Eaglesnestprojects.org



Eagle's Nest Projects Start-up Manual (Preliminary, Rev 12.10.28)

So you have decided to build an Eagle's Nest Project. Congratulations! The RV-12 is the ideal student-built aircraft, and ENP gives you the support you need. By the time your Young Eagles are done, they will be a better educated convocation, and one fine airplane will be leaving the nest. This is a guide to help organize the project and minimize preparation time and frustration. ENP is here to answer many of your questions, and ease the difficult process of getting your project “off the ground.”

Your students will learn about aviation, building, discipline, and...themselves. We hope that someone sponsoring or mentoring this project has built an airplane, hopefully one from Van's fine line of aircraft. If this isn't the case, it can still be done. There will just be more learning to be done by the leaders of the group build. The RV-12 is actually very easy to build—as airplanes go. It does, however, demand a high level of attention and care. The building techniques used on the RV-12 differ somewhat from those of other Van's aircraft in that most rivets are pulled rather than solid.

While Eagle's Nest was started to get projects into local school systems, we recognize that in some case this is not practical, or even possible. We will work with local EAA chapters, CAP squadrons, or other aviation-based organizations if this is deemed a practical approach. We will also work with schools outside the public school system—church-sponsored schools and home school organizations. Colleges are also prime organizations to consider a project, either as extra-curricular, for-credit, or as projects they could mentor in local high schools.

If you haven't built before (or even if you have,) contact an Experimental Aircraft Association Technical Counselor. There is probably one in your area who would be willing to participate. Contact your local EAA chapter, or see the Contacts and References section on how to find one. Contact your local FAA Flight Standards District Office (FSDO) early in the build. They will be helpful when it comes time to register and inspect your airplane.

Finances:

Deciding to build is one thing; paying for it is yet another. I hope this has already been worked out, but if it hasn't, here are a few ideas. There are many options here:

The organization or school system may provide the money (check with them)

There may be another not-for-profit organization that will provide the up-front costs.

You may be able to find local donors (corporate or individual) willing to provide the money.

These same people might advance loans until the aircraft can be sold.

A “club” of three to five members might agree to buy the aircraft (a source of mentors, also.)

You may be able to “sell” the finished aircraft up-front, having the individual cover the cost.

It might be possible to raffle the finished plane, even before it is built, or during the build.

Some items such as stationary tools or supplies may be donated by the manufacturer or dealer.

Some dealers will provide good discounts, although may not be willing to donate. Ask.

Car washes, concerts, etc. can raise at least a portion of the needed money.

Donations should be collected during Open House or other activities (usually for petty cash)

Grants may be available in some cases.

Eagle's Nest may be able to pre-sell your aircraft, or arrange other financing.

Certainly there are other ways to finance the project. Since laws vary from state to state, it is your responsibility to make sure all are followed. Legal and binding documents must be prepared for some of the ways listed, and this should be done professionally. Eagle's Nest may be able to help you here. Aircraft sub-kits, hand tools, and some other items will be supplied directly through Eagle's Nest, making the process simpler and cheaper. All orders and order arrangements (shipping times, etc.) will be handled by ENP, keeping your workload to a minimum. See the documentation in Attachment Five.

Project Requirements:

People:

The number of students can vary, but six to ten is best. Less than six and the project may drag, over ten and it may be difficult to supervise. If the group is over eight or so, be aware that there may be times when not everyone will be able to work on the project. This is especially true near the end of the build, when installing the engine and avionics. Planning can help with this problem, but it will happen. By that time, you will have worked out your scheduling problems, and the students will understand.

(NOTE: Building in “shifts” is being tried, with great success. This allows double or perhaps even triple the number of students to participate. It does take more planning. We plan on covering this approach when we have adequate information.)

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It is helpful to begin with firm rules as to who can participate. The standard will be up to you, but having rules up-front can prevent problems down the line. For instance, when can a new student join the group? Only at semester breaks, or any time there is an opening? Are grades to be considered as prerequisites? What discipline is expected? If you are working within a school, these things should be discussed with the staff. They may be the best final authority for these decisions.

Age of the students isn't all that important, within reason. Since this project may take over one year, it would not be wise to have all seniors involved. A certain amount of continuity is desirable, and having “hold-overs” will speed the training of new students coming in later. Students younger than ninth grade could participate, but will require more supervision.

Selecting the group should not be difficult. If there is enthusiasm, chances are there will be results. It is very unlikely you will have kids with previous building experience, but it could happen. Good mechanical aptitude is always a plus, and in some cases this may not be evident. Simple testing could be done, but is not necessary. Just remember that those with lower aptitude will require more training and supervision. Job assignments later may be done to fit the abilities of the various students. If some seem more adept at photography or record keeping, they can be assigned jobs within those areas. Group organization will be covered in “Getting Started.”

Standards should be enforced for staying a part of the group. These should include maintaining grades and attendance at the various work sessions. Remember that students will miss sessions from time to time. Band, football practice, or other activities will come up. Be flexible, but consistent. These rules should be written to avoid confusion later on.

There is no the ideal group. The initial Eagle's Nest group was made up of very bright kids, most typical and traditional in their lifestyles and habits. Projects may be done with a wide variety of groups. What changes in approach will be necessary, if any, will be the responsibility of the leaders. EVERY group will be different, that is a certainty. And yes, there will be turnover during the build.

Eagle's Nest builders should become EAA Student Members. This is only $10 per year (free if they are Young Eagles) and makes them eligible for many things, including scholarships and discounts at Airventure Oshkosh. A local EAA chapter will be happy to give each a Young Eagle's orientation flight, and may offer membership in their chapter. These are things that will build enthusiasm. YOU should also join EAA, if you are not already a member. EAA's help can be priceless in this endeavor.

There is also free membership available to student builders in the AOPA (Aircraft Owners and Pilots Association) through the new AV8Rs program. This is another avenue to scholarships and other dividends. See Contacts and References.

Finding mentors may be a bigger problem than finding students. The level of mentoring will be reflected in the time required for completion of the project, and it could reflect on the quality of the finished product. Too little mentoring is not a good thing. To some extent, the students will dictate the level of mentoring needed. Websites helpful in finding mentors are listed in the Contacts and References section. In some cases, Eagles Nest Aviation may be able to help, also.

Mentors need not be accomplished aircraft builders. Some knowledge of aircraft construction would be helpful, although almost anyone can be taught enough to mentor. I would suggest that those with the desire who lack experience work with another mentor until they become comfortable. This will take only a couple of sessions. People with teaching experience are often well suited to becoming mentors on this project. In general, the kids will quickly understand who can help them with any problems. ENP is developing mentor training aids.

The number of mentors is important. The ideal initially might be one-on-one, but this is rarely possible. During much of the time, mentors would be doing very little that would be constructive. One-on-two is more doable, and may be more than needed. While it will vary from group to group, generally, as the work progresses, the ratio may be allowed to go down. There probably will never be a time that one person can oversee a group build. At some point, one per team may be sufficient. At this point, all mentors should have a good grasp of construction techniques and inspection procedures. Late in construction, two mentors can probably handle it. By that point, experience will let you know.

