Sheet Metal Boot Camp
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The EAA SportAir Sheet Metal BootCamp is a two-day immersive experience designed to instruct you in the craft of building a sheet metal kit aircraft. Many aspects of sheet metal construction, not normally covered in our standard Sheet Metal course will be discussed, taught, and practiced. With lots of hands on experience.

We will cover setting up your workshop, tools, material prep and layout, drilling, pre-assembly, final assembly, special tools, painting and corrosion and more during this two full day course.

In addition, we’ll practice techniques learned with lots of hands on experience building two practice projects; a multi surface angle project and a wing section project, complete with hinges, access panels and more.

You will get up to speed quickly on important aspects of sheet metal aircraft construction like proper riveting techniques, air drills, flush riveting, dimpling, safety and more.

The instructor will work with you; not only in-group but also individual sessions to assist you in honing your new found sheet metal skills.

Partially lecture, mostly hands on, at the conclusion of the course you will receive a completion certificate, EAA’s Sheet Metal for Kit Aircraft book, EAA’s Sheet Metal DVD, and an instruction manual that details all aspects of the topics covered.

In addition, several special programs will accompany the Sheet Metal Boot Camp course:

A behind the scenes tour of the Museum and EAA’s Kermit Weeks aircraft maintenance facility.

A private tour of Sonex, a leading aircraft kit manufacture based in Oshkosh.

An evening program detailing “What’s Involved in Kit Building”, a two-hour presentation about the ins and outs of starting and completing your project – pizza dinner included.

Lunch is provided on each day, be prepared to work hard and leave late, taking away the confidence you need to successfully start and complete your sheet metal aircraft project.

Finally, Aircraft Spruce and Specialty offers special discounts to workshop participants. You will save on your purchases of tools, reference materials, supplies and hardware. Many times recouping your investment in the workshop program!

Do I need to be an EAA member to attend?
No, the workshops are open to anyone interested in learning the skills necessary to build their own aircraft.

Can I take more than one workshop at a location on one weekend?
You are only able to take one workshop each weekend. Each workshop is a full two days in length.

When I complete a course will I be able to do all the related work on my project unassisted?
Since each workshop is only two days in length, it is impossible to teach you everything you need to know. We do tell you where to get further assistance and we certainly provide you with the confidence necessary to begin your project. The fundamentals are taught and you will need to go home and practice.

How much time is actually spent doing "hands-on" activities?
The majority of the workshop time is spent doing "hands-on" activities. Be sure to wear your work clothes. In most courses, about 25% of the total time will be spent in lecture and discussion.

What are the hours of the workshops?
Registration for the workshop begins promptly at 7:30 a.m. on day one with the workshops beginning promptly at 8 a.m. Day One activities conclude about 5 p.m. Day two is 8 a.m. to 3:30 p.m, but we’ve been known to continue until 5pm as needed on Day two.

Do I need to bring any tools with me?
No, all tools and materials are provided.

Can I purchase materials at the workshops?
No, however you will receive a discount sheet from Aircraft Spruce & Specialty that will allow you to order materials at a discount with complimentary shipping.

Will I have time for lunch?
Yes, 1 hour is scheduled for lunch each day.

How many people will be in each class?
We try to limit class size to an instructor/student ratio of no more than 16 students per instructor. The welding classes are limited to 12 students due to tooling requirements.

How can I find out what hotels are available in the area?
The best source is Google Maps, Expedia or other travel site. They have the most up to date information and special pricing

I would like to bring my spouse or building partner. Is that possible?
Yes, we encourage family and friends participation. Each person attending the course with you must be a registered and paid participant. There are limited seats in each course and each participant must be enrolled at the current course fee. There have been questions in the past about bringing along a spouse, family member, or friend to observe or audit the course with you. We’ve found over the many years we have presented these courses that unpaid observers quickly become hands on participants, which is unfair to other paid participants of the course, which is why we require all to be enrolled. If you have a specific question about this policy, please feel free to email us at

I would like to bring my child. Is that possible?
Children 16 or older are allowed to enroll and participate when accompanied by a parent that is also registered for the course.

Can I pay for the workshop the day I arrive?
No. We must receive payment prior to the workshop. In the past we have experienced a number of "no-shows" from people who have not prepaid. If you need to cancel, a full refund will be provided as long as you notify us at least seven calendar days prior to the workshop.

What if I have to cancel my enrollment?
A full refund will be provided as long as you notify us seven calendar days or more prior to the workshop. These workshops are specialized courses with limited attendance to enhance your learning experience. If you cancel within seven calendar days of the workshop a $100 cancellation fee will be assessed. A “no show” will not be entitled to a refund.

How will I know where the workshop is located?
Workshop addresses and map locations can be found in our information packets. In addition, we will have signs directing you to the workshop.

Do I take anything home with me?
All courses provide you with a detailed workbook and a certificate of completion. In several courses you will build a small project to take with you.

Do I receive a workbook?
Yes, a workbook is provided for each workshop.

Are the instructors volunteers or professionals?
All of our instructors have high qualifications. They are professionals in their field and have years of experience.

What if I am undecided about building an airplane?
We recommend that you take the Fundamentals of Aircraft Building workshop. This workshop will give you "hands-on" experience in all types of aircraft construction.

Can I get credit for IA renewal by attending your workshop?
Several FAA district offices have given credit for the workshop. It depends upon the local FSDO.

Will I learn to weld aluminum in the gas welding class?
Because of the complexities we do not demonstrate aluminum welding.

Can I bring my own welding torch?
Yes, we encourage you to do this.

