Sequoia Aircraft Corporation F.8L Falco Instructions for use

F.8L Falco
Construction
Manual

F.8L Falco
Construction
Manual
Sequoia Aircraft Corporation
2000 Tomlynn Street, P.O. Box 6861 • Richmond, Virginia 23230 • 804/353-1713 • Fax [phone] • www.SeqAir.com

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F.8L Falco Construction Manual Revision 4, March 1, 2002
List of Effective Pages
Revision 4
March 1, 2002
The F.8L Falco Construction Manual was originally written in 1984, and since then portions of
the manual have been revised in 1986 and 1989 to correct minor deficiencies. At the time of
these revisions, a system of tracking revisions had not been fully adopted, and Revision 1 and 2
were identified only by dates on the bottom of each page.
Revision 3 is a completely new version of the manual because the illustrations, previously pasted
onto the master pages with rubber cement, are now all an integral part of the document on our
computers, and the manual has been extensively reformated with a new typeface and layout style.
However, the content of the manual is essentially unchanged from Revision 2.
Revision 4 is a further refinement with larger type, formatting changes and minor changes to the
manual.
This construction manual includes what we have written to date. In the future, it will be
expanded to add more chapters. When we have the time, Chapters 11, 12 and 13 will be
expanded to take you through the construction of the wood parts on a step-by-step basis with
many illustrations. Other than that, the construction manual is essentially complete through
Chapter 28.
For additional information, please visit the Falco Skunkworks at our website. There we have a
large collection of articles, notes, hints and tips on building a Falco.
Dates of issue for original and revised pages are:
Original June 10, 1984
Revision 1 June 10, 1986
Revision 2 April 4, 1989
Revision 3 October 10, 1995
Revision 4 March 1, 2002
List of effective pages:
Page Revision Number Date
Preface (1 page) 4 March 1, 2002
i thru vi 4 March 1, 2002
1-1 thru 1-8 4 March 1, 2002
2-1 thru 2-8 4 March 1, 2002
3-1 thru 3-2 4 March 1, 2002
4-1 thru 4-8 4 March 1, 2002
5-1 thru 5-4 4 March 1, 2002
6-1 thru 6-4 4 March 1, 2002
7-1 thru 7-2 4 March 1, 2002
8-1 thru 8-10 4 March 1, 2002
9-1 thru 9-6 4 March 1, 2002
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11-1 thru 11-4 4 March 1, 2002

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F.8L Falco Construction Manual Revision 4, March 1, 2002
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13-1 thru 13-4 4 March 1, 2002
14-1 thru 14-12 4 March 1, 2002
15-1 thru 15-4 4 March 1, 2002
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27-1 thru 27-30 4 March 1, 2002
28-1 thru 28-26 4 March 1, 2002
A-1 thru A-6 4 March 1, 2002
B-1 thru B-6 4 March 1, 2002
C-1 thru C-4 4 March 1, 2002
D-1 thru D-20 4 March 1, 2002

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F.8L Falco Construction Manual Revision 4, March 1, 2002
Preface
It is customary to acknowledge those who have assisted in the writing of a book,
however this manual is the result of assistance from hundreds of Falco builders.
Indeed, it is a rare builder who has not made some contribution to our collective
understanding of the construction of the Falco. We are all indebted to those who
have contributed their ideas and comments. If you find this manual of assistance,
remember that much of what you are reading has been the result of lessons passed
on to us by Falco builders. If you have any comments, ideas or new procedures
for assembling the Falco, please let us hear from you so that future builders can
benefit from the lessons learned by previous builders.
Alfred P. Scott
President
Sequoia Aircraft Corporation

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F.8L Falco Construction Manual Revision 4, March 1, 2002

