Setting up the Shop

I had to find a place where I could build the airplane, I thought about building it in a hanger at a local airport, but I live in downtown Chicago and any airport was gonna be an hour drive. I wanted something closer, something that if I only had a few hours I could still make it to and get some real work done. I started looking for Wharehouse space that I could rent. Luckily I’m not the only one who needs space to build things, or have small shops in so there is market for this in Chicago. I found a space that is close to perfect for starting out. It’s 400 sq. Ft. In the corner of the building with an exhaust fan in the ceiling already and a heater for the entrance way right above it.

The space is secure and lockable, which is really important to me considering how much Ill have invested in there once the tools and the airplane parts start to show up. Now I just have to design and build a shop!

AIR SYSTEM

I decided I want to prime the interior parts, right now I think I’m going to go with the Stewart Systems ExoPoly, so i needed to think out an air system that would all work to that end. I also might tackle the finish airplane paint job so I wanted all the components to work with a larger compressor in the future. I decided to go smaller for my air supply, fits my needs for now, and got a Craftsman 33 gallon compressor it will output 6.8 SCFM@40PSI so was my limiting factor for HVLP spray guns. Luckily for me I found one at Eastwood, the Concours LT, that was designed for home shops with small compressors that only needs 4CFM@30PSI and has an optional 1.5mm tip that the paint system I’m looking at using recommends, So far so good! I know in the future I’m going to want a much much bigger compressor, so I choose an air supply line system and filter to support that dream. I went with the RapidAir Maxline M7500 3/4” 100’ kit for the air supply line and fittings then for the filter I choose the DeVilbiss CamAir QC3. The trouble with using the 3/4” kit is having to step the size up and down. I used Flexzilla Pro High flow 1/4” NPT couplings, so I went from 1/4” coupling up to a 3/4” leader house to connect to the Maxline system. Then when the pipping got to the filter the filter inlet was 3/8” and outlet 1/4” so I had too get fittings to step down and back up. The outlet block are 3/8” so i had to get a fitting to step them down to 1/4” and then I added a 45 degree before the NPT. So while I like the 3/4” line for future Todd’s shop it added several steps and fittings to get everything to work. The Maxline was really easy to straighten without a tool, could it be straighter sure but would I spend the money on the tool if I did it over, No. Lastly I piped my Flexzilla hose reel to one of the outlet blocks and left the other one with a NPT fitting.

WORK BENCH

I found plans on the internet that I liked and tried to follow them, but ended up making a few modifications on the dimension. I might build another one in the future if i need the space.

PAINT BOOTH

I want to be able to paint in my shop, That is why I’m leaning toward the Stewart System waterborne paint since It’s non-hazardous and non-flammable. Still i wanted to control the air so i build a sudo paint booth. First i made a drop ceiling using 2 header boards and a cable hanger. Then I covered the top in 6mil plastic and created 6mil roll up curtain walls. I left part of the drop ceiling uncovered and put cheap furnace filters up there to filter the inlet air and am using a MaxAir 12” fan and hose connected to the exhaust fan in the space to remove air from the booth. Even though the paint is non-hazardous I’m going to use a nice furnace filter in front of the fan to filter the air before it leaves the booth.

TOOLS

I bought the RV14 Kit from Cleveland tools, I sprung for the DRDT2 and the pneumatic rivet squeezer. I’m sure I will need more tools alone the way like a bench grinder, Dremel, and probably a 1” bench sander. I’m going to wait and let the kit progress dictate the purchase of more tools though. For my paint gun I bought the Eastwood Concours LT and am planning on getting the DeVilbiss cup setup to make cleanup easier.