construction by Daniel D. Kautz
This page contains the extent of my progress building a Carlson Sparrow Ultralight from SKYTEK. The project was located in my (large) garage at home in Ohio. The intention was to experience the same problems and solutions any typical first time home builder may face. The project was abandoned and components returned to Carlson Aircraft Inc. because of my relocation to Dallas, Texas and current status as an apartment dweller.
Although I had access to the Carlson shops (about 12 miles south of my location) all work was performed at my locale. I started with a bare garage as would many first time builders. As needs develop, I added additional benches, tools, lighting... whatever. It became clear to me that a fully equipped shop would greatly speed the process, but then I imagine few first time builders would start that way!
I had access to many sheet metal tools. I own a full sheet metal shop which includes an eight foot metal shear, various bending breaks, rolls, formers, etc. None of these machines are required to assemble the Sparrow. In fact, the Carlson sheet metal parts included in the kits are finished to the extent, the home builder does not require access to expensive shop equipment at all.
As you view the pictures observe some of the actual tools (in the backgrounds) used in the assembly process. The purpose of this series is to provide you a "taste" of what is required to assemble the Carlson Sparrow Ultralight or in fact, any of the Carlson Sparrow kits. However, it will not be a step by step instruction.
This is the finished riveted vertical stab. The left horizontal stab is being trial fitted so the cross tube lengths can be cut to fit the actual dimensions of the pre-welded fuselage.
Welded steel fuselage as supplied from Carlson. Welded engine mount on floor in front. Aluminum wing spars being stored (off floor) on horses behind airframe. Rudder against wall in background.
After trial fit on fuselage, left horizontal stab jigged to table top. Long tube farthest from camera will be fitted while stab is again "plugged" into fuselage. Diagonal tube also not installed yet. Note: The gas welding set in the background is not required to assemble the Sparrow. That is for other projects.
Here are the completed (riveted) tail feathers. The airframe has been turned around from previous pictures. One person can easily pick up the frame and carry it at this point. (I did!) Other metal parts have been picked up off the concrete floor. (Not a good place to store metal.) Fancier shops may have racks on walls to store metal and materials.
Here is the left wing under construction. The ribs are riveted to the spar at this point but the trailing edge has not been applied. Also the drag and anti-drag wires are in place. The table is four foot by sixteen foot and perfectly level.
This is a close-up of the lightened spar, compression tube, drag (and anti-drag) wire attachment and the light weight ribs. The jury strut mount brackets are laying on the table. The two small holes under the compression tube is the mounting point for the forward jury strut bracket.
The left wing and airframe make it to Florida and Sun-N-Fun 97! This is also the first time the fuselage is on the gear. Thousands of aviation buffs "fondled" these components and we were constantly complemented on their quality, design and craftsmanship. I am sure many more Sparrow Ultralight kits have been ordered.
The airframe and wing are getting more miles on them in this condition then they will when completed! Here is the display at Sentimental Journey in Lock Haven, PA. Note the Piper Aviation museum display trailer in the background.