Aviation products pedal planes

Aviation products pedal planes DEFAULT

Pedal Planes



Welcome To the group!

For those who have joined and want to build a pedal plane, but do not know where to start, here are some links to get the inspiration and ideas flowing.

Some companies that offer pedal plane kits, plans, and parts:


Aviation Products, Inc. (Link above) They are pretty much the "Gold Standard" and the company that is most known and utilized, but that is not saying they are all you have for options. Numerous kits and plans are available. This group is in no way affiliated with Aviation Products, Inc., so please do not ask me questions with regard to that.


Trace Tucker: Trace offers both a beautiful Stearman and P-51, as well as a superb P-40 at his Etsy site (link above). You will save time and money building one of his ships. They are very attractive and you will cut your build time down considerably with his kits. Please consider his kits if you are new to woodworking, as I found out the hard way, there was a lot of unseen cost in the build when I needed power tools for the build.

Thanks to Kevin Dahlhausen for pointing out this beautiful RV Pedal plane kit: http://www.thepedalrv.com/


The Stevenson Projects page *link above) has a biplane that can be modified to make a parasol (top wing only). This build is a little larger than the Aviation Products build as well. (Thank you Doug Eliason for pointing this one out!)

A great source for parts for your pedal planes wheels, and a place to find metal replacement parts for some manufactured pedal planes can be found here: https://pedalcarworld.wixsite.com/pedalcarworld

If you all find out more plans location, please feel free to share, and I will add it to this pinned page. I excluded individual eBay, Craigslist, Etsy, and Amazon links, as they are infrequently a place that has the plans reliably or often, but you can also occasionally find plans and kits on those websites as well.

Please refrain from asking specifics, such as linkage questions or pictures, unless you own a copy of Aviation Products, Inc plans. Please do not share Aviation Products, Inc plans (in picture form) on here. I ask this to not cause any reason to have litigation brought onto this group.

For those that think that building a pedal plane is a daunting task, mine was my first real wood working project. I didn't have any of the right tools when I started mine! You can do it! Here's my build log, in reverse chronological order. If I can do it, you can too!


Welcome to the forum and have fun!


Scott Shea

Sours: https://www.facebook.com/groups/PedalPlanes/posts/10153899030268427/

I really enjoy passing on the love of aviation to young people. I fly Young Eagles every chance I get and recently decided to immerse my granddaughter in aviation. For her first birthday, I bought her a plush Dusty Crophopper from the Disney movie Planes. This year was her third birthday, and I thought she might be old enough for a pedal plane.

I bought the plans for a Christen Eagle from Aviation Products (www.pedalplanekits.com) when my youngest son was about 3. I was still building my Cozy, so I didn’t have time to build both. The Cozy took priority, and I never built the pedal plane. I hung on to the plans, just because. When my granddaughter showed some interest, I decided it would be worth pursuing. I hoped she would appreciate the gift.

Landing gear and wheelpant parts with bearings.

The plans from Aviation Products are amazing—very detailed and complete. They outline everything that needs to be done. Aviation Products also offers kits for things that some builders may not feel comfortable fabricating. I thought I would be able to fabricate the whole aircraft myself. I have moderate woodworking skills, OK metal fabricating skills, and adequate welding skills. I thought I could build the plane in about four to six weeks, so I backed up six weeks from her birthday and got started.

The first thing I needed was a sheet of 3/8-inch AC plywood. None of the building centers in my area stocked it, so I special ordered it. I knew I needed AC to get a smooth surface for the pilots to touch. A lower quality board would be too rough. I also bought the metal and a 1×10 board for the wheelpants and nose.

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Fuselage after initial sawing with bulkheads in place.

Control System, Landing Gear and Crankshaft

I started working on the gear legs and the controls. The controls are made from thin-wall conduit, which is very easy to fabricate. Cut the tubing to length and squash the ends where the bolts will connect the parts together. There is a bellcrank that needs to be welded, so this was my first chance to try some welding on this project. I did an adequate job, and it came out quite strong, but I had things out of phase, so it had to be redone. After getting all the controls done, I made the two cabane struts, again out of conduit. Some bends around a squashed section in the middle where the wing attaches came out very nice.

