This is an index page to aspects of building engineering under the Experimental Category.

The Engineering section will highlight each building style available using the example of a good project to show you enough of the aspects of that style of construction so that when you are asking questions you have an idea of what's going on.

Reference Guide reference material for the construction of Amateur Built Aircraft
Wood Frame Construction,
Sheet Metal Construction,
Tools for Aluminium Construction,
Composite Construction,
Tube Construction,
Fabric Covering (Part 1 & Part 2).
New Builders Information Pack. All you need to know about getting started in homebuilding your own aircraft.
Carbon Monoxide Poisoning Article from "Vector" magazine, New Zealand.
Notes on Good Riveting by Sam Richards
Cockpit Design by GAMA
Drill Sizes
FAA Prop care AC 20 - 37D
Thermal Expansion of Aluminium Pistons

Electrical Load Analysis

Any electrically dependant aeroplane needs to have an electrical load analysis done before first flight.
Electrically depandant aircraft are those that depend on electrical power for safe flight - these include those wilth electronic ignition (not magneto), and those flying NVFR and IFR.

The aim is to confirm by calculation that:
a.  the electrical capacity available is sufficient at all phases of flight to ensure completion of the flight.
b. that if the alternator fails, the battery can provide 30 minutes of adequate power to enable a safe landing.
c. to determine what loads need to be shed in the event of an alternator failure.

The attached spreadsheet is just one example of a load analysis for an IFR aircraft with two independent electrical systems, system 1 has a 40 amp alternator, and system 2 a 20am alternator. There is a crossfeed switch to supply power to the other system in the event of one alternator failing.

Generally 20% of an alternators capacity should be reserved for recharging the battery after intermittent loads are applied such as electric flaps, radio transmissions, undercarriage cycling and so on.

There is no hard rule as to what phases of flight must be modelled for load. Its up to the builder to identify the most electrically demanding state. In this case preflight inspection, taxi, night circuit training, and night cruise were modelled.

The analysis revealed that night circuits are the most electrically demanding phase of flight, and that its necessary to cycle the landing lights to ensure good electrical capacity.

The analysis also revealed that an inflight failure of the 40 amp alternator would lead so some load shedding to complete the flight, and a checklist was developed to implement load shedding.

For further guidance read the Aero Electric Connection by Bob Nuckolls. You can click here to see a worked example.

If you have a well photographed project that has proven itself over the years, include it here or on our Projects Page.

Please note that the methods shown here are an individuals method of construction. Please consult your 'Authorised Person' if you have any doubts before construction.