Sequoia Aircraft Corporation F.8L Falco Construction Manual Download

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F.8L Falco Construction Manual

4–4

Revision 4, March 1, 2002

You will need an assortment of drill bits for both metal and wood. You will not want to build a
Falco without a set of

brad point bits

. These bits cut a very clean, smooth hole in wood, unlike

normal twist bits which tear their way through the wood. Be sure to buy a set which has a 3/16”
bit as this will be the one that you will use the most. The set sold by The Fine Tool Shops is
highly recommended—drill bit sizes are 1/8”, 3/16”, 1/4”, 5/16”, 3/8”, 7/16” and 1/2”.

For metal, you will need an assortment of

high speed steel drills

. We recommend getting a set of

bits in fractional-inch and number sizes. The following fractional-inch size bits are required:
1/16”, 3/32”, 1/8”, 5/32”. 11/64”, 3/16” and 1/4”. The following number size bits are required: #43,
#40, #30, #21, #19 and #3.

In addition, you will also need a .1875” and a .250”

reamer

. This is used for reaming the bushings

for the hinges. You may use a twist drill bit for this, but a reamer does a much nicer job.

You will need the following

taps

: 4-40, 10-32 and 1/4-28.

You will need a 100° included angle

countersink

. You do not need the fancy stop countersinks

sold for aircraft sheet metal work. The one that you want is a single flute countersink. It looks
like a stubby drill bit.

To install the taper pins for the retraction system, you will need a

Brown and Sharp No. 1 tapered

reamer

. This may be purchased from a local machine tool supply company or from Travers Tool

Company (see F.8L Falco Kit Price List).

You will need a few

transfer punchs

. A transfer punch is a special type of punch used to locate the

center of a hole. It works like a centerpunch but the punch is the exact diameter of the hole and
has a small point at the center. You need two sizes, 3/16” diameter and 1/4” diameter. Obtain
from Travers Tool Company or locally.

Band Saw

A small band saw is invaluable. Rockwell-Delta makes one that will cut both metal and wood.
This type of band saw is essential if you are going to make many metal parts. If you are only going
to cut wood, then you can stick with a cheaper saw. Black & Decker makes a small bench-top
band saw that sells for less than $100.00. There are a lot of similar saws sold through mail order
catalogues and advertised in

Fine Woodworking

magazine.

Table Saw

This is a big maybe. If you make all of your own wood parts, you will need a table saw (or a radial
arm saw). Given the choice between a table saw and a radial arm saw, we would go with the
radial arm saw.

Radial Arm Saw

A radial arm saw is much more versatile than a table saw, and it is more desirable for a Falco
builder. One of the principal advantages is that you can use the saw for scarfing plywood. Make
sure that the saw that you buy has a spindle on the back of the motor. This is used for installing a
3” diameter drum sander. If you cannot do this, do not buy the saw.

Coping Saw

One Falco builder recommends the Garrett Wade “precision fret and coping saw”. The frame is a
nearly rigid aluminum casting, and the blades are held in place by small steel blocks into which
they're clamped with hex-head set screws and then the blade-plus-blocks assemblage is put into

Sequoia Aircraft Corporation F.8L Falco, Construction Manual

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