comes in two large half-shells and three belly sections. Recessed flanges at the fuselage/cowl split line are designed to be stronger and make installation easier, creating a perfectly flush cowling. Piano hinges and Camloc fasteners are used to allow easy cowling removal for engine inspection. There are molded scribe lines for the wing and horizontal stabilizer cutouts, eliminating the guesswork and time involved in layout and measuring.

Low drag NACA-style cabin air vents are included, which are easily installed by the builder. Fuselage shells feature factory molded longerons sandwiched between the skins that substantially increases the strength and bending stiffness of the fuselage. Precision recesses accommodate windshield, canopies, and rear window installations.

Jump Start Fuselage Option

With the Jump-Start fuselage, you can be sitting in your Glasair making airplane noises the day you uncrate the kit! The fuselage halves and the forward and aft belly panels are all precisely jugged, fitted and seamed together. In addition, reinforcement laminates at the wing root and stabilizer areas are completed; wing and stabilizer cutouts are made; canopy bow and rollover structure laminates are in place; the fuselage reinforcement rib is fabricated and installed; the firewall is fabricated and installed (complete with reinforcement rib, engine mount recesses and corner gussets); and a high-performance, zero-drag COM antenna is bonded into the vertical fin. The Jump-Start fuselage kit also includes enough vacuum-bagged precure laminate for most of the major remaining builder-installed airframe structures, such as the seat back, baggage compartment closeout, aft fuselage bulkhead, control tunnel etc. In the Glasair III kit, the nose gear box is fabricated and installed, and the nose gear cutout is made. In addition, the III kit includes the horizontal stabilizer with the shearweb and six of eight ribs factory installed, making it nearly ready to close. In all, the Jump-Start fuselage saves the average builder between 350-450 hours.

Click here for more detailed jumpstart pictures. >>

The Wing

Wing configuration is designed for the widest possible range of high and low speed operations. Dimensionally, the Super II and III wings are identical. Structurally, they vary to accommodate different weight and speed envelopes. Glasairs are not subject to the high speed stalls, hot approaches and long rollouts that characterize most high performance aircraft. Short, grass or gravel field capability were a must in designing the Glasair. Our wings were designed to achieve slow speed performance and maintain good penetration in turbulence over 200 mph. They also achieve a good degree of laminar flow, yet have no undesirable characteristics when flying through rain.

The one-piece wing incorporates solid fare and aft I-beam spars spanning wingtip to wingtip, eliminating failure modes associated with three piece wing designs. Both spars have sturdy, machined attach fittings that fasten the wing to the fuselage, enabling removal of the wing to facilitate repair, inspection, or when transporting the aircraft to the airport for the initial flight.

Both Glasair models have time-saving premolded recessed attach flanges for the inspection covers and wing tips. The fuel sump is premolded into the lower wing skin and the seat pan cut-out area is scribed for easy removal. The Glasair III comes with molded gear door flanges to insure an accurate flush door fit.

Wing tips for the Super II and III have an upswept Hoerner-type trialing edge to provide improved lateral stability and to reduce induced drag. The tips feature premolded, recessed flanges for the red and green navigation light lenses which easily bond to the flange and fit flush with the external surface.

Wing tip extensions add approximately 24 inches to each side, increasing the wing aspect ratio. In 20 minutes you can change from extended wing tips to standard tips. Economy cruise performance at 17,500 feet increases by 7 mph and stall speed drops by about 6 mph. Climb performance increases by 150 fpm and roll stability is improved.

