Essential Tools for General Aviation Hobbyists: Building and Maintaining Your Aircraft

General aviation (GA) isn't just a sector, it's a passion shared by homebuilders, private pilots and small MRO operations across the country. Whether you're building a Van's RV in your garage or managing maintenance for a Piper Archer at your local airfield, using the right tools can mean the difference between smooth flying and preventable downtime.

This guide outlines the essential tools for general aviation maintenance and aircraft building, grounded in practical applications and current industry best practices. 

Why the Right Tools Matter in General Aviation?

General aviation aircraft operate in diverse conditions and are often maintained by owners or small shops. Unlike commercial airliners, GA aircraft rely heavily on owner-assisted maintenance and amateur-built aircraft support, making tool selection critical. From annual inspections to experimental aircraft assembly, quality and precision are non-negotiable.

Top General Aviation Tools for Aircraft Maintenance and Homebuilding

1. Hand Rivet Squeezer

When assembling aluminum airframes like those from Van's, Sonex, or Zenith, a rivet squeezer is indispensable. Unlike industrial pneumatic systems used in commercial aviation, hand or benchtop rivet squeezers provide the control and precision GA builders need, especially in tight spaces. Look for alligator yoke or C-yoke configurations.

2. Dimple Dies and Skin Dimplers

If you're working with pre-punched skins, proper dimpling ensures tight flush rivet fits—a must for aerodynamic efficiency and corrosion prevention. Dimple dies paired with a DRDT-2 dimpler or C-frame are go-to tools in the GA builder's arsenal.

3. Cleco Fasteners and Pliers

Clecos act as temporary rivets, essential for mockups and pre-assembly. Most general aviation kits require hundreds, and they come in multiple sizes (1/8”, 3/32”, etc.). Invest in a complete set and a spring-loaded plier.

4. Torque Wrenches (Inch-Pound and Foot-Pound)

Proper torque ensures bolt integrity without stripping or under-tightening. GA aircraft often rely on Lycoming or Continental engines, where incorrect torque can lead to serious failures. Use calibrated, aviation-grade torque wrenches.

5. Spark Plug Gap Tool and Cleaner

GA aircraft engines like the O-320 or IO-360 rely on standard aviation spark plugs that require precise gapping and regular cleaning. A good gap tool and cleaner can extend plug life and enhance combustion efficiency.

6. Borescope for GA Engine Inspections

Small-diameter borescopes allow you to inspect inside cylinders, valves, and exhaust paths during annual or pre-buy inspections, without pulling a jug. 

7. General Aviation Multimeter

A fundamental but indispensable tool for checking battery charge, continuity, and voltage drops. Many GA issues stem from corroded wiring or aging voltage regulators. Choose a model with auto-ranging and backlit displays for hangar work.

8. Digital Weighing System

Weight and balance are more than just a checkbox; they're a regulatory requirement and flight safety measure. Aircraft like the Cessna 172 or RV-7 require accurate, repeatable weighing after maintenance or build. Aviation-specific scales offer better stability and error correction than standard shop platforms.

Bonus Tools for GA Homebuilders and Technicians

• Safety wire twister pliers – Secure fasteners subject to vibration.
• Fluting pliers – Adjust formers and ribs during fuselage or wing construction.
• Angle drill attachments – For drilling in hard-to-reach areas inside airframes.
• Cable tension meter – Critical for properly rigging control surfaces.

Where to Buy GA Tools: National Aviation’s Online Store?

For general aviation professionals and hobbyists, sourcing reliable, aviation-specific tools can be a challenge. That's why many turn to National Aviation's online store, a trusted name in the GA community.

At National Aviation, we offer:

•  A full line of aircraft tools and pilot gear
•  Free shipping on orders over $350
•  Same-day shipping on most items
•  A seamless, easy-to-use shopping experience
•  10% off your first order with code NA25

Our inventory is curated for general aviation, with products tailored to piston aircraft, experimental builds, and private pilot maintenance needs.

Visit National Aviation today and use code NA25 to save on your next upgrade or maintenance job.