Test fitting the control system.

Next, I started on the landing gear struts. I followed the plans, and because I hadn’t purchased the wheels, I didn’t know how big the bearing was going to be. Once I found the right sized wheels, I found the plans were correct, and I was able to put the wheel bearings in place without any modifications. The drive wheel has both bearings removed and a nut welded to a washer for the replacement. The nut screws to the pedal crankshaft, and another nut has the threads drilled out. Welding the wheel was tougher than the conduit. The sheet metal used for fabricating the hub of the lawnmower wheel is very thin, and the washer is about four times thicker. Managing the heat was much harder.

Fabricating the crankshaft for the pedals was a fun challenge. I had never tried to bend solid half-inch bar stock like that. Building a jig was the key, and using lots of heat at the bend locations made it come out pretty accurate. Afterwards, cutting to length was done with an angle grinder. One end is threaded for attaching to the drive wheel.

Fuselage, Tail Feathers and Wings

The plywood showed up about this time. The plans come with full-size templates, so laying out the parts is easy. I taped the templates to the plywood and traced them. Where the plans had straight lines, I used a straightedge to be sure everything was as straight as possible. I did most of the rough cutting with a sabre saw, and then finish cutting on a band saw. Some parts wouldn’t fit in the band saw, so I put a finer blade in the sabre saw and cut closer to the edges.

Sides are bent using an iron and wet cloth.

The fuselage sides have dados for the bulkheads and a bend just behind the cockpit. I cut the dados on a table saw. The plans have you build a jig for the bend, then suggest using an iron and wet cloth to steam the area. I thought bending the plywood fuselage sides would take hours. Using the method suggested, it took about 15 minutes per side. I left each side under pressure overnight.

Fuselage in jig for alignment.

With all the parts cut and fabricated, I could start assembly. There was a fuselage assembly jig in the plans that was ideal for getting everything square and tight. That assembly was critical for later steps. A little gluing and clamping ensured the fuselage and bulkheads were assembled square in all directions.

Initial assembly is square and tight.

The joint used for the rudder and horizontal stabilizer was perfect if cut correctly. I was shocked how tight, square, and well locked it was when I first dry assembled it. I considered not gluing the joint because it was so hard to get apart. I did finally get it apart and glued properly. The slot in the back of the fuselage needed no additional trimming when I slid the tail assembly in place.

Removing the fuselage from the jig only took a couple screws. I was able to work on the bottom of the fuselage at this point. There was a block that needed to be fabricated out of two pieces of

plywood and four dowels for the bellcrank. Clamping and gluing allowed that part to come out strong, then it was screwed to the seatback bulkhead.

Many parts are assembled with hardwood dowels, as the places where screws will penetrate the plywood from the side may cause the plys to split. The locations in the plans are exactly where they need to be to prevent the split and give a strong joint. I wanted to be flexible and wait until assembly before committing to the dowel location, but the location worked out to be in the correct place every time.

By following the plans, the rear cover and mid cover fit well.

The wings and parts of the fuselage need the edges rounded. Using 80-grit sandpaper and a good sanding block made all of the edges round. Most of the plywood shaping was done by hand with the block. It wasn’t hard and gave me control to not sand where I shouldn’t.

The plans insisted on making everything soft for the pilots of this airplane. Most of the screws were flush, with some round head. The sharp pointy end never protrudes where the pilot can come in contact with it. The threaded bolts in the landing gear struts were almost flush when coming through the steel. Even in places where little mechanics might want to fiddle with things, there was nothing that should hurt them.

The gear legs went into the holes in the sides of the fuselage exactly where they were drawn in the template. I didn’t always get the holes in two parts exactly where the plans drew them, but the holes had enough tolerance to allow assembly to be completed. The gear leg has a wheelpant bracket as part of the design. This bracket is also where the crankshaft bearings attach. The designer thought that some pilots might be shorter than others, so the gear legs have two sets of holes. The top holes allow the pedals to be closer to the pilot, and the bottom holes allow taller pilots to have comfort. As the pilot grows, the position can be adjusted.