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F.8L Falco Construction Manual i Revision 4, March 1, 2002
Table of Contents
Chapter 1 Preparing for Construction
Welcome! 1-1
Where to Start? 1-1
Family and Friends 1-1
Your Shop 1-1
What to Make? 1-2
Setting Standards 1-2
Modifications 1-3
Visit a Falco Builder 1-5
Plan Ahead 1-5
In Search of Experts 1-5
Contacting Sequoia Aircraft Corporation 1-6
Plans Assumption 1-6
Chapter 2 Reading the Plans
The Falco Plans 2-1
The Basic Views 2-2
Sections & Views 2-3
Dimensioning 2-4
Water Lines, Butt Lines & Stations 2-4
General Tolerances 2-4
Not to Scale 2-4
A Few Terms 2-5
The Language of Lines 2-5
A Few Symbols 2-6
Revisions 2-6
Need More Help? 2-7
Where Do You Find Part Number...? 2-7
The Plans vs the Construction Manual 2-7
Chapter 3 Your Shop
Close to Home 3-1
Space Requirements 3-1
Lighting 3-1
Temperature Control 3-2
Humidity Control 3-2
Getting It In and Out 3-2
Chapter 4 Tools
Introduction 4-1
Measuring Tools 4-1
Clamps 4-3
Drilling Tools 4-3
Band Saw 4-4
Table Saw 4-4
Radial Arm Saw 4-4
Coping Saw 4-4
Stationary Belt/Disc Sander 4-5

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F.8L Falco Construction Manual ii Revision 4, March 1, 2002
Scarfing Jig 4-5
Air Compressor 4-5
Pneumatic Staple Gun 4-5
Hand-Operated Stapler 4-6
Staple Lifter 4-6
Die Grinders 4-6
Electric Hand Sander 4-6
Carbide Abraders 4-7
Sanding Blocks 4-7
Gil-Bilt Power Tool Kits 4-7
Laminate Trimmer 4-7
Offset Screwdriver 4-7
Moisture Meters 4-7
Torque Wrench 4-8
Gluing Supplies 4-8
Chapter 5 Planning Ahead
The FAA 5-1
The Experimental, Amateur-Built Category 5-1
Notifying the FAA 5-3
Chapter 6 Machining, Welding & Fabrication
Introduction 6-1
Aluminum Alloys 6-1
Steel Alloys 6-1
Bronze Alloys 6-2
Plating 6-2
Welding 6-2
General Tolerance 6-2
Drill Sizes 6-2
Bushings 6-2
Hinge Fabrication 6-3
Spherical Bearings 6-3
Nose Gear Fork 6-3
Landing Gear Mount Fittings 6-3
Main Landing Gear Legs 6-4
Chapter 7 Corrosion Protection
Introduction 7-1
Alodine Conversion Coating 7-1
Zinc Chromate Primer 7-1
Polyurethane Enamels 7-2
Steel Parts 7-2
Do Not Paint... 7-2
Do Not Plate... 7-2
Chapter 8 Aircraft Woodwork, Materials
Spruce 8-1
Other Woods 8-1
Birch Plywood 8-1
Moisture Content 8-1
Glues 8-4

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F.8L Falco Construction Manual iii Revision 4, March 1, 2002
Aerolite 8-5
Penacolite G-1131 Resorcinol 8-5
Plastic Resin Glues 8-6
Epoxy Glues 8-6
Test Blocks 8-9
Chapter 9 Moisture Protection of Wood
Introduction 9-1
Requirements of Finishes 9-1
Protective Power of Wood Finishes 9-1
The 1950’s Techniques 9-1
Recent Developments 9-3
Application Procedures 9-4
Under Metal Fittings 9-5
Chapter 10 Woodworking Methods
Introduction 10-1
Scarf Joints 10-1
Making a Scarf Joint 10-3
Conditioning 10-5
Beveling Plywood 10-6
Staples & Nails 10-6
Bending Spruce and Birch Plywood 10-7
Clamping Methods 10-11
Drilling Holes 10-14
Bolt Torques 10-15
Drain and Vent Holes 10-15
Chapter 11 Making Ribs
Watch Those Dimensions 11-1
Jigs 11-2
Making the Ribs 11-3
Wing Ribs 11-4
Chapter 12 Making the Fuselage Frames
Fuselage Frame Jigs 12-1
Making a Lamination 12-1
Open vs Closed Laminations 12-2
A Few More Tips 12-2
The Fuselage Curve 12-3
Chapter 13 Making the Spars
Spar Jigs 13-1
Plywood Grain Direction 13-1
Plywood Scarf Joints 13-2
Spar Cap Joints 13-2
The Ends of the Spars 13-2
Doubling Up 13-2
The Aileron and Flap Spars 13-2
The Forward Wing Spar 13-2
The Main Wing Spar 13-2

