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Hands, Mind, and Heart

What started as a handful of passionate enthusiasts has developed into a major force—and a significant component—of the aircraft industry.

Tips for Steel Tube Construction

By Frank R. Libertif (originally published in EAA Sport Aviation, May 1994)

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    I am a Technical Counselor, an EAA member and a member of EAA Chapter 176. When building my Tailwind, I fabricated several fixtures that should be useful to others using steel tubing construction.

    This fixture is for welding aileron and flap fittings for controls having round steel spars. The shaded area is steel bar (1/8" thick x 1-1/8" wide).

    Tube Welding

    Tube Welding

    Jig fixture for making elevator hinge fittings.

    Tube Welding

    A = Stationary round bar fastened by machine screw drilled and threaded on opposite side shown.
    B = Movable bar slides up to round bar when round tubing is slipped on its radius and round bar. Two screws fasten it tightly against A.
    C = 1/4" thick bar.Top and bottom fittings are clamped on B, and spot welded. Then fitting is slipped off jig fixture and welding is completed.

    Tube Welding

    This fixture is for accurately drilling round steel tubing. Drill one side, then the other, with undersized drill bit. Then line bore with a finish size bit.

    Tube Welding

    Tube Welding

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