But beware! After the first year, you will probably lose some students. Some may graduate, some may move, or some may find they do not have the time to commit to finishing the project. Very probably you will have absolutely no trouble getting replacements! Word will be out that this is a great thing to do. Then, all of a sudden, you will have students without the skills and experience you have grown used to. The need for mentors will increase again, and the load on the leader will increase, perhaps more than you might expect.

If you have one new builder, or perhaps even two, they will fit in and be mentored by the most experienced students. If you have three or more, I suggest you assign them a separate component to give them the joy of finishing something themselves. We chose a flaperon as a suitable component. Perhaps have one “old-timer” and a couple of mentors work with them and them only. This will free up the experienced people to continue without too much interruption.

Where can you find mentors? Your local EAA Chapter is a good place to start. Contact parents of the group for potential mentors. Local aviation repair shops would be good also. Service clubs, schools, and church organizations may have willing people, but their level of expertise may be low. You might contact your local retirement community. There could be retired teachers (or others) willing to help. If these are your only sources, plan on training classes for those who are willing. This will not take a great deal of time. Teaching ability—and the desire to work with young people—may well be more important than building experience.

There may be legal requirements for screening mentors. This is a sad fact of our post-modern world. Check with the school system for specific requirements. Screening students for eligibility is up to you, as is discipline and grade requirements. Fairness and understanding is important, but the integrity and safety of the group must be maintained. Do not allow the group to control the project!

Space:

Does an Eagle's Nest Project have to be built in a school? Not really. We believe the school is the best place, but this may not be possible. Any safe, secure area with the proper facilities could be used. This is a matter for your consideration, as even church groups could pursue a project. Keep in mind that a school will expose more students, and even more adults, to the building process than probably any other situation. By “building process,” we are talking about much more than just the airplane!

There is more to spacial requirements than just square footage. Lighting, heat and/or air conditioning, and adequate storage are important. It will take more room for a group to build an RV-12 than it would take for just one or two people. Many RVs have been built in single car garages. This can't happen with a group. About the minimum area to start is a 20'X25' clear area, not counting storage and fixed power tools (air compressor, drill press, etc).

Temperature. Normally, comfortable (or even bearable) is good enough. There is at least one time during the Finish Kit assembly where this won't work. Working on the canopy (plexiglass) requires a temperature of 85 degrees or higher. This requires having control of the thermostat, or working in the summer. If you will be working in an unheated hangar and need heat, use only equipment that will not produce carbon monoxide. Safety considerations are always foremost!

Lighting. This should be as good as or better than what is required for normal office or classroom work. Errors are often hard to see. Have not only good overhead lights, but hand-held (drop cords) or mounted lighting for working in tight places. A flashlight can be very handy.

Storage. Note that almost all small items arrive from Van's in numbered bags. Some contain one part number; some have many mixed together. You need very organized storage for these small parts. Rather than attempt to devise your own method, we provide a simple system consisting of five compartmented boxes, labels, filling instructions, and a finder list. Assemble the boxes as shown in the provided diagrams, place the labels on as directed, and put the contents of each bag in its proper place. Note that a few bags must be sorted. Then, when a part or fastener is needed, look up the number in the list. It will tell you where it is! DO NOT LOSE YOUR PACKING LIST, HOWEVER!

Keep these boxes closed when not in use, and store them flat. Spilling one is disastrous. This “Organization Package” provides a good storage solution, and can save dozens, if not hundreds of hours. While even used medicine bottles could be used, we do not recommend them. Medium sized items can often be stored on shelves or in drawers. Large items (sheet aluminum and such) can be hard to organize if the area has other uses. It is often best to store these in the original shipping box until needed. Also consider that finished assemblies will need storage. Wall hanging is often a good option, and wing racks can be made that are easily moveable.

If you are ordering a number of kits at one time (a good way to save on shipping,) notify Van's that you will not be opening one or more of them until later and they will extend your time to report missing items. Van's will replace anything missing if it is reported within 30 days of receiving the kit. EXAMINE ALL BOXES ON ARRIVAL AND NOTE ANY DAMAGE! This must be done to assure that the trucking company will cover damaged goods. Store unopened kits off-site if necessary. Storage should be dry to avoid the possibility of corrosion. On the initial Eagle's Nest project, the school had the carpentry class build a temporary building which could later be sold. Such a building should be at least 8' X 24' (inside) with a full width door, and be lockable. 8' X 16' with a five foot door will get you by until the finish kit.

Keep in mind the size of existing doors. There is a point where a fuselage might be “trapped” in the construction room if the exit doors are not large enough to remove it! 36” doors allow the fuselage (minus the roll bar and landing gear) to JUST pass through, rolled 90 degrees. At other stages: roll bar on—4', landing gear on, no wheels—6' 1/2” (you can pull the gear together a bit for a 6' opening,) wheels on—7' 6”, stabilator on—8' plus a little for clearance. Since the wings can be removed in minutes and without tools, they present no problem if they can be installed inside.

At some point you may need a larger work and storage area. This may happen when the wings are complete, or when the fuselage is fully assembled. This is the time when a hangar at the local airport can be handy. Completed items can be stored there, also. Don't overlook local storage companies if storage becomes a real problem. These are often inexpensive, and you might ask to free storage. Don't forget that businesses may want to be a part of this project. If painting is to be done, it can be done whenever an assembly is complete. Keep in mind we have a recommended paint shop, however.

Tables: To some extent, this depends on the number of students. If you use the team principle, have one more table than there are teams. Table size isn't critical, and you probably can use the tables you already have. If not, a standard EAA table is 2 X 5' and works well (see the References section for location of plans.) Many people prefer smaller tables, making three from one 4 X 8' sheet of plywood. These may be a bit small for a group. Fine large tables can be made from hollow-core doors. These can often be found at hardware outlets in slightly damaged condition for very reasonable prices (or as donations.) Note that tables may be damaged during construction. There might be numerous holes drilled into them. Plan accordingly.

The height of the tables should be higher than you might expect. See the EAA plans, and consider the height of the students. It is good if all tables can be the same height, but of course not absolutely necessary. Once the fuselage is nearly complete, you will need a table only about 28” high. This can be made by cutting one down. In general, tables are not a big problem in building the RV-12. The majority of construction of Eagle's Nest One was done on regular classroom tables.

Other space concerns include compressed air. A group will need quite a large volume at certain points during the build, even early on. If you have an air compressor, use it, but be ready to replace it if it is a serious bottleneck in production. If you are buying one, get one with plenty of capacity (5 hp or more, and an oiled compressor will be quieter than an oil-less. Be considerate of your neighbors when it comes to noise.) Pressure should be regulated to no more than 90 psi. This can be done with an inexpensive regulator if you are using a compressor permanently set at a higher pressure. Companies such as Lowes might donate a compressor. It never hurts to ask! ENP may also be able to arrange for this and other power tools. Let us know your needs. During the original project, the school plumbed air into our room. Asking pays off!

Tools:

Eagle's Nest will provide your tool package. We have chosen Avery Tool as our supplier and will modify the tool list to your needs. By going through Eagle's Nest, you are eligible for “loaner” tools, video instruction materials, and other material that will be very helpful during the build. Attachment Two is the basic tool list we provide.