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F.8L Falco Construction Manual iv Revision 4, March 1, 2002
Chapter 14 Antenna Installation
No. 1 Communications Antenna Installation 14-1
No. 2 Communications Antenna Installation 14-2
VHF Navigation Antenna Installation 14-3
Marker Beacon Antenna Installation 14-3
Transponder Antenna Installation 14-4
DME Antenna Installation 14-4
ADF Antenna Installation 14-5
Special Considerations in Wiring 14-5
General Comments 14-5
Loran Antenna Installation 14-5
Loran Antenna Design Requirements 14-6
Apollo II Loran Receiver 14-6
The Loran Antenna 14-6
The Ground Plane 14-9
Grounding Other Metal Parts 14-9
Noise Suppression 14-10
BNC Assembly Instructions 14-10
Chapter 15 Electrical System
Navigation & Strobe Light System 15-1
Equipment Installation 15-1
Wire Bundle Routing 15-3
Chapter 16 Tail Group Assembly Preparations
Kits on Hand 16-1
Basic Principals 16-1
Background 16-2
Drawing Notes 16-4
Hinge Installation Notes 16-6
Preparatory Work 16-7
Chapter 17 Tail Group Hinge Installation
Elevator Hinge Installation 17-1
Rudder Hinge Installation 17-3
Elevator Balance Weight Installation 17-4
Chapter 18 Elevator Assembly
Chapter 19 Stabilizer Assembly
Stabilizer Assembly 19-1
Chapter 20 Rudder Assembly
Fin and Rudder Assembly Notes 20-1
Rudder Assembly 20-1
Chapter 21 Fin Assembly
Chapter 22 Aileron/Flap Assembly
Kits on Hand 22-1
Aileron/Flap Hinge Installation 22-2
Aileron/Flap Assembly 22-4

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F.8L Falco Construction Manual v Revision 4, March 1, 2002
Chapter 23 Wing, Preliminary Assembly
Kits on Hand 23-1
Other Materials 23-1
Spar Fittings Installation 23-1
Main Wing Spar/Fuselage Frame No. 4 23-8
Forward Wing Spar/Fuselage Frame No. 3 23-12
Fuselage Frame No. 5 23-17
Fuselage Frame No. 6 23-20
Control Stick Assembly 23-24
Landing Gear Retraction Gearbox Assembly 23-25
Main Landing Gear Assembly 23-33
Main Landing Gear Bushings Installation 23-35
Wing Rib Preparation 23-36
Wing Skins 23-37
Chapter 24 Wing Assembly
Kits on Hand 24-1
Wing Assembly Jig 24-1
Wing Assembly 24-5
Skinning the Wing 24-27
Chapter 25 Fuselage, Preliminary Assembly
Kits on Hand 25-1
Other Materials 25-1
Cowling Supports Installation 25-1
Nose Gear Assembly 25-2
Engine Mount 25-6
Rudder Pedal Assembly 25-8
Fuel Tank Band Mounts 25-8
Firewall 25-8
Fuselage Frame No. 1 25-9
Fuselage Frame No. 2 25-26
Fuselage Frame No. 7 25-30
Fuselage Frame No. 8 25-34
Battery Box Lamination 25-35
Fuselage Frame No. 9 25-36
Fuselage Frame No. 10 25-37
Fuselage Frame No. 11 25-37
Fuselage Jig 25-38
Chapter 26 Fuselage Assembly, Part 1
General Comments 26-1
Fuselage Assembly 26-2
Chapter 27 Fuselage Assembly, Part 2
Nose Gear Bay Assembly 27-1
Cockpit Flooring 27-6
Battery Box Installation 27-16
Exhaust Port Framing 27-27
Nose Gear Screwjack Support Assembly 27-30