Jump Start Wing Option

With the Jump Start Wing Option, the major structural assembly has been completed for you! All the ribs are fabricated and installed; all landing gear support rib reinforcement is done; virtually all control system hardpoints and reinforcement laminates are installed; all fuel transfer cutouts in the nose ribs are made; the aft shearweb is fabricated and installed and the ribs are trimmed for the upper wing skins and the fuselage attach fittings are installed in the main spar. In the Glasair III, the landing gear boxes are also positioned and bonded to the lower wing skin and the landing gear cutouts in the lower skin are made. And in the Glasair III wing, the aft fuel bays are completed, including the aileron control and fuel transfer tunnels. All ribs and the shearweb are vacuum-bagged, resulting in greater strength, lightness and consistency than could be achieved in builder-fabricated parts. All work on the Jump-Start wings is done by experienced laminators to high factory standards. This option reduces overall assembly time for the average builder by 300-400 hours, depending on model.

Click here for more detailed jumpstart pictures. >>

The Tail

New time-saving features have been implemented into the Glasair Super II and III empennage sections. The horizontal stabilizer and elevator are formed in separate molds with matching elevator counterweight cutouts molded into the horizontal parts. Horizontals for the Glasair III are a carbon graphite fiber/E glass hybrid for appropriate stiffness.

The elevators are manufactured with factory reinforced molded counterweight arms for necessary strength requirements. They are installed using centerline hinging which provides a symmetrical airfoil when the elevator is deflected either upwards or downwards. An independent manual trim system provides elevator back-up control and works on a simple worm gear mechanism. An optional electric trim is also available for all models.

Rudders for the Super II and III have premolded counterweight arms which match perfectly to the vertical fin for a close, low-drag fit. Tail light assemblies are also premolded into the rudder parts. If you want to sample composite construction and learn how easy it is to work with composites, you can order a Glasair Super II or III rudder kit, build it, and then order the rest of the airframe.

The Controls

Glasairs use a conventional, three-axis, dual stick control system for pitch and roll, and dual rudder pedals for yaw. Mechanical or optional electric slotted flaps are employed for slow flight and can be set from 0 to 34 degrees. Solid push-pull tube linkages are used between the cockpit controls and the control surfaces themselves. Aircraft grade self-aligning rod and bearings used with the solid linkages give the Glasair smooth, positive control response. Stainless steel cables link the foot pedals to the rudder.

The slotted flap installation is undoubtedly one of the best improvements that has been added to the Glasair line in recent history. The benefits of the slotted flaps are significant:

• Reduces stall speed by 6 mph
• Reduces landing and takeoff roll
• Significantly improves landing visibility during approach
• Reduces approach speeds (an invaluable safety feature for a forced landing)
• Increases maximum flap speed from 120 to 140 mph

Both the ailerons and flaps are designed to allow tight surface gaps thus reducing drag even further. These controls are hinged on the lower surface with extruded aircraft piano type hinge.

The Fuel System

There are two fuel tanks in your Glasair: one main tank in the front D-section of the wing and a header tank aft of the firewall. An engine driven mechanical fuel pump and an electric auxiliary pump supply fuel to the carburetor or fuel injector. The Glasair III has additional fuel bays in the wing, allowing greater fuel capacity. Tank baffles and one-way valves are installed to prevent fuel sloshing. Fuel sumps with drains are located at the bottom of each tank. The fuel vent system includes fuel vent float valves that help prevent fuel spills while parked on uneven ground or while flying inverted during aerobatics. Unlike many other homebuilt kits, Glasairs include the complete fuel system from fuel tanks to the carburetor or fuel injector because Glasair Aviation believes the correct type of fuel system hardware is critical to the safe operation of any aircraft.

The Firewall

All Glasair Super II and III kits include a thoroughly tested firewall system for composite aircraft. Nontoxic Rohacell foam is used as the core material in the composite firewall bulkhead. A one-half inch thick sheet of ceramic fiber insulation, which is protected from engine oils by a lightweight alumimum sheet, provides fireproofing and noise insulation on the forward side of the firewall. This firewall withstood the FAR Part 23 2000 degrees F 15-minute burn test.

The Cockpit

The cockpit dimensions have been generously increased on both the Glasair Super II and III over previous Glasair models without sacrificing performance. Roomy side-by-side seating and a large baggage compartment make long cross country flights enjoyable. There is plenty of room on the instrument panel for full IFR equipment.