Van's instructions were barely a starting point when it came to tools. They were written for an individual builder, not a group. If you desire more or optional tools, you may contact a supplier such as Cleaveland Tool or Avery Tool directly (see References section) for their recommendations. They may offer discount to a school.

There is no substitute for quality, especially when it comes to drills. Brands like Sioux are superb, but expensive. Hand held battery powered drills can be used, but cannot replace the air drill. Corded drills really should not be used as the cords can be damaged on sharp aluminum edges, causing shorts. Do not use dull drill bits, and do not try to sharpen them unless you are an expert.

Do not buy as you go; get what you need up front. There are many tools that are purely luxury items that some builders will say that you need. Don't go overboard here. Don't buy a pneumatic squeezer. They are expensive, aren't used all that often, and can be dangerous in untrained hands. Save the $500 and teach your students how to use a hand squeezer. We can loan a pneumatic squeezer for the large number of squeezed rivets at the beginning of fuselage construction. A variety of edge deburring tools will improve learning. The kids will quickly figure out which works best for them.

See attachment two for the list we provide from Avery Tool. We had a number of tools such as the socket sets, screw drivers, wrenches, and continuity checkers which came from local suppliers or were already stock items. You are expected to provide such tools from your own local suppliers. Good, medium-quality tools suffice. We suggest Lowe's as a good source—Lowe's supports ENP!

Very few power tools are needed: A ½” shaft grinder with a 6” Scotchbrite wheel (wheel listed in attachment two.) A bench sander. A drill press. (The drill press can actually replace the grinder as the power for the Scotchbrite wheel.) A band saw or scroll saw saves lots of time. Lathes, mills, and other fancy stuff is nice, but not really needed on this project. Keep in mind a band saw requires CLOSE supervision! All tools must meet OSHA standards, and strict safety measures observed at all times. All these may be replaced with hand tools, but quality may suffer and it will take extra time. Safety glasses are mandatory.

You may contact us for availability of used tools and large tools such as drill presses and tool cabinets, or contact Avery Tool (see Contacts and References list.)

Supplies:

See Attachment Three. Note that the kit where the item is required is listed first. These can usually be purchased locally, but some things should be ordered from an aviation supply house. Note that, unlike tools, some of these items have a shelf life. Fuel tanks sealant, for example, should be purchased within a few months of it being needed. Eagle's Nest Aircraft can provide supplies through our approved supplier list. Contact us before ordering composite materials. We usually have extra we can send directly.

These are some of the things to be done before building your Eagle's Nest Aircraft. Don't begin until you are ready. It would be an error to have your group waiting for things they don't have, or to not have mentors lined up when the kit arrives. Preparation time will almost certainly include training the students, and perhaps some of the mentors. Explain this to the students up front.

Time:

How long is this going to take? That is a tough one. Skill levels, hours per week, number of workers, and other factors will determine that. If you work about six hours per week, and don't work during the summer, about two years (four semesters) should be a good estimate for a group of ten. Training time could add to this. Working during the summer could shorten this by a semester. For a group to do this project in one year would require a very heavy time commitment, perhaps four evenings or twelve hours per week. An estimate would be about 1800 worker-hours for average high school age students, about twice what it would take an individual.

I recommend that this be considered a learning process, not an aircraft factory. By taking more time, it may be possible to get more people involved. Involvement is a key to the overall success of this project. Having other departments (photography, journalism, etc) will not speed up the program, but will encourage more students. Your situation will dictate how much of this can be done.

Getting started:

Let's keep in mind the reason for building experimental aircraft—the FAA says that they are built for our “education and entertainment.” Never forget that. When it ceases to be fun, or when the learning stops, something will happened, and it probably won't be good. Keep it fun, and monitor the learning as much as the quality of the project. This should not be a problem!

It is likely this group will bond well during this project. Encourage activities outside the work environment occasionally if it seems appropriate. Everyone enjoys a pizza party now and then! Encourage parents to be involved. Expect a high level of pride in being a part of such an unusual and significant project.

I would suggest name tags for the students if they aren't known by all the mentors. Mentor name tags would help, also. Actually, name tags will be helpful for much of the project as you may have visitors talking with the students.

Van's will be made aware of your project and the people that may be contacting them. They will be helpful in many ways. Tell them who you are when we order the first kit. Now would be a good time to establish how you will log your build. ENP provides a copy of KitLog Pro, which is a good way to keep track of your build, and let the outside world know what you are doing. See Contacts and References.

The actual teaching process can be automated, and it is a good idea to use available aids. Consider how students take in information today. They are used to YouTube and probably get some of their training through video or PowerPoint presentations. There are huge amounts of information available to you to present to your students. Even if you have little idea of how to roll an edge on sheet metal, the EAA has done a video on it! Eagle's Nest will provide you instructional DVDs for use with each of your sub-kits. This is provided for in your start-up package. Helpful videos are listed with the training material, but the list may not be complete. New videos may be on line. We highly recommend the use of videos on the EAA website, over an above those available on YouTube and other sites. These are guaranteed to follow industry standards. Eagle's Nest provides instructional DVDs that we suggest you use, beginning with the DVD on tool use. The DVDs on the kits should be available for mentor use, and possibly for student use, as you see fit. They should not be used as a substitute for reading the instructions, and in some places they are known to be out of date (especially anything dealing with avionics and wiring.) While it is your call, we suggest that the mentors use the DVDs as an overview of each section. The DVDs are to be returned to Eagle's Nest when you finish with them.

Eagle's Nest has an agreement with Van's Aircraft to provide you with .pdf copies of the plans, all on one CD. We no longer provide paper copies prior to kit arrival These digital plans are great! They allow instant access to any page of the plans, at one location. While they are very helpful, MAKE SURE they have not been rendered obsolete. There may be a revision in the plans that has not appeared in digital format as yet. The plans that come with each sub-kit are the final say, and it is up to you to make sure everything is up-to-date. This will allow you to send plans home on flash drives, so students can study ahead. DO NOT ALLOW THESE TO BE TRANSMITTED TO ANYONE OUTSDIE YOUR GROUP! These are for Eagle's Nest build groups only, per agreement with Van's.

Use what ever technique you feel comfortable with to get your students up to speed. If you are a skilled RV-12 builder, you may not need automated help. See how YOUR group responds and learns. The MOST important thing to stress is to follow the instructions! You will find that most questions, especially early on, can be answered with, “Read the instructions.” Stress this often.

Teach not just how, but why things are done. The first rule we set during the very first session is an example. The rule was that we would only use Sharpies to mark parts. No pencils allowed. By telling the students that pencils cause corrosion, they understood why. There is a reason for almost everything you will be doing. The education only comes when those reasons are understood. “Just do it” should not be an answer. Remember that education is half of the reason we are doing this.

Remember that pilots use check lists! You are dealing with potential pilots here, and this is a good time to get into the checklist mindset. A checklist for closing at the end of each session might contain reminders about oiling the pneumatic tools as required, making sure all drill bits were returned to their place, tool boxes are locked, and that batteries were removed from battery chargers. Other items of course are up to you. Other checklists can help in overall organization.