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F.8L Falco Construction Manual vi Revision 4, March 1, 2002
Chapter 28 Fuselage Assembly, Part 3
Kits on Hand 28-1
Bottom Forward Fuselage Skin 28-19
Aft Top Fuselage Section 28-21
Forward Top Fuselage Section 28-24
Appendix A Sources
Woodworking Tools A-1
General Tools, Metal & Wood A-3
Aircraft Tools A-3
Aircraft Hardware and Materials A-4
Engines and Accessories A-5
Appendix B References
Aircraft Woodwork, The Best Books B-1
Aircraft Woodwork, Other Books B-2
Aircraft Construction—General, The Best Books B-2
Aircraft Construction—General, Other Books B-3
Aircraft Covering & Painting, The Best Books B-4
Aircraft Engines B-4
Aircraft Engineering B-5
Publications B-6
Appendix C Paint Scheme Colors
Appendix D Glue Instruction Sheets
Aerolite 306 D-1
Penacolite Adhesive G-1131 D-5
Weldwood Waterproof Resorcinol Glue D-10
Aerodux 500 D-16

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F.8L Falco Construction Manual 1–1 Revision 4, March 1, 2002
Chapter 1
Preparing for Construction
“Perfection is finally attained not when there is no longer anything
to add, but when there is no longer anything to take away.”
Antoine de Saint Exupéry
Wind, Sand and Stars
Welcome!
Welcome to the Falco. Like many others before you, you have fallen under the spell of this lovely
airplane. You are about to embark on a unique and enjoyable experience.
We look forward to working with you, hearing of your progress and finally that you have flown
your Falco. We hope you will find, as we have, that the Falco attracts a special type of person.
Where to Start?
The hardest part of building a Falco is getting started, so if you want to build the Falco, send your
order off now for the tail group kits and go to work.
The first step is to study the construction manual and the plans. You can expect to feel
completely overwhelmed at first. As you go over the drawings, your mind will go on “overload”.
Don’t worry, this happens to everyone… and it doesn’t last. At some point, you will begin to
understand the drawings. Little details which escaped your notice at first will start to make sense.
You can expect the project to become something of an obsession, and eventually, as all Falco
builder have done, you will even find that you will see the airplane in your dreams!
A lot of the Falco drawings are for parts which you will buy, so don’t spend a lot of time studying
them. Concentrate on the parts you will make and the assembly work you will do. There will be
many details which will not be clear at first, but they will come into focus as you approach the
assembly. So don’t spend a lot of time worrying about things that lie far in the future.
Concentrate on the first stages of the construction, which will be the tail group.
Family and Friends
It would be a good idea to discuss the Falco project with your family in advance. While you may
be thinking of the project simply as something that you want to do, you should not forget that the
Falco is likely to consume a lot of your time and energies. It will be a happier experience if
everyone in your family is behind the project and understands that you will be spending a lot of
time in the shop.
Friends are a different matter. In the early stages of the project, you will find friends and
acquaintances will not readily understand what you are doing. The notion of building an airplane
is foreign to them, and it will tend to sound like a pipe dream. Once the project is underway,
however, you will find that people can relate to an actual airplane under construction better than
they can to an idea. As the Falco takes shape, you will even find that visitors become something
of a distraction.
Your Shop
You will need a nest for your bird to hatch, so you should make plans for the shop and equip it
with tools. If you are able to have the shop at home, you will be able to spend more time on the
project. Your family will enjoy having you around and being able to check in on you. Nothing is
worse than building an airplane at the airport or some other remote location. Traveling to and