Rough shape of nose bowl with cowling fitted and riveted.

Wheelpants, Cowl and Tail Fairing

Fabricating the wheelpants and nose took some real woodworking skills. Both the wheelpants and forward section of the cowl are laminated 3/4-inch pine boards that need to be shaped. I tried spokeshaves, chisels, and various planes, but settled on a power belt sander with 40-grit sandpaper for most of the shaping. The belt sander worked, but I am sure there would be better ways to do it. When I was done, I had a couple inches of dust on everything in the garage.

Wheelpants before and after rough shaping.

Shaping with a sander leaves a mess.

When all the wood was shaped and assembled, the sheet metal work began. The top and bottom of the cowl are covered with an aluminum skin. The plans have patterns for all the aluminum parts as well. The rear part of the fuselage was the first part I covered. The pattern was spot on and took no more trimming than the instructions said it might. The mid-cowl has a cabane strut through it and required oval holes. This worried me; metal to metal, there isn’t much forgiveness, but again the patterns were spot on.

The lower cowl was flared around the exhaust area, and the bending tool was built according to the instructions. This bending tool was used around the edges of the top cowl as well, so there are no sharp edges exposed for little pilots or mechanics to get cut on. Something didn’t quite work out with my top cowl, and I needed to split it and splice a section of scrap aluminum to make half of the cowl fit. I chose to rivet these parts together and make it look like it was hinged.

Wings and wheelpants after painting.

Finishing Touches

All the wood needed to be sealed. A good, high-quality sanding sealer is recommended. I put on about 2-1/2 coats, using all of a quart to cover the inside and outside of all the wood (the inside didn’t get a full coverage of the last coat). The metal needed to be primed before painting; I just used a rattle-can grey primer for the steel and aluminum.

The airplane was partially disassembled before painting. The plans recommended using an aircraft paint, but I chose to use a common hardware store lacquer paint (Rust-Oleum). I sprayed the plane in my driveway using a large drop cloth and a simple paint gun.

Fuselage after painting.

After painting there were items that needed to be added. The cockpit is lined with a coaming made of air hose. There is also a bit of air hose above the cockpit on the back of the top wing. I’ve seen my granddaughter bump her head into the back of the wing, so this was an excellent design enhancement.

The wheels and the wheelpants have very little tolerance, but the welding, crankshaft bending, and assembly had an accumulation of errors. Aligning the wheel flaw opposite the crankshaft flaw was the best way to make the tolerance acceptable. At worse, there was about 1/4-inch runout; at best, I got it down to less than 1/8-inch runout.

Reassembly took much longer than I anticipated. Many of the screws had never been installed. I needed to be careful to not scratch the paint replacing the hardware in the various parts of the plane. The birthday party was to be on Saturday, and I was still assembling late into Friday night.

At the party, my granddaughter’s best friend jumped in first. Both my granddaughter and her friend really seem to like it. The seat only holds one, and they took turns for a while. Eventually one or the other seemed to like wing walking. I hope it brings them many years of service.

Cockpit view shows the coaming made from air hose and VFR instruments on the panel.

The decals didn’t arrive until the day after the party. No one seemed to mind a plain white airplane. When the time worked out, I brought the plane back and put the decals on. They really add to the looks and make it a more colorful airplane.

In the end, I didn’t care if anyone liked the plane; I really enjoyed building it. The building process brought me back to building my Cozy, and it gave me a sense of accomplishment every step of the way. The plans are very complete and outline everything that needs to be done.

Sours: https://www.kitplanes.com/pedal-power/
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Flying has always been a passion for Daniel White. In fact, aviation runs deep in his family. His father is an airport manager, his sister works at an airport, his mother works for a major airline company, and White himself is a pilot and certified flight instructor. He even proposed to his wife while flying!