Everyone wants to be a part of the building process. It is best for mentors to not do actual building early in the build. You are needed as a mentor, and it is difficult to break away if you are in the middle of a procedure. A good practice is to only do actual hands-on work to teach a skill, or when everyone knows the process and you aren't mentoring. Also, some processes, like drilling out rivets, can damage parts. It may be best to do these; weigh the risks and do what seems best.

You might begin each session with a review of what has been learned, or what mistakes were made during the last build session. Handouts can be passed out to each student. These should point out what should have been learned, and to some extent, the order in which it was learned. Examples are in a separate binder. Use them as appropriate. They are guidelines in that they can not account for the time element or size of the group. Some groups will progress faster, and you may have a longer or shorter work period. Also, your group may find totally new ways to make mistakes!

If you plan to give study assignments between sessions, consider sections of the basic builder's manuals. These can be important throughout the entire build. Studying a few pages of plans can also simplify life for the mentors during that particular work session. Basics are more important at first, specific instructions more so later.

Eagle's Nest Projects provides a CD with the complete plans set when you receive the first kit. This is free of charge. It will be helpful for you to study before the kit arrives. It may also point out areas that require special attention during the training sessions. Keep in mind it may not be current, and all instructions regarding the electrical system are obsolete. Van's can provide multiple copies of the plans when the kits are delivered, saving you from having to make your own copies. Be sure to order what you need. The digital plans may negate this need.

At this point, designate one copy the MASTER COPY. This is where all items are checked off as they are completed. This saves many headaches as the build progresses. Have one student responsible for making entries here, or one student per team. This is a good place to have a teacher or mentor verify the quality, just before the item is marked as finished. A Student Librarian can be a handy position here. This is discussed in the next section.

Student Organization:

While you may begin the learning process with a simple classroom structure, at some point it makes sense to organize the group. More will be accomplished, and there is the possibility of learning different skills. A team approach works well, especially during the first part of the project.

Each team should have two to four members. Each team should have a team leader, and perhaps a tool person. The team leader should be responsible for the majority of the decisions; who does what, etc. A tool person could be responsible for learning how to use new tools and teaching the other team members. They might also do set up, such as setting air compressor pressure, and get and put away tools as needed. All team members should have quality “no-go” say. Near the end of any particular sub-kit, all members of a team should have absorbed much of the knowledge of the other members.

Another person that should serve the entire group would be an inventory manager. If everyone is looking for the parts they need, much time is lost. One team may confiscate a parts bin and leave another team without what is needed to do their jobs. While the “parts guy” might be able to do other jobs at times, having one person knowing where/how things are stored can save lots of time. You will have to decide how you want to assign these tasks, although the inventory specialist (and perhaps a mentor working with him/her at least part time) should be chosen early. You may find that the parts manager can also manage and maintain the Master Copy of the instructions. This may allow them to have parts “picked” before they are even needed. NOTE: Eagle's Nest has done extensive study into the small parts storage situation. Our system works, if implemented early in the build process. Filling the bins properly is key; study the instructions on how to set it up before beginning.

It may expand the individual learning process if these positions can be swapped when moving from one sub-kit to the next. Note that switching jobs may not always be a good idea. If one team member develops good skills at one job, say, deburring holes, it may be wise to let that person “own” that job.

There may be individual jobs outside the team structure. These might include Tool Manager, Website Coordinator, Photographer, Librarian, or any number of other specialties. These could be full-time, or in conjunction with team duties. A small number of students might “float,” being available to fill in for absent students, or where an extra set of hands would come in handy. Much of this will depend on the size and makeup of your group. No one can organize your group but you.

The initial Eagle's Nest Project had a Project Manager, once into the actual build. While not absolutely necessary, it can also take some of the load off the mentors, and it gives someone experience at a higher level. Consider the learning process. At some time in their lives, most of these students will work in an environment with several levels of management. Virtually all will have a supervisor of some type. This project is a good way to develop management skills, and to allow practice having managerial responsibility.

There were several ways to approach having a student Project Manager. One way is to select someone who will be there for the entire project, providing continuity as older students graduate and leave the program. This rules out seniors as Project Manager. Another way would be to select a senior and, at the end of the school year, select someone to replace him or her. Other students may be more willing to follow the lead of an older student, and this is representative of the Real World. Managers come and go. Having a chance at promotion could be an important part of this style program.

A student Project Manager might be someone with less mechanical skills, but one who is highly organized. You will have to determine the criteria, and even if this is a position you want filled. We found our PM useful in keeping the teams staffed when there were absences, in making decisions on scheduling, requisitioning tools and supplies, and in public relations when we had visitors. Our PM had to record all steps in the Master Plans as they were completed. We feel the PM learned a great deal about management, and left with more confidence. We began the project with a senior as PM, and he did posses good mechanical skills. I can see his resume now: High School—Supervised the construction of a two-place all metal aircraft!

In short, we are not just building an airplane. We are building skills. Properly organized, your Eagle's Nest Project can promote learning on many levels. Management is one of them.

Options:

Be aware that there will be decisions that are purely optional during the build. To prime everything, prime only the joints, or prime nothing except what is required is an example. Another is whether to remove all the blue plastic before starting, or to only remove plastic from areas that will overlap or require work. It may be best to do your own research here, but briefly, if you are in a damp climate, priming is good. Priming adds weight, presents a mess factor, and can be hazardous, however. Removing the blue plastic saves time, but may expose parts to damage. Discussing these items with a local EAA Technical Counselor might be a good start in determining your choices. NAPA 7220 is a good option if minor priming is desired. Note that some parts MUST be primed, and are noted.

There are options available from Van's such as lighting, auto pilot, and interior panels and carpet. These are totally up to the owner of the project. Options such as wheel pants are usually best left until after the aircraft is completed, although this is still optional.

Practice Kits:

(Practice kits as supplier by Van's Aircraft are optional and one of several ways to train. This is included for those who wish to use them.)

Van's offers practice kits that are a great teaching tool, but are not structured toward RV-12 techniques. They can be a valuable teaching aid, but not necessary to build the RV-12. They may be used to gauge commitment and skills, or to teach instruction-reading and certain metal working skills. We hope in the future to have a kit especially for the RV-12.

These are $35 per kit, and each kit can be built by from one to three students. While these kits were made for practice on the other RV models, they can be used for the RV-12. About the only thing they lack is practice with nutplates, and they use only a few pulled rivets. They are in some ways more difficult than building the RV-12, and a good place to make the inevitable errors. Note that the mentors/supervisors should study these kits and the plans well before starting student training. They aren't as simple as they look! A “C” frame dimpler is needed for these kits, but not for the RV-12. If you do use these practice kits, contact ENP for a loaner C-frame.

Review the kits and their plans well. Pay special attention to the rivet call-outs as they are made for practice purposes and don't necessarily follow building logic. If you are unfamiliar with the kits, assemble one yourself, at least to the point where they are clecoed together. Determine what will be done first (from the plans) and prepare accordingly. We did not make the wooden tool called out as we were using a commercial edging tool. This is up to you. ALWAYS USE PROPER SAFETY PRECAUTIONS! Eye protection is mandatory.

