This Article was published in the November Issue of an EAA Newsletter:
WEEKEND SHEETMETAL AND RV-BUILDER WORKSHOP REVIEW by Eric Puschmann
Have you been wanting to build a metal airplane or RV-XX, but felt you needed training before you tackled those expensive metal parts? Do you have a lot of quesitons about drilling, riveting, and corrosion proofing? I got my RV-7 tail kit in February, attended an EAA Sportair Sheet Metal basic workshop in March, installed six rivets in April, and then the project sat while I tried to get the nerve to continue. When my office threatened to start a pool to determine when rivet seven would be installed, I decided I needed to get going. About that time, Tom Emery started a weekend RV workshop at his home near Pittsburgh. Being only 270 miles away, I knew this was something I needed to attend, and I was not disappointed.
First, a bit about Tom: He's been an A&P for about 30 years. Tom started his career by spending several years on the Reno air race circuits building such planes as the Dago Red and the unlimited air racer Tsunami, and rebuilding the first civilian T-38 supersonic trainer. Then he worked for Northrop-Grumman on the B-2 for nearly 20 years in Southern California. During that time, he built a Bushby Midget Mustang, Hatz Biplane, Baby Lakes, RV-6A, and about 30 RV tail kits. Tom also taught the Sportair RV Workshops in southern California for several years before retiring to a full time A&P job in Pennsylvania last summer.
Now Tom offers his workshop one weekend per month with dates posted on his website (http://www.wparvbuilders.nstemp.com or call 412-257-8350). Although I had attended a very well run EAA Sportair workshop in Dallas last Spring, when I arrived at Tom's workshop, I realized I was in for a really personalized weekend. I was extremely lucky in that I was the only student at the September workshop. Tom started out by reviewing my building experience, then he tailored my workshop to meet my needs. Throughout the next two days, we primed all my tail kit parts, assembled the horizontal spar, and got well started on the remainder of the tail kit. Tom also provided me lot of tips and shortcuts that can only be provided from someone with his extensive experience. I left the workshop ready to begin the remainder of my kit. Tom's workshop currently costs and includes the materials to make an aluminum airfoil - just like at the Sportair RV workshops that Tom helped develop. I saved nearly the entire cost of the workshop from a tip Tom gave me about ordering a pneumatic rivet squeezer with three yokes at at savings of over . And, Toms wife Nickie, provided top notch lunches both days.
As if Tom's wekend school within weekend driving distance at Pittsburgh was not enough, Tom will load up his tools and bring the workshop to us. All he needs is a group of 10 students and a workshop and the group can benefit from all his experience without having to travel.
To sum up my weekend with Tom and Nickie - fantastic training! I now feel ready to attack the rest of my kit.
This is a post to the Ohio Valley RVators from student Darrell Clay:
Anyone out there thinking about taking the plunge and building an RV should definetly take the weekend class sponsored by Tom Emery's Western PA RV Builders. My Dad and I spent last weekend with Tom, getting a basic introduction to aircraft tools and methods of construction (including priming). We then built the Van's sample project and discussed applicable regulations.
Tom and his lovely wife Nickie provided coffee and donuts in the mornings and a great lunch on both days of the workshop.
Due to an unfortunate incident involving the nose gear, Tom's RV-6A is back in the workshop for repairs so we got the chance to see the first class workmanship that Tom did when he built his 6. He also took the time to answer all of our crazy questions about "what's this" and "what's that" on the panel, engine, etc.
Knowing what I know now, I'd have been crazy to undertake building my 9A without having gone to Tom's class. It'll be the best that you ever spent on your RV.
This from Dan Checkoway:
Tom is the man. I wouldn't have started, and I wouldn't have finished this RV if it wasn't for his help and encouragement--in the workshop and thereafter.
Personally, if I lived anywhere near PA I would opt for Tom's workshop over any standard SportAir workshop. I'm not knocking SportAir...just saying I like the way Tom teaches and commits to keeping his students safe. We were all bummed when Tom moved out of SoCal back to BFE.
This one from Son Hoang:
You'll be happy with Tom, Son Hoang N64SH RV6A 110 flying hours.......thanks to Tom Emery.
This from Tom Short student in January, 2005 Workshop:
I just got back from the weekend class at Tom Emery's shop in PA and I can unconditionally recommend this to anyone considering building an RV. I have been researching and reading about this project for over a year but the amount of information I learned from Tom is unbelievable. I now know what all these tools are for, how they work, how to set them up, and which ones I want to buy. Tom let us work in his shop and use all of his tools, so we got a great look at what is good and what isn't. He has a wealth of information and tips, and is really interested in teaching his students how to build safe airplanes. We only had 3 students (class is limited to 5 - compare that to the EAA Sportair workshops that may have 12+), so Tom was there to demonstrate all kinds of cool stuff. We each completed the sample airfoil project from Van's (you can see our photo on the website listed below).