Because aviation is such a major part of his life, it’s no surprise that White is always looking for ways to get his two young children interested in flying, too. At 2018’s EAA AirVenture Oshkosh, he spotted the kit for a 1943 12-D Taylorcraft at the Pedal Planes booth and leapt at the chance to introduce his kids to aviation with a one-of-a-kind gift.

“I remember seeing a Christian Eagle pedal plane in the early 1980s and begging my parents to make one for me,” White said. “While I never had one of my own, I always wanted to build a pedal plane for my kids.”

White purchased the Taylorcraft kit from a company called Aviation Products, Inc. which is known as the “gold standard” in pedal plane design. For over thirty years, the company has offered realistic replicas of popular aircraft made for aspiring pilots from ages 3-7. The company offers 14 different models that can be built from detailed plans or complete kits with all the parts and hardware included.

Building the pedal plane was a labor of love, says White. He started the project in early September and worked on it for a few hours almost every day until it was finally completed in December.

“At first, I was a little overwhelmed by the amount of work involved in building the plane. It was a big project but it was fun at the same time,” White said. “I joined a group on Facebook of pedal plane builders who provided a lot of good tips and advice.”

Like most pedal plane builders, White wanted to make his plane look as authentic as possible.

“I decided to go with the blue and cream paint job because it was a historical paint scheme for a 1943 Taylorcraft. I worked with an auto detailing paint shop to have it professionally painted and even included the N-number I have registered with the FAA to represent the airplane I want to have someday,” White said.

Forward facing view of Pedal plane toy on the ground

 Pedal Plane

White also reached out to us at Hartzell Propeller to request small decal stickers for the propeller blades, which spin when the plane is pedaled by its mini-pilot. “Because the plane came with a metal prop, I just knew I wanted it to be a Hartzell for that authentic look,” White said.

Forward view of blue and white pedal plane with close up view of propeller

Daniel White’s Pedal Plane

White finished the project in December, just in time to give the pedal plane as a Christmas present for his 4-year-old daughter, Isabella, and 20-month-old son, Jameson. White says his children were thrilled to have a pedal plane of their own.

“It’s a great way to pass down my love of aviation to the next generation. I hope it stays in the family forever. I want my kids to be able to pass it onto their kids and know that I made it for them,” White said.

If you’re looking for a unique way to inspire the budding young aviator in your own life, take on the challenge of building a pedal plane! Not only is it a fun project to complete, but it might even be a good starting point if you’re thinking about building an airplane of your own.

And if you already have a pedal plane, consider bringing it along to this year’s EAA AirVenture in Oshkosh. A group of pedal plane builders is organizing a “PedalVenture” event with plans to set the unofficial world record for the most pedal planes in one gathering.

Blue and white Taylorcraft Pedal Plane on the ground

Blue and white Taylorcraft Pedal Plane











(Image credits: Daniel White).

Sours: https://hartzellprop.com/wings-and-wheels-pedal-planes-for-mini-pilots/
Building The Aviation Products P-51 Pedal Plane 07

Too good. Meanwhile, Zhenya scribbled to me in full. My penis, in principle, is not small, and the fact that she swallowed it right up to the tonsils gave me special pleasure.

Products pedal planes aviation

Moreover, the torturers threatened to arrange a round dance for the girl if she reported them to the police. Well, Oksana ended up in the zone for severely beating up a young teacher when she gave her a two in Russian for six months. And Oksanka would have been in the zone for five years if she had not met there with the same outrageous women like her, Ninka and Verka. They then threw Oksanka the idea of escape.

Building The Aviation Products P-51 Pedal Plane 07

She asked suddenly. Everyone looked there and saw that mom was standing in the doorway, and grandfather was behind him, as he was naked. Only his penis had already fallen by half. Mom was silent, moving tear-stained eyes from one naked body to another. Her lips trembled.

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Her to the side. And now it breaks down under its weight and perceptibly slides off my forearm, returning to its usual place under the fabric of the T-shirt, by inertia, once again so lightly slapping me for the last, swaying by inertia. I, barely in control of myself, already turn my face openly to the owner of such a gift and, with an embarrassed smile, I apologize.

At the same time, continuing to turn to face her, I openly examine her. Young.

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