Canopies and Windshield

Nearly two decades of design refinements and flight test in the 250 - 350 mph range - including high "G" airshow performances - have led to definitive canopy and latch design. Glasair Aviation's systems are so highly regarded that many builders and manufacturers of other popular aircraft kits purchase them direct from us for their own aircraft.

Both models feature a dual gullwing canopy system. This is a trademark of the Glasair line. Intensive research showed that this form of entry provides the best combination of access and safety. The canopies can be easily removed in the air or on the ground in case of emergency. Coupled with the sturdy frame that houses them, the canopies provide maximum protection in the event of a rollover. The canopy frames are supplied premolded and factory assembled to form lightweight, rigid frames. This is a huge time-saving feature. Finished frames come with precision recessed moldings required for easy installation of the latch and hinge mechanism.

The Glasair latch design features an emergency access exterior handle that operates independently of the interior mechanism - a safety feature required on certificated aircraft. You will enjoy excellent visibility through optically clear Plexiglas that is thick enough to provide a quiet, safe environment at top speeds.

Experience

No experience working with composites? No problem! Several of our builders have never tackled so much as a birdhouse and certainly most have never done anything with composites. However, these same builders report that, after a careful reading of the instructions provided, they quickly learned that there was nothing beyond their abilities and tackled the project with confidence. Glasair Aviation assembly manuals are thorough, easy to follow and have been field tested by hundreds of builders. Illustrations are clear, simple and professional. As a result, you can truly learn as you go without creating mistakes that require you to buy expensive replacement skins like you would on an aluminum aircraft.

Let’s be honest here. Few people ever tackle a project as sophisticated and dynamic as building their own aircraft. It used to be that completions were rare.. Not so with the modern Glasair kit. The completion rate is very high and the sense of accomplishment expressed by our builders takes on a magnitude few projects in life can ever come close to equaling. What's important is that so many people have finished and flown their Glasairs. And what is perhaps most remarkable is that our builders are invariably surprised at how much enjoyment they derive from the building process. Some are genuinely disappointed to see it end, and indeed, a number of them have turned around and started another Glasair or GlaStar project.

Also, there is LOTS of help waiting for you. Ask anyone who's built a Glasair: Once you start construction, you become part of a fraternity. It's a global network of experts who can tell you what it takes, how to do it, and when. They have been there, done that. There are probably a lot of helpful resources quite close to you, but there is also tremendous, friendly factory support. Glasair Aviation has become famous for the thoroughness of technical support we provide our builders. It has constantly been referred to as the best in the industry. We have helped hundreds of builders, like you, get to the flightline.

In addition, detailed assembly videos are available to assure that you get your Glasair airborne as quickly as possible. Also, don’t forget to travel to the many airshows across the country to meet with the hundreds of Glasair builder and owners. It’s no secret that Glasair builders have won more awards at airshows around the world than builders of any other composite kit aircraft. This includes numerous Grand Champions at Oshkosh and Sun 'n Fun. (See the “Trophy Room” on our website for just a few examples.)

In summary, You Can Do It! Hundreds already have. They're ready to cheer you on and offer advice, and some will be happy to pitch in.

Tools Required

You will need a hand drill, saber saw, sander, hole cutters, chalk line, level, tape measure, files, C-clamps, vise, putty knife, plumb bob, sandpaper, paintbrushes, squeegees and about a dozen more assorted hand tools. You will be joining fiberglass parts, bolting things on, stringing wire, swaging a few cables, filling and sanding the seams. What you will find amazing is how fast the fuselage, tail, and wings piece together.

Work Space

For work space, a one car garage will suffice until final assembly. A two car garage would be preferable. Some of our builders have used the living rooms of their apartments and others have done most of the work in their basements.

Glasair Aviation, LLC's Commitment To You

Our philosophy can be stated in one sentence. We want to give you the most value for your investment.