What type of covering system is used in the fabric covering class?
The Poly-Fiber system is used. However, nitrate and butyrate dope is also discussed.

How much time will be spent vacuum bagging in the composite class?
A very limited time is spent on vacuum bagging. The technique is demonstrated and is enough to familiarize you with the procedure.

Do you teach us how to finish a composite airplane?
Yes, we discuss all aspects of composite finishing.

What spraying system is used in the fabric workshop?
Depending on the facility, we may spray some of the fabric coatings. If this is not possible, spraying technique will be covered. We use primarily the HLVP systems.

May I bring my own project to the class to work on?
We do not encourage people to bring their own project. We have a set curriculum that includes a project that we have designed. If we had separate items to work with it would only create confusion for the rest of the class.

Does the electrical course teach me how to install avionics and antennas?
Yes, in addition to basic wiring of the electrical systems.

I’m designing my own aircraft, do any of the workshops cover basic design issues?
No, structural design will not be covered in any of the workshops.

Why do you not have the workshops in more locations?
The EAA SportAir Workshops are presented as a self sustaining program of the EAA. It is very difficult to find suitable locations. We ship everything we need for the classes in large wooden crates. It is very expensive for us to travel. We try to schedule classes only where we can be assured of a large attendance.

I would like to host a SportAir Workshop. What are the requirements?
Finding new facilities are the biggest challenge for this program. EAA is a non-profit organization and the SportAir Workshops are presented as a self sustaining program. It is very expensive for us to take this program on the road. We try to schedule classes only where we can be assured of an attendance cover operational costs.

Minimum facility requirements are as follows:

  • Location must be in or close to a sizable metro area
  • Forklift rated at 1,000 pounds for loading/unloading large crates
  • Enough space to hold at least 4 workshops with 16 students simultaneously
  • Adequate lighting
  • Bathroom facilities
  • Willingness to help grow grassroots aviation

If this sounds like something you could host, we would love to hear from you at or 1-800-967-5746.

★ ★ ★ ★ ★
"Enjoyed a very educational sheet metal course! The hands-on projects were perfect to learn the necessary skills. Perhaps offering additional advanced projects for those who finish early would be the only recommendation."

★ ★ ★ ★ ★
"Great course. I was looking for a refresher for my 40+-year-old A&P and this fit the bill. Renewed my skills and gave me the confidence for sheet metal repairs. Thank you."
— Dave G.

★ ★ ★ ★ ★
"Very good class. Project covered many aspects of metal works. Instructor is very good and knowledgeable. Now I have the confidence to move forward with my project."
— P.H.

★ ★ ★ ★ ★
"Excellent experience! I had some sheet metal training in 1991, but have not touched it since then so this was a great refresher. I thoroughly enjoyed the class and have high regards for the instructor and the projects we created. Using the different skills and tools was great. Having a hands-on experience was much better than watching a video or reading about it. I will definitely attend another Sport-Air Workshop."
— Brian R.

★ ★ ★ ★ ★
"Knowledgeable and excellent instructor. His explanations were short but thorough. It was a very instructive program."
— Frank K.

★ ★ ★ ★ ★
"Great Experience, Mark gave us practice on techniques that will be used on building a homebuilt or maintenance on my own. I am glad I took the time off from work to learn new skills."
— Garry C.

★ ★ ★ ★ ★
"Mark Forss was very accommodating and very knowledgeable. Instruction was well organized and presented. The extras (tours and Lunch) were awesome. Great job and thank you…"
— Bill M.

★ ★ ★ ★ ★
"The course and experience was fantastic! Mark was an excellent instructor. As a total novice in sheet metal I came away with substantial knowledge, ability and confidence to start my project."
— Douglas G.

★ ★ ★ ★ ★
"Mark, this was such an outstanding course I’m not sure what I could say to improve it. Great mix of classroom and hands on. Good use of breaks, great section on painting and corrosion. Thanks for helping me realize that I can do this!"
— Robert M.

Day One - 8am to 5pm

Overview of Kits
Workshop setup and location

Prep and layout of parts
Pre Assembly

Break For Lunch and Tour of EAA’s Kermit Weeks Aircraft Maintenance Facility

Final Assembly Techniques

Project One - Multi Surface Angle Part

Hands On with tools and materials


What's Involved in Kitbuilding with Pizza Dinner

Day Two - 8am to 5pm (we sometimes conclude by 6pm so be prepared to stay longer)

Review of previous days activities

Metal Forming – Making your own parts

Project Two – Wing Surface with hinge, Access Panels and more

Hands On With Tools and Materials

One on One’s with the instructor

Break for lunch and Private Tour

Special Tools

Corrosion prevention

Painting and Finishing

Wrap up discussion, student evaluations and Completion Certificates


Time permitting we will discuss and have demos on fiberglass techniques used in sheet metal aircraft.

Mark Forss Mark Forss is a Lifetime EAA Member and has been a part of EAA staff since 2001. He’s directed the EAA SportAir Workshop programs since 2002. Over the past 15 years Mark has taught hundreds of EAA members the crafts of Sheet Metal, Composite and Fundamentals of Aircraft Construction at workshops around the country with the EAA SportAir programs. He’s a Private Pilot with single and multi engine ratings, is part owner of Sonex #450 and likes to build things in his home shop. Prior to EAA, Mark worked in the field of Industrial Design and was an Industrial Model Maker, creating full scale models, molds and prototype products for many Fortune 500 companies. He’s also worked for a time at Sonex Aircraft, and during AirVenture oversees the Oshkosh Forum and Workshop presentations.

Sheet Metal