Aircraft Sheet Metal Course

Lesson 1 • Reading Aeronautical Drawings

Introduces orthographic projection, title blocks, and revision systems used in aircraft drawings. Students gain ability to interpret work orders and fabrication blueprints accurately.

Lesson 2 • Material Identification and Properties

Identifies aluminium alloys, stainless steel, titanium, and composite-adjacent metals used in airframes. Understanding material properties prevents incorrect substitutions and structural failures.

Lesson 3 • History and Role of Sheet Metal

Traces sheet metal's evolution in aircraft construction and defines the trade's scope. Contextualises why precision and standards are non-negotiable in aerospace applications.

Lesson 4 • Shop Safety and Hazard Control

Covers personal protective equipment, chemical hazards, and machine guarding requirements. Directly enables safe participation in all subsequent lab and shop activities.

Lesson 1 • Filing and Finishing Edges

Addresses file selection, stroke technique, and edge finishing to remove burrs and achieve smooth profiles. Proper edge finishing prevents stress cracks and fatigue failures in service.

Lesson 2 • Cutting Tools and Techniques

Teaches hand snips, aviation shears, and hacksaws for straight, curved, and notched cuts. Correct tool selection prevents burrs, distortion, and material cracking.

Lesson 3 • Layout and Marking Techniques

Covers scribing, centre-punching, and template use for accurate part layout. Precise layout prevents material waste and downstream dimensional errors.

Lesson 4 • Drilling Fundamentals

Covers drill bit geometry, speed selection, and hole quality standards for sheet metal. Correct drilling technique is prerequisite for all riveting and fastener installation work.

Lesson 1 • Grinders and Finishing Machines

Teaches bench grinder, belt sander, and deburring machine use for edge and surface finishing. Proper machine finishing removes stress risers and prepares surfaces for assembly.

Lesson 2 • Slip Roll and Plate Roll Operation

Addresses roll setup, pinch adjustment, and forming cylinders and cones on slip and plate rolls. Rolling skills are required for cowlings, ducts, and curved structural members.

Lesson 3 • Drill Press and Hole-Making Machines

Covers drill press setup, work-holding, and use of step drills and reamers for precision holes. Machine drilling ensures consistent hole quality required for structural fastener installation.

Lesson 4 • Cornice and Box Brake Operation

Teaches clamping bar setup, bend sequence planning, and angle verification on cornice and box brakes. Accurate brake operation is foundational for all structural and skin forming tasks.

Lesson 1 • Flat Pattern Layout Methods

Covers geometric development of flat patterns for simple angles, channels, and Z-sections. Correct flat patterns ensure parts fold to blueprint dimensions on the first attempt.

Lesson 2 • Bend Allowance Theory

Explains neutral axis, K-factor, and bend radius relationships that govern metal deformation. Mastery of theory eliminates dimensional errors caused by incorrect bend allowance assumptions.

Lesson 3 • Springback Compensation Strategies

Addresses overbending, radius adjustment, and material-specific springback factors to achieve target angles. Compensation strategies reduce rework and scrap on precision aerospace parts.

Lesson 4 • Development of Curved and Compound Parts

Extends flat pattern skills to cylinders, cones, and simple compound curves using geometric development. These skills are required for duct, cowling, and fairing fabrication.

Lesson 1 • Hole Preparation for Riveting

Covers drilling, reaming, deburring, and countersinking holes to rivet installation tolerances. Proper hole preparation is the single greatest factor in rivet joint strength.

Lesson 2 • Rivet Types and Selection

Identifies solid, blind, and specialty rivets by material, head style, and strength designation. Correct rivet selection is mandatory for structural integrity and regulatory compliance.

Lesson 3 • Blind Rivet Installation

Addresses pull-type and drive-type blind rivet installation in limited-access locations. Blind rivets are critical for areas where bucking bar access is impossible.

Lesson 4 • Solid Rivet Installation

Teaches bucking bar selection, rivet gun pressure, and driving technique for flush and universal rivets. Consistent installation technique produces rivets meeting shop head dimension standards.

Lesson 1 • Repair Documentation and Approval

Teaches completion of repair records, use of approved data sources, and sign-off requirements. Proper documentation is legally required for return-to-service authorisation.

Lesson 2 • Skin Repair Techniques

Addresses flush patch, overlay patch, and insert repair methods for aircraft skin panels. Skin repairs must restore aerodynamic smoothness and structural continuity simultaneously.

Lesson 3 • Repair Design Principles

Covers patch sizing, doubler design, rivet pattern layout, and edge distance requirements for structural repairs. Correct repair design restores original load path without adding excessive weight.

Lesson 4 • Stringer and Frame Repair

Covers splice plate design and installation for damaged stringers, frames, and longerons. Internal structural repairs require precise fit-up to maintain fuselage geometry.

Lesson 1 • Chemical Surface Treatments

Addresses alodine, anodizing, and phosphate conversion coating application for corrosion inhibition. Chemical treatments create the adhesion base required for primer and topcoat application.

Lesson 2 • Dissimilar Metal and Sealant Use

Covers isolation tape, sealant application, and faying surface sealing to prevent galvanic corrosion. Proper isolation and sealing are mandatory at all dissimilar metal interfaces.

Lesson 3 • Primer and Protective Coating Application

Teaches epoxy and zinc chromate primer mixing, spray application, and cure verification. Primer application is the primary corrosion barrier for all repaired and fabricated parts.

Lesson 4 • Corrosion Identification and Types

Identifies surface, intergranular, galvanic, and stress corrosion by appearance and location. Early and accurate identification prevents structural degradation from progressing beyond repairable limits.

Lesson 1 • Cleco and Temporary Fastener Use

Covers Cleco selection, installation sequence, and temporary fastener management during assembly. Proper temporary fastening maintains alignment and prevents hole elongation before final riveting.

Lesson 2 • Assembly Fit-Up and Final Inspection

Teaches gap and flush measurement, shimming, and final assembly inspection against drawing requirements. Final inspection validates that the assembly meets all dimensional and workmanship standards.

Lesson 3 • Precision Hole Location and Drilling

Addresses jig drilling, transfer drilling, and coordinate layout for multi-part assemblies. Precise hole location ensures interchangeability and correct load transfer in structural joints.

Lesson 4 • Joggle and Offset Forming

Teaches joggle depth calculation, tooling selection, and forming technique for skin-to-structure transitions. Joggles allow flush skin attachment over underlying structural members.