What planned adventure in life can top that of building your own airplane from scratch – -- using just raw materials, common tools and a set of plans?

It requires a builder with special skills, knowledge, and an attitude complete with persistence and imagination. Not all of us are cut out for a project like this… although most of us can appreciate the rewards that will result!

The purpose of this video presentation is to expose you to the world of building a metal plane from plans, demonstrated by one of the most considerate pair of builders you will find anywhere. You will witness the type of skills, materials, tools and commitment that is required to accomplish this feat. These two gentlemen, Mark Townsend and David Barth (owners of Can-Zac Aviation Ltd the Canadian distributor for Zenith Aircraft Company) donated their time and expertise in making this video so that we could share their passion for this hobby.

This 2 disk DVD video (over 3.5 hrs runtime) is divided into the following chapters for easy navigation:

From Plans to Form Blocks
Creating Cutting Blocks and Form Blocks
Producing the Metal Rib Blanks
Deburring and Polishing Techniques
Forming Ribs
Fabricating the Rudder Spar
Fabricating the Rudder Horn
Fabricating the Rudder Skins
Creating a Full Size Wing Rib
Tips, Tricks and Techniques

Mark and David take you thru each step of the process required to create the components needed to build a Zenith rudder. A rudder was chosen because it contains nearly all of the components that are needed to complete the remaining parts of an airframe: ribs, spar, skin, control horns, etc. The presentation begins with just raw materials and common tools. By the conclusion of the 2 DVD set, you will have witnessed all of the internal rudder components completed and will now be at the point that kit builders start their rudder project - ready to assemble these components into a finished rudder. This next step of rudder assembly is detailed in the companion DVD video from HomebuiltHELP entitled Metalworking101.

Details of the fabrication process are explained and demonstrated - such as: how to translate blueprint plans to a form block drawing, cutting, sanding and finishing the form blocks using common tools; choice of form materials (plywood, MDF, particle board, hardwoods, etc); tools for cutting aluminum sheet, (power shears, hand shears, scoring knife), forming rib blanks around form blocks (how many hammers can be used!), fluting techniques for curved edges, cutting lightening holes, various methods for deburring and polishing, sheet metal bending using a home made brake, and much more. Both Mark and Dave spend equal amounts of time explaining these operations and expend just the right amount of humor to make this truly fun to watch.