We want to see you on the flightline, enjoying your completed Glasair. To that end, we have dedicated our talents to developing and refining kits and aircraft that meet the needs of builders and pilots like you. We design and engineer high performance aircraft for homebuilders. We select the materials and construction methods that are most appropriate for your mission, that provide the greatest strength and endurance, and that are easiest to work with and to maintain.

Our builders consistently affirm the correctness of our decisions. That's why we enjoy the highest level of credibility in the business. Glasair Aviation is constantly evolving with new technology, new ideas, new ways of improving what already exists. The standards are always rising here.

Communicating With Our Customers

Communications are vital to builders and the factory, so Glasair Aviation has always taken an active role in assuring that good lines of communication exist and stay open.

Manuals

The unsurpassed assembly and owners manuals are thorough, well illustrated and written in language that is precise, clear, and simple to follow. Each of our models comes with an owners manual specific to its configuration. This is something that many others in the industry leave for the builder to compile.

Bulletins

Our engineering department also contacts builders with service bulletins, service letters and revisions to update everyone on refinements to the aircraft. This is an important part of our safety program, intended to keep builders current with evolving technology.

Assembly Videos

Glasair Aviation has produced optional instruction videos for most phases of your project.

Technical Support

Glasair Aviation builders can contact our builder support staff for prompt courteous assistance. Our award-winning technical support provides superior guidance.

Social Events

We welcome our builders to a variety of get-togethers at Oshkosh, Sun 'n Fun, Arlington, Copperstate, and other aviation events.

Assessing the Competition

The Glasair line offers a unique combination of style, performance, utility (large baggage capacity), strength, quality and proven reliability that is simply not available in any one competitor’s aircraft. There are a few designs out there that offer speeds that are similar to or may slightly exceed a particular Glasair model. Some designs are more expensive; a few are less expensive. Some are built with composites, some use other materials. However, none of the competition offers all that the Glasair does in one aircraft. Also consider that Glasair Aviation has set the industry standard for thoroughness, friendly factory support.

We encourage you to truly compare high performance kitplanes before making your decision to buy/build. First, take the time to sit down analyze and actually write down what your mission profile is. Are you simply going to fly locally on Saturday for the $100 hamburger? Are you going to be traveling to locations beyond 300 miles with your wife and 3 or 4 days worth of combined luggage? Do you intend to perform aerobatics which might subject the airframe to G loadings of +6 or -4 (whether intentionally or not)? With this task completed, now grade each aircraft you are considering on how it meets your mission profile. Honestly assess its style, performance, comfort, utility for cross country trips, strength, quality and reliability record, keeping in mind all of your intended uses. This should narrow your list to just a few aircraft.

Now, by all means, test-fly each aircraft you are considering building! You are going to spend many hours flying this aircraft and you don’t want to spend a few years building the airplane and then find out that this particular aircraft is not the right one for you. When you go to fly the aircraft, insist on flying from the pilot’s seat, fly it in all configurations, and see how it feels when approaching a stall and when in slow flight. Shoot a few landings on pavement and sod. Learn firsthand what it's like to flare and rollout. How’s about the baggage space? What are the G limits of the aircraft? Do you like the way it looks and feels?

When speaking with factory representatives, ask about their builder support programs and response to phone calls to the factory. Be sure to look at the quality and the contents of the kit. Look at all the systems that are included, such as the landing gear, and ask people who have flown with those installations what they think of them. Also, be sure to talk to builders about their experience with the company and their kits.

In your research, we are confident that you will not only discover what a joy it is to build and fly a Glasair, but that you will conclude that the Glasair’s unique combination of style, performance, utility (large baggage capacity), strength, quality and proven reliability offer an aircraft with a broad mission profile that is simply not available in any other aircraft.

Go to "Performance & Specifications of the Glasair III" >>

Go to "Performance & Specifications of the Glasair SII" >>