Distribute tools as appropriate. With our students, tools, and supplies in place, we are ready to begin with the Practice Kits. First thing to do will be to separate items into piles with the proper parts to do one kit per student or team. Your kits probably all came in one box, so getting a “set” is important. Post one set of plans in a prominent place so that all students can view them without the clutter of plans everywhere. It might be helpful to have a kit semi-assembled to show what the finished product will look like. Each kit comes with its own set of plans, so keeping track of what is complete should be easy. This should be up to the individuals themselves and subject to review by the mentors.

Go over the first day's class program with the class and view any videos you feel are needed. Some suggestions are (click on) Rivets 101, Sheet Metal Tools 101, Hints for Homebuilders – Deburring Metal, Filing Aluminum, Removing Plastic Coating from Sheet Metal (if you are planning on removing area at a time) or others. ENP recommends Sheet Metal Tools 101 and Rivets 101 for the first session. These make life easier as they answer many common questions. You may of course skip the videos and do hands-on presentations of what has to be done. ((edit this for DVD location))

The first day the students should learn marking, measuring, and perhaps something of drilling aluminum. Stress keeping parts well identified (top, left end, etc.) and using Sharpies instead of pencils or scribes. Spend time learning to use clecos properly, and explain their color codes. Stress proper clamping while marking and drilling, and not drilling into fingers! Stress drilling all holes in a stack (multiple parts) at the same time. Show proper use of the deburring wheel (NOT to let a corner catch into the soft wheel and damage the part/cause injury.) Discuss reasons for deburring. This is a good time to introduce Van's aircraft plans, section 5, covered briefly in the Practice Kit.

It may be necessary to have different kits be done in different sequences, some having the edges deburred first, some marked and drilled first, etc. This can prevent too much waiting and wasted time. It is important that all kids get off to a good start, so this may be a stressful time for the mentors. Don't take on too much the first day! Stop production and talk about problems if necessary.

By the end of the first session, you will have learned more than the students! Do not be too critical of mistakes. If a hole is drilled too big, use a bigger rivet. If too near an edge, re-drill properly and forget it. Make sure the student knows the proper way and laugh it off. In this way, the student will learn the importance of paying close attention to instructions.

First session goals: Learn deburring of edges and holes. Learn how to use clecos and clamps, how to remove plastic coating, how to measure/mark holes, drill sizes (#30 & #40,) and how to drill. Perhaps learn dimpling. Discuss countersinking and how to determine if a countersink is deep enough. Don't expect to get to riveting.

In continuing sessions, begin with a review of what was learned previously. Point out problem areas, but not those having them. They will know. Show those videos appropriate to those advancing more rapidly, and work with those having more problems. An occasional “helping hand” may be necessary, but don't make it a habit. Let the students do all they can do. Learning is very important at this stage, more important than the finished product. Make sure each student understands his or her errors, and how to correct them. It may be best to have some of the students doing really well to help those struggling with certain things.

Note: A “C” frame may be used for many of the dimpling operations. This isn't one of the tools listed, and it really isn't necessary during construction of the RV-12. It does do an excellent job of dimpling, and it is very easy to use. If you have one, use it. There are many other tools that can be used. The educational value can be important, but we can't cover all possibilities.

As Time Goes On...

If you aren't a full-time teacher, you have some surprises in store, especially if you don't work with high school students regularly. Working with kids is fun! This must be obvious to you quickly if this is to be a successful project. A project leader must enjoy the prospect of spending many hours in close contact with the group. Just like the kids, the project leader is in for a long experience in “entertainment and education.”

You may find that some students do not stick with the program. While this may be disappointing, do not let it discourage you. A certain percentage may have to drop out for one reason or another. Often this can be due to conflicts in time, but lack of commitment (or just not enjoying the work) can happen. Not everyone is meant to be an aircraft builder. You will find replacements.

Take time to promote the project. Your local newspaper or radio station can be good sources of promotion. Keep track of local fly-ins. Almost any group will look at having an Eagle's Nest project on display as an attraction, and the kids will love the attention the project will bring. Even local fairs or festivals may offer you free booth space to promote the project. Do plan to be a big part of any in-school program like an Open House or Parents Day. ALWAYS have a donations pot! A five gallon water jug is perfect—no one will be tempted to wander off with it, and prospective donors can see how generous others have been.

Let local service clubs know about the build. They often need speakers, and you can present something they certainly have not seen before. Better yet, see if one or more of your students would be able to present the project. This is an incredible learning experience, and will impress the group more than you might imagine.

Plan for social functions outside the classroom. This should include local fly-ins, pizza parties, class trips to aviation-related schools or museums, or even trips to the big fly-ins such as Sun 'n Fun and Airventure Oshkosh. These will be enjoyable, educational, and chances to meet other builders and pilots. Airventure Oshkosh is a chance to meet other Eagle's Nest groups and see planes built by other high school students. These trips do take consider time, planning, and money, but are very worthwhile. One such trip during the build is strongly encouraged! Encourage the students to become Young Eagles and to join EAA (national) on-line. This is free to Young Eagles and necessary for a trip to Airventure Oshkosh. The Chief Mentor should help with membership paperwork.

If it is at all possible, students should participate in at least one trip to AirVenture Oshkosh. ENP will help coordinate trips, and will probably be able to secure free admission for the students. Mentors and others will be required to pay their own way. If such a trip is possible, you might consider making it a requirement to be in the program. AirVenture provides a great learning opportunity and growth experience for all involved.

Within a few months of beginning the build, you may find yourself referring to these young builders as “my kids.” You may find that their questions to you will go well beyond the things they need to know to build the RV-12. Some may be personal, and some may be calls for help in other areas of their lives. ENP does have a Chaplain that may be able to help, in some cases. Only you know how to handles these things in ways agreeable to both of you. Just don't be surprised...

You will experience highs and lows. So will the kids. You will all be thrilled at the completion of aspects of the project. You will be discouraged when a part is damaged or assembled incorrectly. Don't be. Take all setbacks as learning experiences.

It is important to not show favoritism to any of the students, and this can be difficult. You are coaching a team, and everyone must play. Keep the relationships as even as possible. It is probable that, by the end of the build, you will have many new young friends.

At the end of the build, you should plan a “graduation” celebration. After all these hours and months, the project is complete! It is time to consider how the students will feel. They will be proud and happy, but there will be a let-down. What next? Eagle's Next provides each student remaining through the program (as determined by the project leaders) a Certificate of Accomplishment. It would be appropriate to have a social function, whether a formal dinner or less formal is up to you, and recognize the builders and mentors. Eagle's Nest may be able to provide a speaker for the function. Former Astronaut Robert “Hoot” Gibson spoke at the graduation of the Eagle's Nest One crew. Hoot is President of our parent organization.

Then (or possibly even sooner) you will want to enroll the builders who qualify in Sporty's Ground School. This is great preparation for testing for their Sport Pilot License. Remember that qualified builders are eligible for pilot training, either in the original Eagle's Nest One, or the plane they have completed. Stress that passing the written exam IS required, and that it requires extensive study.