Additionally, there are several hours of discussion on topics like certification, aircraft hardware, etc.
Tom's wife, Nicki, whips up a great meal for lunch every day, so there is no need to leave the workshop and search for food (we had burgers, hot dogs, baked beans, potato salad and homemade cake the first day!)
If you are considering a workshop I echo Dan Checkoway's thoughts and highly recommend Tom Emery. Not only is the workshop cheaper, but there is more personal attention and more hands on experience. If you're willing to spend thousands on tools and kit parts, consider this a very small investment (moneywise) towards making your kit building process a lot easier. I have seen lots of questions posted on several forums that will be no brainers after Tom's workshop (trust me - I'm no expert, we just learned a ton this weekend!).
Check him out....
http://www.wparvbuilders.nstemp.com/
Thomas
p.s. I get no kickbacks or anything, this is an unsolicited recommendation...
Email Received from May Students:
Tom & Nickie,
Thank you both for the very informative & thoughtful workshop! Every aspect was outstanding--especially your home-cooked lunches. The course was exactly what I needed--now I know that I can build an RV!
Wishing the best to both of you,
-Jim
Tom-
I wanted to thank you and Nickie for the great class this past weekend. I had a great time and learned a tremendous amount about metal aircraft fabrication. I'm showing off my airfoil section to everyone I can. You guys were great hosts, and Nickie was awesome with her home cooked lunches. We felt at home the entire time. Best of luck with your "new" RV-6. I'll keep you in mind for the tail section builders assist program also.
Thanks again,
-Jeff-
This was posted on VANS Airforce list by student Jim Beyer:
Paul (and the other lurkers out there),
I have been lurking for quite a while now, somewhat skeptical if I have the skills necessary to actually build an airplaneÃÆÃÃâ ̢̮â¬Å¡ÃâÃÂ¢ÃÆÃÃâÃÂ¢ÃÆÃ¢Ã¢ââ¬Å¡Ã¬Ãâ¦ÃÂ¡ÃÆÃ¢â¬Å¡ÃâÃÂ¬ÃÆÃâââ¬Ã
Â¡ÃÆÃ¢â¬Å¡Ãâæwell let me tell you that after taking Tom Emery's building workshop about 10 days ago, I am 100% confident that I can do it--and do it right the first time!
Tom methodically presented basic information, demonstrated building techniques (read: showed us how to use all of his cool tools--arh, arh, arh), supervised our construction of Van's training project, and then wrapped it up with more in depth information about hardware, certification, etc. While it would be very foolish for me to think that I now know everything required to build an RV, I do believe I have the foundation to build the tail kit the right way the first time, and safely start the journey of RV building.
In summary, I highly recommend Tom's workshop. If you dont live within driving distance or a reasonably priced airline flight into PittsburgÃÆÃÃâ ̢̮â¬Å¡ÃâÃÂ¢ÃÆÃÃâÃÂ¢ÃÆÃ¢Ã¢ââ¬Å¡Ã¬Ãâ¦ÃÂ¡ÃÆÃ¢â¬Å¡ÃâÃÂ¬ÃÆÃâââ¬Ã
Â¡ÃÆÃ¢â¬Å¡Ãâædefinitely find some type of builders workshop. I considered the upfront fee a small investment that Im sure will pay dividends many times over in the long run--not only in real dollars, but also in confidence, tips, and the lack of frustration getting started.
Here's Tom's info.
Tom & Nickie Emery
5014 Thoms Run Road
Oakdale, PA 15071
412-257-8350 - Home
724-344-8175 - Cell
tomsrv@comcast.net
http://www.wparvbuilders.nstemp.com/index.html
-Jim
RV-10 lurkerÃÆÃÃâ ̢̮â¬Å¡ÃâÃÂ¢ÃÆÃÃâÃÂ¢ÃÆÃ¢Ã¢ââ¬Å¡Ã¬Ãâ¦ÃÂ¡ÃÆÃ¢â¬Å¡ÃâÃÂ¬ÃÆÃâââ¬Ã
Â¡ÃÆÃ¢â¬Å¡Ãâæsoon to be builder after we move halfway across the country in a couple months.
