Chapter 1 - Introduction

Congratulations on your decision to build a Super2. The purpose of this manual is to give you a step-by-step explanation of every construction procedure. With any project of this size, however, questions may arise and we want to encourage you to use the resources that are available on the Internet to get the answers you need before proceeding. The construction of the Super2 can be a very educational and rewarding experience.



There are two very distinct approaches that builders take towards a project such as this. The first approach is to hurry and rush the project along, constantly anticipating the actual enjoyment of flying the airplane. Builders who fall into this category typically start off with a big burst of energy and progress, but get easily discouraged because they keep looking too far ahead rather than taking it slowly and carefully concentrating on each step at a time. The quality of workmanship in this category will suffer unless the builder has a lot of previous experience. There is a definite "frustration factor" which is normal here also. We typically find that the frustrated builders are the ones who really don't find any enjoyment in the building, but just want to hurry through the construction so they can finally have fun in their airplane. Although finishing the aircraft is certainly everyone's goal, and is ultimately the catalyst which keeps the project progressing, the building of the Super2 can be just as rewarding as flying it if the right attitude is present from the start. The second approach (and the one which we promote) is for each builder to have the desire to learn as much as they possibly can about the airframe, powerplant, and all the relating systems which make up the aircraft. If this desire is not there at the start, develop the desire as the project progresses. The project should be something each builder wants to do in order to develop a solid sense of confidence in the airframe, and to develop more confidence in his or her abilities. If craftsmanship was never a strong point, then make it a goal to attain during the project. The important point to remember is: make the construction phase of the Super2 project something you want to do and find some relaxation, reward, and enjoyment in doing. In the end, you will be an improved person for it and have a much better aircraft to enjoy. Before beginning construction read this section and the following Fabrication Techniques section thoroughly. Pay close attention to the safety precautions listed in this section.

General considerations

Prior to beginning any construction the following general instructions should be considered.

    • We suggest studying each individual assembly sections prior to beginning construction. This will give the builder a thorough understanding of what is to be accomplished, and will avoid any surprises.
    • Make sure all the tools and materials required are on hand.
    • Proceed in a stepwise manner paying close attention to the WARNINGS, CAUTIONS, AND NOTES.
    • After completing each task listed int the individual assembly sections (such as fuselage or wing assembly) place a check mark in the little square box following "COMPLETED". As a result, the builder will always know where he has left off. (If you also note the date and time, this will make an excellent building log to support inspection and sign-off of your project.)


Avoid breathing the fiberglass particles while sanding or filing the fiberglass. Use a paper particle mask available at most hardware stores. The strong vapor smell of the resin before it cures is from the styrene in the resin as it evaporates away. Always laminate in a well-ventilated area. High concentrations of styrene in small enclosed areas may cause nausea. Avoid breathing these vapors when high concentrations exist. We recommend the use of a vapor respirator which is available at most hardware stores. We also recommend that construction be done in a garage, or area separate from living quarters, because of the vapors present.


The materials used in fiberglass construction are highly flammable, especially the acetone used to clean tools. Keep them away from direct sunlight, heat, sparks, and open flame. Keep track of all materials and store them in a cool, clean, well-ventilated area. Make sure all containers are sealed when not in use.

When resin gels and then exotherms, enough heat may be generated to cause a fire. None of the lay ups on the Super2 pose a problem because they are not thick enough. The only time this could be a problem is when a large batch of epoxy is used in a container, coupled with high temperatures.

DO NOT throw away catalyzed resin before it has gelled, exothermed, and cooled. If you have a pot of uncured resin left over after a laminating procedure, let it gel on a concrete floor before discarding.


Lead is used for the control surface counterweights in the Super2. Lead is a poison that can enter the body either through inhalation or ingestion. Repeated exposures to lead over time can result in accumulation in the body. The effects of exposure to lead include (in approximate order of increasing severity) loss of appetite, weakness and tiredness, insomnia, muscle and joint pain, frequent headaches, tremors, numbness, dizziness, vomiting, poor memory, irritability, and seizures. Overexposure to lead can damage the reproductive systems of both men and women. Birth defects, miscarriages, or stillbirth can occur if either parent was overexposed to lead.
Although it is unlikely that fabricating the control surface counterweights will result in overexposure to lead, it is wise to observe the following precautions: After handling lead, scrub your hands thoroughly before eating, drinking, or smoking. Clean your work area thoroughly after working with lead, carefully bagging any shavings or filings for disposal. Brush your clothing and shoes to remove lead shavings before going into your home from your workshop. Since lead poses a special risk to children whose nervous systems are still developing, banish children and pregnant women from your workshop when working with lead. Store lead in an out-of-the-way place (preferably in a sealed and marked container) where you won't come into routine contact with it. Keep lead out of the reach of children.