We highly recommend that a field trip to AirVenture Oshkosh be a required part of this program. This should be passed on to both students and parents early in the project. Costs of this trip will be in the range of $300-$500, depending on travel costs, less the cost of items provided (passes, etc) by either EAA or ENP. Do not let cost prevent a student from attending! Find a way...

Paperwork

We have discussed keeping records of things as each instruction is finished. Other records that may be important include attendance. This can be used to select people for special things like field trips. A Commitment Letter (see Attachment Four for an example) can be an encouragement, and is a good way to let parents know what the students will be doing. To be a “legal” Eagle's Nest Project, you must agree to our very basic requirements, as spelled out in Attachment Five. This is proof of your desire to promote youth aviation.

Keeping accurate records of each step as it is completed is important when registering your finished aircraft. Assign someone to this. It may be the Chief mentor, and other mentor, the student Project Manager, or perhaps the librarian. The final inspection and registration paperwork will come very late in the build process.

Problem Areas:

There are things that will slow you down. We will note a few, and hopefully their solutions.

Finding parts. Large parts cause little problem... IF they are properly marked when the blue plastic is removed. Mark each with a Sharpie as the plastic is removed. Store them in the original packing containers if possible. Medium sized parts can be stored in any convenient box. Small parts (those items that can be put into bins) are most easily found by someone who does it all the time. A Parts Manager (or whatever name you wish) makes this better, along with our Parts Organizer Package. HIGHLY recommended!

Installing the wrong nutplates. Spend extra time here, teaching exactly how to locate and identify nutplates. The same is true with washers and screws, but they do not require as much work to replace.

Over-deburring holes is something to watch for. Deburr, don't countersink! One or two turns of the tools is all that is necessary. Teach this very carefully during the early stages, and check from time to time. Deburring in general is a time consuming task, and not as simple as it seems. Stress proper deburring.

Not reading the instructions is usually the underlying reason for all errors. Skipping steps with the idea of coming back to finish a step later may work (and will be necessary at times,) but it can get you into trouble. Avoid this as much as possible. Mentors, watch the DVDs! Keep in mind that much HAS changed in wiring and on other parts of the finish kit videos, however. The instruction sheets that come with each kit are the final word!

Most errors can be fixed easily. Sometimes it may require buying a replacement part, and usually it will involve disassembly, and wasted time. Some errors are worse than others, causing great loss of time and (in cases like the canopy or cowl) can cost lots of money. Pay particular attention when large assemblies go together, and when large parts are fitted. It would be a shame to have to replace the wing carry-through because of mis-drilled holes! Not so much with a rib or other small part.

Areas that require extra vigilance include the spars, large skins (extra shipping costs,) canopy and frame, and the fuselage longerons. The longerons are very critical to the overall strength of the aircraft, and even the look and fit. An error in shaping a longeron would cause days of rework, if not a great deal of money. Follow the directions exactly, but ask for the longeron dies we provide on loan. They greatly simplify this task, and make a better product.

Skins are often damaged by getting in a hurry removing the blue plastic covering. Only pull from close to the skins, not at a large angle. They are easily dented or buckled if not done correctly. NEVER get in a hurry when removing plastic coatings! TEACH THIS EARLY!

Pay special attention to use of the 3M deburring wheel. This is the most powerful tool that is used extensively in the build. Not only can parts be ground away, but improper use can catch and throw parts, creating a danger of injury to both the part, operator, and bystanders. Always move the part AGAINST the direction of rotation of the wheel. Do not allow a corner to “catch” the wheel. Watch the “Hints for Homebuilders” video on the EAA website titled “Sheet Metal Tools 101” under the sheet metal section. Multiple grooves are better than using only one groove. This greatly extends the life of the wheel (times the number of grooves!)

Cutting hinges: It is possible to cut a hinge the right length, but with the end tabs all wrong. LOOK AT THE DRAWING! Cutting one wrong is a sure way to have to order more, costing money and slowing down the process. Same is true for drilling hinges in the servo tabs. Pay close attention to alignment and spacing.

Late in the process, engine mount bolts require special care. While not called out in the plans, blue Locktite will prevent loosening. Proper torquing is very important.

List of other videos that may be helpful in avoiding problems, all in the sheet metal section. These are good training for both the students and new mentors:

Sheet Metal tools 101

Rivets 101

Riveting 101

Blind Rivet Identification

Deburring Metal

Drilling out a Rivet

Drilling out a Driven Rivet

Filing aluminum

Microstop Countersink Basics

Installing a Nut in a Hard to Reach Place

Keep in mind that not everything is obvious, nor are airplanes like automobiles. An example would be the wheel bearings. They are NOT tightened the same as those, say, on a boat trailer. Do not assume, and don't let your students assume, either! I can almost guarantee at least one number three bolt being twisted off even though the wrench was hardly bending! Stress using the torque wrench. These are areas where the mentor must watch. This even gets into safety and reliability issues. KNOW that your students know how to properly tighten things. CHECK critical areas. I read something once—I think it was, “Trust, but verify.” Perhaps a good motto.

Attachment One:

Here is Van's tool list (from the RV-12 plans, not relevant for a group build, and for reference only:)

1X 6" Bench Vise

10X Small (2") "C" clamps

4X Large (3") spring or "pony clamps

350X #30 clecos

50X #40 clecos

1X 3/32 rivet dimple die set (should include a reduced dia. female die)

1X 1/8 protuding head rivet set (tall, 1/2" thick)

1X 1/8 rivet dimple die set (100°)

1X #6 screw dimple die set

1X #8 screw dimple die set

2X Flush head rivet set (short, 1/8" thick)

1X Flush head rivet set (tall, 1/2" thick)

1X #3 drill bit

1X #11 drill bit

2X #12 drill bit

1X #16 drill bit

2X #19 drill bit

1X #27 drill bit

3X #30 drill bit

1X 12" extension drill #30

1X #36 drill bit

5X #40 drill bit

1X #52 drill bit

1X 1/4" drill bit

1X 5/16" drill bit

1X Q or 11/32nd drill bit

1X 3/8" drill bit

1X 1/4" to 3/4" X 1/16 step drill (Unibit)

1X 100° machine countersink cutter with #12 pilot

1X 100° machine countersink cutter with #19 pilot

1X 100° machine countersink cutter with #27 pilot

1X 120° machine countersink cutter with #30 pilot

1X 100° machine countersink cutter with #30 pilot

1X 100° machine countersink cutter with #40 pilot

1X Countersink cage

1X 1/4-28 tap

1X 5/16-24 tap

1X 3/8-16 tap

1X 3/8-24 tap

1X 6-32 tap

1X 10-24 tap

1X T-handle for taps

1X Fish scale (0-50lbs)

1X Files (assorted)

1X Hacksaw with fine tooth (32 teeth per inch) blade

1X Hand blind rivet puller "POP" Riveter PRP-26A, USM Corp.