P.S. Standard disclaimer -- no affiliation, just a satisfied customer, yada yada yada
[October 17, 2005]
I took Tom Emery's RV builders class this past weekend (10/15-16) outside of Pittsburgh, PA. I had to be in Columbus, OH today to make a network upgrade, so I got work to pay for my mileage to the class! Can't beat that. My dad went with me and we had a blast. When we got there, Tom had a 7A being put together that was decked out. He also brough out his 6A. Beautiful. This was my first time seeing a RV in person. Definitely an overwhealming experience. I was almost detered when I saw how complex these things were before being completely assembled. Tom ran a great class. I went into this knowing nothing about metal, riveting, clecos, etc.. Tom took us through each step and told us the multiple ways for us to accomplish each task. By Sunday at 3:00pm, I knew how to deburr, use clecos, drill properly, backrivet, buck, etc.. He had a lot of useful tips that made a lot of sense. Definitely stuff that I would not of thought of on my own. By the end of the workshop, I felt very confident that I could order the right tools and order the empannage kit and assemble it successfully.
Tom had a lot of great suggestions for general building. Electric elevator trim and manual aileron trim. LYCOMING ENGINE. He didn't badmouth any other aircraft or non-aircraft engine, but he swore by the Lycoming's. He also was a big proponent of the sliding canopy. He had an accident in his 6A not too long ago where he flipped it head over heals. The first thing that shattered was his tip-up canopy, leaving the earth about 2"" from the top of his head. He rebuild his 6A with the sliding canopy and pointed out how it had a mini rollbar in it, with the support bar going into the firewall. I am still up in the air about this choice, but there is definitely a safety and cool factor of the sliding canopy. He also recommended NOT getting an oil-free air compressor. He said that they were basically junk and wear out sooner. Also, he said not to keep track of how much time you keep track on each stage of the build. It is not a requirement of the FAA. It has the tendency to make people rush their project when they compare their time with other peoples. Made sense to me. Finally, he said not to trust any of the websites out there for the definitive source of RV building. He has noted that these websites just cause dozens of people to keep making the same mistakes.
One last thing I need to say about Tom's class both him and his wife Nickie treated us like familly. Some of the nicest people I have ever met. Nickie made such a large lunch for us both days that I don't know how I didnt go into a food comma afterwards.
Mike Bullock
POSTED ON RIVETBANGERS NOVEMBER 30, 2005
I highly recommend Tom and Nickie Emery's Western PA RV Builder's workshop. My only hesitation at doing so is that by recommending them Tom has less time to possibly help me! Sorry Tom -- couldn't resist.
Here is my summary from my builder's log:
Tom and Nickie [Emery] run a two day RV builders workshop every month at their hangar at the Rostraver Airport just outside Pittsburgh, PA. See www.wparvbuilders.nstemp.com. They are super nice people and do an excellent job with this workshop. Tom has decades of experience building metal planes, including many RVs. He built Dago Red, the most successful unlimited mustang to compete in the Reno Air Races. He methodically taught us about metal working, aircraft construction, tools and all of the basic skills needed to build an RV. His wife Nickie kept us well fed and hydrated and supplied the humor to soften Tom's no-nonsense approach to aircraft building. After two days with these folks, I felt competent to tackle my own RV. I highly recommend spending time in one of Tom and Nickie's workshops if you are new to building metal planes.
Antony Parchment
RV7A builder
From Ray Swanson December 10 & 11th 2005 Workshop
WPA RV Builder's Workshop
12/12/05
This weekend I attended the WPA RV Builders Workshop. I cannot stress enough how helpful it was. It's run by Tom and Nikki Emery out of a hanger at Rostraver Airport, about 45 minutes by car, SE of Pittsburgh Airport. Tom's been building airplanes or involved in the aviation industry for most of his life and it shows. He's a great, hands-on teacher, full of encouragement, hints and techniques that are worth the price of entry all by themselves.
Even better is the ability to use the tools we've all read about. I now know exactly what I'm going to buy, what not to buy and what to splurge on. I'm totally sold on buying a pneumatic squeezer, the newer DRDT-2 C-frame from Experimental Aero and the Tatco hand squeezer. And guess what? They're not part of the standard Avery kit. Do some research guys. You may end up spending a bit more money, but the right tool for the right job is absolutely true.
You can't imagine what a confidence booster Tom's class really is. You build the VANs starter project; a two rib section of a control surface. It requires nearly every operation you will ever encounter in building an entire RV kit with lots of riveting practice. You probably end up instaling 50 or more rivets, countersunk and universal head, hand squeezed, pneumatically squeezed, bucked, back riveted and double flush. It is not difficult and even more important is learning how easy it is to drill out the mistakes and replace them.
Take a class guys. . . . and if you're lucky, take Tom's.
FROM JOHN CLAGUE, BUILDERS ASSISTANCE:
Tom,
My thanks to you and Nickie for your gracious hospitality. The tail kit was a huge success. Most importantly, James and I got to spend a long weekend together and work side by side on a project that truly excites us both. That experience alone was worth the price of admission.
The parts are now safely hung out of the way.
Regards,
John
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