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F.8L Falco Construction Manual 1–2 Revision 4, March 1, 2002
from the project will become a problem, and your family will come to resent the thing that keeps
you from them.
What to Make?
One of your early decisions will be which kits to buy and which parts to make. For most builders,
the decision is whether to make the wood parts or to buy them. We would like to offer some
advice.
Except for the main wing spar, making all of the wood parts is fairly easy; however, they take a lot
of time. It is difficult to understand from looking at the plans how such parts could take so much
time, but they do! In fact, building all of your own wood parts can nearly double the building
time.
On the average, builders take from nine months to a year and a half to make the wood parts. This
is the average— some have taken over three years. You should not underestimate the length of
time that it takes to make these parts.
A funny thing happens to builders who build all of the wood parts. At first, they send us lively
letters about how easy it was to do. Later the letters slow down. Some builders stick with it and
go on to finish the airplane, but a lot just burn out.
Many builders are tempted to build all wood parts because they arrive at the conclusion that the
kits are too expensive. While we hear this from potential builders and from those just embarking
on the construction of the wood parts, we have yet to hear it from someone who has actually
made the Falco wood components. In fact, we have heard many such builders confess that they
find the prices of the wood parts very fair, now that they know what it takes to build the parts.
Most builders report that they save about $1.00 to $1.50 per hour by making their own wood
parts.
There are, however, those builders who should make their own wood parts. If you simply do not
have the money, then the only way that you can build a Falco is to make as much as you can. If
you just want to make all the parts, then do it. Some builders find woodwork extremely
pleasurable. If you find pleasure in working with wood, you will have plenty of pleasure just
assembling the aircraft, even if you purchase all of the wood kits.
Our advice is to not worry too much about all of this. Take things one step at a time. Start with
the tail group. Our experience is that builders who purchase the tail group kit never revert to
making their own wood parts. The project takes shape much faster. On the other hand, we
notice that the longer builders work on the Falco, the more kits they buy. It seems to be easy to
get tired of making things.
We remember the Falco builder who decided to make his own tail group. Nine months later, all
of the parts were finished and ready for assembly. The builder has since purchased all of the
remaining wood kits. In the same length of time, we have seen kit builders complete the entire
wood structure of the Falco.
Setting Standards
Before you begin your Falco, it is a good idea to make a resolution on the quality of the
workmanship to go into your airplane. You cannot build a perfect airplane—there are bound to
be little errors—but you should set your standards early. We suggest that you set them very high.

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F.8L Falco Construction Manual 1–3 Revision 4, March 1, 2002
If you take great care to do everything well, you will enjoy the construction of the aircraft much
more than if you are sloppy.
When your Falco is finished, you will find it difficult to look at the airplane without seeing the
errors. Your eyes will naturally focus on the little mistakes that others will not notice. The fewer
errors you have to see, the more you will enjoy owning the airplane. If your workmanship is very
good, you will find the FAA easier to work with—there are few things that give FAA inspectors
more pleasure than walking into a homebuilder’s shop and inspecting a beautifully-built aircraft.
You will also find assistance easier to come by at every turn if you are building a beautiful airplane.
Also, keep in mind that one day you might want to sell your Falco. A beautifully-built Falco will
bring a very good price. A sloppy one will be difficult to sell even at a very low price. You will
find your friends and family hesitant to ride in a crudely-built aircraft, but if it looks professional,
you will have little trouble.
While few builders give much thought to the subject of resale value, you really should think about
this. It’s a good feeling to have built something that others would like to have. The market for
homebuilt aircraft is a little paranoid. We like to make the analogy that it is the way Spanish
men regard their women: they are either ladies or “ladies of the night”—nothing in between.
With a production aircraft, such as a Bonanza, the price will reflect the condition of the plane. If
the plane needs a new paint job, you will get less for it. But with a homebuilt aircraft, the
situation is different. The typical buyer knows relatively little about the construction of an
airplane. All he knows is that he likes the Falco and would like to buy a nice one. In the back of
his mind is this nagging worry about the workmanship that went into the airplane. When
everything is perfect, you can almost name your price. A beautifully-built Falco makes normal
production aircraft look really sad. But what happens if the paint is poorly done? Immediately,
the buyer starts worrying about what else is wrong. Are the glue joints sound? When this process
starts, the sale is off—and price is not the issue. Once this happens, you can cut the price in half,
and you will still not sell the airplane.
One last thought on this subject. All of us, no matter how intelligent or independent, bask in the
admiration of others. The way others see your Falco will materially affect the enjoyment you get
out of building and owning the Falco.
Modifications
As you go over the plans for the Falco and begin construction, you will think about changes that
you would like to make. As the plane comes into focus, it looks very simple. It is, but it is also
extremely sophisticated. The Falco is a very good example of the “Swiss watch” syndrome.
Things fit together beautifully, but if you change one little thing, your life can become misery.
“One change makes a million” is the old phrase, and it is quite true. The Falco plans show you
what to do. They do not tell you why you should not do it another way. Also, the plans often do
not show you the potential interference problems.
As you build the Falco, you will begin to have an appreciation for these little things. You will
suddenly notice how nicely things fit together. The plans do not tell you, for example, how the
aileron control cables clear the rudder and elevator controls at the center of the airplane. It’s one
of those little things that will have you saying “Well, I’ll be. Isn’t that neat.” The Falco is
literally chock-full of that sort of thing.
There is no way to adequately explain the horrible way this “Swiss watch” syndrome grows as the
airplane nears completion. When you have all of the flight controls installed, you will think that