1X Hand solid rivet squeezer with 3" yoke

1X Fluting pliers

1X Combination wrench set (1/4"-3/4" & 10mm-17mm)

1X Cleco pliers

1X Hand Seamer

1X Torque wrench (inch pounds scale)

1X Heavy soft faced hammer

1X Deburring countersink tool with flute cutter

1X Multi-burr deburring tool (Royal style)

1X Screwdriver with #2 phillips bit

1X Allen wrenches, assorted (inch & metric)

1X Feeler guages: .012-.016in.

1X 12' Tape measure

1X Needlenose pliers

1X Diagonal cutter

1X Olfa RTY-2/G 45mm Rotary Cutter (or equivalent)

1X Left hand offset metal cutting snips

1X Right hand offset metal cutting snips

1X Wire crimper/stripper

1X Multimeter (with continuity check capability)

1X Carburetor Synchronizing Too

1X 1/4" drive socket set (with inch & metric sockets)

1X Battery powered drill motor

1X Aviation flaring tool (tube)

1X Tubing cutter

1X Tubing bender

1X Socket and ratchet handle for 1 1/4" nut (big!)

1X Allen Sockets: 4mm, 5mm, 8mm

1X Socket 19mm (3/4in)

Note that this list is intended for an individual and is not sufficient for a group build.

Attachment Two:

Eagle's Nest Group-Build tool list (for a group of six to ten, may be customized)

350 1017 1/8" (#30) CLECO FASTENER

50 1016 3/32” (#40) CLECO FASTENER

1 3/32 DDS 3/32 SPRING BACK DIMPLE DIE SET

1 3/32 FEMALE X 3/8” DIAMETER SPRING BACK DIMPLE DIE

1 1/8 SPRING BACK DIMPLE DIE SET

1#8 SPRING BACK DIMPLE DIE SET

1 1602 SP 1/8" Tall CUP SQUEEZER SET

1 1621 1/8" FLUSH SQUEEZER SET

1 1623 1/4” FLUSH SQUEEZER SET

1 1627 1/2" FLUSH SQUEEZER SET

1X #3 drill bit

1X #11 drill bit

2X #12 drill bit

2X #16 drill bit

2X #19 drill bit

1X #27 drill bit

3X #30 drill bit

1X 12" extension drill #30

1X #36 drill bit

5X #40 drill bit

1X #52 drill bit

1X 1/4" drill bit

1X 5/16" drill bit

1X Q or 11/32nd drill bit

1X 3/8" drill bit

1 11076 #40 PLASTIC Drill

1 11077 #27 PLASTIC Drill

1 15357 1/4" UNDER SIZE REAMER

1X UBX3 UNIBIT #3 STEP Drill

1X 100° machine countersink cutter with #12 pilot

1X 100° machine countersink cutter with #19 pilot

1X 100° machine countersink cutter with #27 pilot

1 30-120 "SPECIAL" ANGLE COUNTERSINK CUTTER #30 X 120 DEGREE

1X 100° machine countersink cutter with #30 pilot

1X 100° machine countersink cutter with #40 pilot

2X 19360 MICRO-STOP C'SINK CAGE

1X 1/4-28 tap

1X 5/16-24 tap

1X 3/8-16 tap

1X 3/8-24 tap

1X 6-32 tap

1X 10-24 tap

2 60300 PAN AMERICAN MINI PALM 1/4" AIR Drill 2600RPM

2 7891 PNEUMATIC POP RIVET Puller

1 3753 SIB CUTTING & POLISHING WHEEL

2 7447 SIB GEN. PURPOSE HAND PADS

1 72758 6 PC. 4" SMOOTH FILE SET

1 4510 SMALL BLOCK FOR DIES & SETS -10 HOLES

6 1046 SPEED DEBURR & C'SINK TOOL

2 22022 ROYAL MULTI-BURR TOOL /w 5 BLA

6 200 CLECO PLIER w/ MOLDED GRIPS

1 9400 RIVET SQUEEZER

1 7730 3" PNEUMATIC SQUEEZER YOKE

1 P26A POWERLINK TIGHT-SPACE POP RIVET TOOL

1 4910 MICRO-ADJUSTABLE TORQUE WRENCH 20 – 150 IN. LB.

5 1014 1/2" X l' SIDE GRIP CLECO CLAMP

5 1012 1/2" X 1/2" SIDE GRIP CLECO CLAMP

1 6510L Midwest offset metal snips left

1 6510R Midwest offset metal snips right

1 1042 Edge seamer

1 515 Fluting pliers

1 575 Hand seamer

1 41011 TP Magnetic Finger

1 23800 Washer Wrench Set

1 Small parts storage system (supplied by Eagle's Nest)

Purchase locally:

Vise (6” is best, good quality)

10X Small (2") "C" clamps

4X Large (3") spring or "pony” clamps

Several cordless drills (optional, but handy)

Calipers

Measuring tapes

Rulers

Wiring crimper (best source, SteinAir, see contacts list)

Various hand tools

1/4” and 3/8” drive sockets

wrenches, std. and Allen

screw drivers

hacksaw

soft-faced hammer

small punch

spring “clicker” center punch (handy for removing rivets)

Tool storage cabinet (roll-away is handy)

Bench sander (disc/belt)

1/2” shaft grinder (Heavy-duty not needed)

Drill Press (may be used in place of grinder to power 3M wheel, with proper adapter)

Band saw (optional)

Available for loan*:

1 470-FM IMPERIAL EASTMAN TUBING BENDER (up to a month loan)

Tube flairing tool (up to one month, comes with tubing bender.)

Scales for weight and balance (one week loan)

Longeron dies (one week loan)

Heavy-duty torque wrench (use with engine kit, one week loan)

* (Loan only to those purchasing Avery-supplied Tool Kit)

Note that all items will be ordered from Avery as a kit for you as part of the startup package. If you have the necessary tools, contact us. Buying the startup package assures you the proper quality and quantity of tools, plus gives you access to “loaner” specialty tools. Lowe's, among other suppliers, has the other tools you may need.

Attachment Three: (Probably incomplete)

(Supplies needed as listed in Van's RV-12 plans)

For Kit: Item:

All 1 box Sharpie pen - fine point; blue or black

All 1 box Sharpie pen - extra fine point; blue or black

All 1 roll Low-tack "painters" masking tape

Emp 1 roll String

Emp 1 tube Super glue

Emp 1X Rectangle sanding block

Emp 1X Cylindrical sanding block; 1 - 1 1/4 Dia.

All 1 tube Boelube*

Fuse 1 can Pipe Thread Sealant (NOT TEFLON TAPE!)

