Two Weeks to Taxi

Builiding a Glasair Sportsman from start to finish.

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The exterior of the Sportsman is constructed of wet layup, room temperature cured fiberglass. Glasair’s employees place the cloth in large tools in which the composite is cured.
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The composite walls are attached to a chromoly steel framework and firewall, all put together by Glasair’s employees.
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Major components of the wings are also assembled prior to the customer arriving at the factory.
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** A large board covering most of one wall in the assembly hangar contains documents where the customer must sign off each task that has been completed.**
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Forty-one plastic bins are set up with tools and parts for more than 600 tasks. The build process is documented with a digital camera, and the customer leaves the factory with a photo album documenting the experience.
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One Glasair worker assists the builder, one cleans up after the last task and a third sets up for the next task, allowing the customer to focus strictly on building his or her airplane. No time is wasted looking for parts or tools.
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Detailed instructions are included for each task to eliminate any mistakes. At the completion of the program, the customer receives a repairman certificate that allows him or her to maintain the airplane.
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Once the airplane is completed, 50 hours of flight time must be completed before the airplane can receive its final sign off. The area surrounding Arlington, Washington, is a beautiful place to be forced to fly around. For more, check out our in-depth Glasair Sportsman feature.