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F.8L Falco Construction Manual 1–4 Revision 4, March 1, 2002
you understand, but you will not. After the instrument panel and the electrical system are
installed, you will have a very good idea. You will not completely understand the degree of
systems integration until you have the Falco ready to fly. Only after you have all of the mess that
goes with the engine installation completed will you finally understand how integrated everything
is. If you don’t care to believe us, ask a builder who has completed a Falco or one who is nearly
finished.
The tendency to dream about “little” changes is only human nature. Everyone goes through this
stage. Please, keep yourself under control, take a cold shower, and concentrate on building the
Falco to the plans. Over the years, a lot of builders have written us about potential changes to the
Falco. Our experience has been that the more modifications proposed the less likely it is that the
builder will proceed with the aircraft to completion. In all cases, the individual is quite sincere
about the perceived need for such a change, but every single builder who has proposed a number of
modifications has eventually given up on the project. Those builders who continue to work on their
aircraft have been exceptionally devoid of such proposals. Thus, when we receive a letter
proposing a number of changes to the Falco, we interpret the letter to mean “I am not going to
build a Falco... just engaging in a pleasant daydream”. Please excuse the language, but our
description for this is “mental masturbation”, and we answer such inquiries in the briefest possible
manner.
The amount of time spent designing the Falco is difficult to comprehend if you have not been in
the design business. The design of the electrical system took about 3,000 hours, more time than
most of you will spend building the Falco. You will install parts and assemblies in your Falco in a
matter of a few hours. The design of these same things frequently runs into months. Please try to
keep this in mind before demanding that we tell you why you cannot install your new idea.
Part of the design process is the critiquing of your own work. You need to spend a lot of time
studying the design, playing the devil’s advocate, trying to simplify the thing, comparing the part
to other designs, etc. You need to be able to look at the design with a cold, rational attitude. You
ask yourself if the most brilliant designer in the world could not do better. You pin the drawing
on the wall and spend weeks of studying the design at odd moments. This process of objectively
critiquing your own design is one that we have noticed is usually lacking from the many proposals
that we have received. Remember, it doesn’t make it a good idea just because you thought of it! If you
find yourself holding on to an idea for this reason, it is irrational, emotional thinking, and it has
no place in good design. As an example, take our cabin heat valve. Compare our design to those
of production aircraft, and you will find that none is as compact, as simple or gives full flow. It’s a
brilliant piece of design. For us, it involved months of work studying every possible way of doing
this, looking at every production aircraft we could find. We are proud of this little feature of the
Falco design—proud that we have the best little cabin heat valve in aviation, and proud that we
copied this design from a 1971 Messerschmitt BO-209 Monsun. Lord knows who Messerschmitt
copied it from! So... don’t hang on to an idea just because it came out of your head.
There is also the subject of the danger involved in modifications. Few builders are qualified to do
the engineering required to make changes, and fewer still are aware if the dangers involved. It has
been a constant source of amazement to us to see the many ways that builders can get into trouble
without realizing it. As a result of our experience, and after witnessing the safety record (dismal)
of other modified homebuilt aircraft, we have become inflexibly opposed to modifications. The
subject, frankly, is anathema to us. There is no question that any number of modifications can
safely be installed on the Falco. Indeed, we have spent years and huge sums on engineering the
many improvements we have made on the Falco. These improvements are modifications to the
original design, but we have done the engineering and spent the time to check out interference