Fuse 1 can Fuel Tank Sealant**

Fuse 1 tube Firewall Sealant* (may substitute equivalent 3-M product from Home Depot)

All 1 tube RTV Sealant

Pwr Plnt 1 tube Clear Silicone

Pwr Plnt 10 ml Loctite 221

Wing 10 ml Loctite 243

Pwr Plnt 1 tube Loctite Heavy Duty Anti-Seize

Finish 3 yd 9oz/sq yd plain weave "E-glass" fabric*

Finish 1 yd Peel ply (optional)*

Finish 1 qt kit of epoxy resin & hardener*

Finish 1 qt Acetone (for clean-up)

Finish 25 Mixing cups (Solo™ clear plastic cups recycle code #1 or #5)

Finish 50 Craft sticks (a.k.a. popsicle sticks)

Finish 1/4 lb flocked cotton fiber (a.k.a. "flox")*

Finish 1/4 lb glass spheres (a.k.a. "micro-balloons")*

Finish 1 roll Mylar Packing Tape

Finish 1 roll Duct tape

Finish 1X Balloon (Fuel tank test)

Finish 1X 8 x 36 Protective paper

Finish 1X 8 1/2 x 11 sheet of 60 grit sandpaper

Finish 2X 8 1/2 x 11 sheet of 80 grit sandpaper

Finish 2X 8 1/2 x 11 sheet of 100 grit sandpaper

Finish 1X 8 1/2 x 11 sheet of 150 grit sandpaper

Finish 2X 8 1/2 x 11 sheet of 220 grit sandpaper

Finish 3X 1" wide paint brush (cheap, natural bristle type)

Finish 1X 2" wide paint brush (cheap, natural bristle type)

Finish 1X 3" wide paint brush (cheap, natural bristle type)

Note that some items may be ordered from Van's. Most are available from any aviation supply house. Many items are best purchased locally. Those items marked with an asterisk (*) should be purchased from an aviation supply house. Aircraft Spruce is one of many sources. Items marked with a double asterisk (**) should be purchased from Van's when needed (shelf life is a concern.) (We may source these, but haven't yet.)

Attachment Four (Example)

Eagle's Nest Builder,

Welcome aboard! For the next year, you will be doing something only a tiny percentage of students ever get to do—you will be building an airplane! This may be your first project that is totally outside your comfort zone. It will require more commitment than anything you have ever done, but the rewards will be worth it!

An airplane is an interesting an exciting thing, but it begins as just a bunch of parts. Your job will be to put them all together. You will be part of a team, and as such, you must all learn to work together. This means you will check their work, and they will check yours. Since you have not done this before, you will not be the final judge of your work. You will follow the lead of your mentors and leaders. Following instructions is not only important, it is mandatory.

This airplane will be safe and useful. It is an excellent design. Nothing will be accepted that would in any way change that. The quality and beauty of your work, however, will reflect your commitment to excellence. It will be seen by many pilots who have built aircraft similar to this. This airplane will be a reflection of YOU!

This project demands a commitment on your time. While we understand that your school work must come first, and that you have other outside activities, this must be high on your list of priorities. Your team members will be counting on you. Keep in mind that, if your grades slip, you may not be able to continue with this program, so make sure you are ready to dig deep into your spare time.

Why should you do this? Nothing can beat the pride of great accomplishment, and this will be just that. Also, you will be eligible for field trips, airplane rides and participation in other activities. You will make new and interesting friends. You may even be able to get your pilot's license—free!

All that we ask is that you agree to do your best and attend work sessions regularly if at all possible. You will be expected to follow all safety procedures, and to work to the best of your ability. By becoming part of the Eagle's Nest Team, you agree to this. At times, you may be required to get permission slips from your parents. We expect your cooperation here also.

Welcome to the Eagle's Nest!

_____________________, Chief Mentor

Student Name/Signature_______________________/______________________________

Parent Name/Signature________________________/______________________________

Date__________________

Attachment Five (Example only, VERY preliminary)

I, ____________________, desire to build a Van's RV-12 aircraft under the Eagle's Nest Projects educational program . In doing so, I promise that this aircraft will be built by students for their education and entertainment, and that the program will be properly supervised and directed by responsible adults. I further agree that this project will be completed within a reasonable time frame (less than three years unless special conditions dictate otherwise.) I understand that prices may fluctuate if this time is exceeded. I understand that all major transactions will be with and through Eagle's Nest. This includes aircraft kit and tool kit purchases, all of which will be negotiated separately. ENP will work with the suppliers to set shipping schedules. Mounted and or stationary tools are not included in this agreement. Supplied tool kits will remain the property of the builder as long as Eagle's Nest Projects are being built. After that time, Eagle's Nest may request they be returned for use by other builders. Stationary tools and tool chests may be available through our agreement with Lowe's. Tell us your needs and these may be available for the cost of shipping.

I agree that this aircraft will be under the control of Eagle's Nest Projects until its completion, and that all directives from ENP and Van's Aircraft will be observed. Final ownership of said aircraft will be determined prior to that start of construction, but will not occur until airworthiness has been established. I further agree that this aircraft may be used to promote the ENP/Friends of the RV-1 organization upon its completion, but that this shall not detract from its eventual use and/or sale. Such promotion may include displaying the finished aircraft at AirVenture Oshkosh. All such expenses would be the responsibility of ENP/Friends of the RV-1.

Any and all options may be added during the build at my choice, and I agree to pay the amount listed on Van's price list for these items unless otherwise agreed upon. There will be no charge for labor. I agree to decorate the vertical stabilizer of the finished aircraft as directed by Eagle's Nest for a period of three years from date of first flight. Interior and remaining exterior colors will be my choice. Painting costs in excess of standard are my responsibility.

I agree to hold ENP/Friends of the RV-1, its officers and Directors, mentors and all others involved harmless in all things, and to provide necessary insurance and security and safety procedures.

Signed_______________________, Date___________

Location of build: _____________________________________

Attachment Six: ( PRELIMINARY)

Things Eagle's Nest Projects provide: (As of 6/10/12)

Umbrella membership in 501(c)(3) non-profit organization

Protection

Allows donations to be tax-deductible

Team status

Family status!

Startup help

Startup manual

Complete RV-12 plans set on CD (pdf format, unavailable except through ENP) for training/study

Tool needs determination and sourcing, customized for your size group.

Possible financial help

Direct ordering of aircraft kits

Help finding mentors

Free website software

Free building DVDs from Homebuilt Help

Free Parts storage system!

Misc references books

18” X 24” “Eagle's Nest Project” sign

Tool loans for specialty tools

Heavy-duty torque wrench

Longeron dies

Weighing scales

Tubing tools

Personal identity items (Tee shirts, etc.)

Possible used tools, including larger power tools

Training aids

Oshkosh Airventure planning help (possible financial help for students)

Signs and promotional literature.

Scholarship possibilities for students

Ongoing technical assistance

Painting services for the finished aircraft

Help in selling finished aircraft if needed

Certificates of Accomplishment for student graduation

Student flight training

Other assistance as necessary

Contacts and References:

EAA Websites:

To join EAA: Go to

To join AOPA AV8Rs: Go to av8rs/

Technical Counselors: To find a Tech Counselors in your area, go to and select your state and area.

EAA Chapters: To find an EAA chapter in your area, go to

EAA sheet metal videos: For video helpful to building the RV-12, go to

and select as needed

Suppliers mentioned:

Cleaveland Tools:

Avery Tools:

Aircraft Spruce and Specialty:

Stein Air:

RV General Interest Websites:

Van's:

Van's Air Force:

KitLog Pro

Friends of the RV-1 RV-

Ernie Butcher, Director, FoRV-1 (713) 823-9509

Bob Kelly, Founder and Chief Mentor, Eagle's Nest Project: (812) 392-2860 or (812) 701-5454 (cell) vbob1@

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