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F.8L Falco Construction Manual 1–5 Revision 4, March 1, 2002
problems. If you are not prepared to spend the time and money on engineering, then you should
not expect us to be enthusiastic about the design change. Also, to do this type of thing properly
will involve a lot of our time. We do not have the time available.
Our policy is that we will not supply any parts for a modified Falco. We will not allow the name
“Falco” to be used for the airplane, and you may not use our paint schemes, which are
copyrighted. We have found that the vast majority of Falco builders approve of this policy. It is
easy for an airplane to get a bad reputation because of a crash of a modified design. The public
only knows that it was a “Starflight” that crashed and so assumes that all such airplanes by the
same name share the problem inherent in the design. This affects the reputation and resale value
of the airplane—something none of us needs.
You will also find that potential buyers will be interested only in a standard Falco. They will not
be interested in a highly-modified airplane. If you don’t believe us, take a look at the ads in
Trade-A-Plane. One-of-a-kind aircraft never seem to sell, despite the fantastic performance claims
and the publicity inevitably given to such unique aircraft. It will be the same with the Falco,
people will want a Stelio Frati-designed Falco—not one designed by Frati and you. Think about
it, would you want a Falco that some amateur built using his own ideas on how the wing spar
should be designed? Stick with the plans.
Visit a Falco Builder
If there is a Falco builder near you, by all means pay a visit. It is best to visit a builder who has the
basic structure put together but has not yet started skinning the fuselage or wing. Take a camera
and shoot at least two rolls of color print film. You will find that black and white film does not
work well, as it is hard to see the details in the wood. Shoot photographs from every conceivable
angle. You will feel foolish doing this, but you will be amazed how helpful these photographs will
be later on. You will be able to look at the photographs and see things that you did not notice
while you were with the airplane.
Plan Ahead
You should begin to order the tools and materials you will need. By planning ahead and ordering
well in advance, you will always have something to do. One of the most frustrating aspects of
building an airplane is watching the mail for something that hasn’t arrived. If you find yourself in
this predicament, it is your own fault. There are bound to be little delays in delivery, but if you
plan far enough in advance, these delays will not hinder your progress.
In Search of Experts
You should be on the lookout for a helper. There are going to be many times when you will need
two people, and a partner will be a big help, and the work will go faster.
If you do not belong to the Experimental Aircraft Association (EAA) you should join. This
organization is dedicated to the subject of homebuilt aircraft. Their magazine, Sport Aviation, is
good, and you will find something of interest in every issue. (You should also be warned that you
will also find a lot of very amateurish ideas published in the magazine.) Above all, you should
join and support this organization since they are the primary reason we have the freedom to build
and fly our own aircraft. No other country allows such freedom as we have in the U.S., and your
support of the EAA is the best way to see that we keep our freedom.
You might also consider joining a local EAA chapter. Most EAA chapters are nothing more than
social gatherings of people who do not build airplanes. In general, you will find that the aircraft
that they are building are not of the same class as the Falco. You will find an occasional expert

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F.8L Falco Construction Manual 1–6 Revision 4, March 1, 2002
among the ranks of the chapter members; however, our experience is that the true experts tend to
be lone wolves. They do not tend to be joiners or socializers. You must seek them out, and you
can expect their enthusiasm to rise only after they have seen your aircraft under construction.
Contacting Sequoia Aircraft Corporation
From time to time, you will have a question for us. Usually, you will find that the question will
answer itself in time. If it is urgent, please feel free to call. Ordinarily, we prefer that you write in
your questions. There are several reasons for this. First, our day at the office is sometimes hectic,
and we can serve you better by taking the time necessary to answer the question in writing.
When you write, we ask that you number your questions and refer specifically to the drawing
number or sheet number. We can answer your questions quicker and easier this way, and it
eliminates any possible confusion.
Also, when you ask a question, you might not completely understand what we are saying in our
answer. If the answer is in writing, you will be able to refer to the letter and study the answer in
detail. It is much better for all concerned if you write in your questions. We make it a point to
answer questions from builders on the day the letter is received, so there will not be a long delay
in getting an answer.
Lastly, remember the adage “There are no dumb questions… only dumb answers”. Many builders
are reluctant to bother us with questions that they think are “dumb”. If you seek out the advice of
others, it is a good possibility that they will not be aware of the proper way of doing something,
particularly as it relates to the Falco. In particular, we have found that other homebuilders are
frequently the worst source for answers. Their experience may be based on building an amateur-
designed airplane, or they have learned a lot of short-cuts and bad habits which they obligingly
pass on. We would prefer to be the source of all of your answers. This way we can be sure that
you are getting the correct answers. If we don’t know what is confusing to you, we will not know
the sort of things to put in future editions of this manual.
Plans Assumption
If you lose interest in building a Falco, we would like to remind you that the plans purchase
agreement specifically prohibits the sale, gift or transfer of the F.8L Falco plans without written
consent of Sequoia Aircraft. In addition, all of the Falco drawings contain a notice to this effect.
The F.8L Falco aircraft design is the property of Stelio Frati, the designer of the aircraft, and it is
available from Sequoia Aircraft Corporation by contract between Mr. Frati and Sequoia Aircraft
and this contract prohibits the resale or transfer. All Falco builders should be aware of this
condition of the plans purchase agreement. Unfortunately, a few choose to ignore the terms of
their contract. This leads to a difficult situation to all concerned.
The usual situation comes up when a Falco project is sold. Personal finances, change in
employment, or death of the builder sometimes forces the sale of a project. In most
circumstances, we are consulted and offer advice. We always remind the seller of the prohibition
of the resale of the plans. In most cases this is not a problem for either party, and the transaction
is handled smoothly and properly by all concerned. In a few cases, the seller chooses to ignore the
terms of the contract and sells the plans anyway. This is a simple case of fraud, and we are always
happy to assist in any litigation or prosectution. Some publication, such as the EAA’s Sport
Aviation, will not accept advertisements for used plans for the Falco, Pitts or other designs that are
sold with this condition.
If you wish to sell your Falco plans, the purchaser purchase the drawing by paying $300.00 to
Sequoia Aircraft and signing a Plans Assumption Agreement. We have this form available on

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request. For your information, the price of the Falco plans is broken down as follows: roughly
$100.00 covers the cost of printing the drawings and construction manual, $100.00 goes to Mr.
Frati (his only compensation), and $200.00 remains for Sequoia Aircraft Corporation to cover its
costs. Thus, for us, the transfer of a set of plans is the same as the sale of a set of plans except that
we do not have to print and ship another set of drawings. Particularly in the case of overseals
builders, it makes more sense for everyone if plans are resold since no additional shipping costs are
incurred.
For those occasional situations where a set of plans has been sold to an unsuspecting purchaser,
these terms and conditions come as a shock. For this situation, we offer the following:
•Sequoia Aircraft Corporation is a business. We support all of our builders, and
in return we expect to have the plans purchased from us.
•We make every effort to avoid such situations, but if a potential builder does not
contact us in advance, there is no way that we can help him. We regret any
trouble or problems that may arise from such a situation.
•We are entirely inflexible on the subject. There is nothing to be gained by
attempted negotiation or protracted correspondence. We have never negotiated
on this point, and we never will.
•We don’t understand why someone would want to build a Falco and not buy the
plans from Sequoia Aircraft, thereby depriving Mr. Frati and us compensation
for the work we have done with the airplane.
•On a positive note, we look forward to working with all Falco builders on the
completion of their aircraft and hope that any unpleasantness caused by any
misfortune will be quickly forgotten.