Travel Tool Bag contents

[Ed Haywood]

Recent loss of my hangar led me to reconfigure my tools for mobile packout. That in turn has led me to set up a bag of tools left at the aircraft, to be used for XC trips. Contents so far:

Pliers, needlenose, dikes, screwdrivers
Combination wrench set
Adjustable wrench
1/4" ratchet and socket set
3/8" ratchet and selected sockets*
Safety wire
Duct tape
Zip ties
Steel bristle brush
WD-40 and tube of synthetic grease
Wire stripper/crimper, few feet of wire, butt splices and ring terminals
Jack adapter

To balance bulk and weight against utility, I limited larger sockets to those I know I might need. I have a deep 7/8" hex socket for pulling plugs, a 12 point 9/16" socket for landing gear nuts, and a 10mm for my EarthX battery terminals.

Intent is not to be able to handle anything that might arise, or to make permanent repairs. It is just to make expedient fixes when stuck where help or tools might not be available. Focus is on owner maintenance items such a loose hardware, cracked fairing, broken wire, cut fabric covering, fouled plug, etc.

Example: 5 years ago enroute to Oshkosh, I stopped at Rough River Kentucky. The next morning at my preflight, I discovered one of the hinges on my side window was missing the hinge pin. A few loops of safety wire through the barrel got me to Oshkosh and home.



So what do you have in your travel maintenance bag?

 

[Rcmutz]

A credit card!

 

[Roger Wilco]

Recent loss of my hangar led me to reconfigure my tools for mobile packout. That in turn has led me to set up a bag of tools left at the aircraft, to be used for XC trips. Contents so far:

pliers, needlenose, dikes, screwdrivers
Combination wrench set
Adjustable wrench
1/4" ratchet and socket set
3/8" ratchet and selected sockets*
Safety wire
duct tape
zip ties
steel bristle brush
WD-40 and tube of synthetic grease
Wire stripper/crimper, few feet of wire, butt splices and ring terminals
Jack adapter

To balance bulk and weight against utility, I limited larger sockets to those I know I might need. I have a deep 7/8" hex socket for pulling plugs, a 12 point 9/16" socket for landing gear nuts, and a 10mm for my EarthX battery terminals.

Intent is not to be able to handle anything that might arise, or to make permanent repairs. It is just to make expedient fixes when stuck where help or tools might not be available. Focus is on owner maintenance items such a loose hardware, cracked fairing, broken wire, cut fabric covering, fouled plug, etc.

Example: 5 years ago enroute to Oshkosh, I stopped at Rough River Kentucky. The next morning at my preflight, I discovered one of the hinges on my side window was missing the hinge pin. A few loops of safety wire through the barrel got me to Oshkosh and back home.

View attachment 153620

So what do you have in your travel maintenance bag?

This is a great idea for a thread. The necessities, and nothing more. That leaves us with Vice-Grips, a hammer, safety wire, and duct tape. And super glue. And...

But seriously, I do recommend the Vice-Grips.
My airplanes have all had a couple of relatively oddball bits that required a 5/16 or 11/32 wrench.
Your list includes 1/4 and 3/8 ratchets and sockets. I've found that a 1/4" ratchet and socket set can maintain nearly everything, a notable exception being the spark plugs. So, I carry a 3/8 torque wrench and the 7/8 socket for that purpose, along with a 3/8 to 1/4 adapter so that I can use the torque wrench on other fasteners.
I also include a small assortment of hardware: screws, nuts, cotter pins, of appropriate sizes.
Small tubes of LockTite and anti-seize may not meet the definition of "necessity," but they're light and don't take up much space and I like to use them when called-for.
Lastly, I have a PDF copy of the maintenance manual on my iPad, in case I am AOG at some airport with a problem that I can't solve.

Well, I guess my list includes more than the bare necessities. Except that everytime I break down somewhere, it seems that I need something that I didn't bring, and very little of what I did bring.

 

[robin ardoin]

I carry combination wrenches for most common fasteners, racheting screw driver with inserts, 1/4 socket set/ slected 3/8 ratchet and sockets/extension. Long reach needlenose pliers, diagonal wire cutter, dedicated flush diagonal for zip ties only, alternator brush kit and belt (and, as of late, alternator...more to that story), fuel lube for fuel cap orings, mouse milk for the wastegate, oil, funnel, tri-flow spray, fuses, multimeter and thcik disposable nitrile gloves. I am fortunate that my 210 has incredible UL and the space to put plenty of extras.

 

[farmrjohn]

From what I've been seeing on the internet you better lock up that 10mm socket

 

[Half Fast]

My kit is very similar. I also have a small funnel, a spare airplane key, a tire pressure guage, a small flashlight, a couple of rags, and some hand cleaner.

For a mechanic to work on an airplane legally, he must have a copy of the plane's maintenance manual. I can't count on an A&P at any out-of-the-way field to have documentation for my Musketeer, so I have the manuals and IPCs for the plane and engine stored on a thumb drive in my tool bag.

Everything fits into one of these bags from HF:

https://www.harborfreight.com/12-in-tool-bag-with-21-pockets-61467.html

 

[455 Bravo Uniform]

Add a hex/allen to tighten or pull out radios from the stack if needed.

 

[asicer]

From what I've been seeing on the internet you better lock up that 10mm socket

I've done that and they still disappear. It's as if they have teleportation capabilities.

 

[Ed Haywood]

I've done that and they still disappear. It's as if they have teleportation capabilities.

Fortunately there are exactly 2 nuts on my airplane that take 10mm. The battery terminals of the EarthX. They also take phillips head, if you have Arnold Schwarzenegger wrists.

The strangest fasteners from a tool perspective would be the high torque nuts on my landing gear bolts. Those require a 12 point 9/16" socket or box wrench. I had to buy a box end adapter to torque them properly. Fortunately one can buy anything from Amazon.

 

[asicer]

Fortunately there are exactly 2 nuts on my airplane that take 10mm. The battery terminals of the EarthX. They also take phillips head, if you have Arnold Schwarzenegger wrists.

The strangest fasteners from a tool perspective would be the high torque nuts on my landing gear bolts. Those require a 12 point 9/16" socket or box wrench. I had to buy a box end adapter to torque them properly. Fortunately one can buy anything from Amazon.


View attachment 153634 View attachment 153635

Huh, hard to tell from the picture whether that's a true 12-point fastener or a XZN triple-square fastener. As long as your wrench works, I suppose it doesn't matter much.

I'll bet @Tools has both

 

[murphey]

7/16" and 9/16" box wrenches take apart just about everything in the cherokee. Couple of hex for the radios. A phillips for the seat rails and flat head, just because. Vice-grips, needle-nose and slip pliers. All this in a small plastic case in the baggage area that also contains 2 qts of oil, safety wire, paper towels, an extra tire tube. Anything more, I need a shop because I'm not going to add the weight of a jack and tools to change the tire.

 

[Doc Holliday]

Only tool bag I need or carry

 

[Stewartb]

Here’s my Cub bag of tools. I love my Ready Ratchets. They hold their own sockets.

 

[Ed Haywood]

Huh, hard to tell from the picture whether that's a true 12-point fastener or a XZN triple-square fastener.

They are NAS 1805 high strength self locking 12-point flange nuts.

 

[schmookeeg]

I do feel like an uber to and fro the nearest harbor freight settles a lot of this. Even for values of "nearest" that might be >100mi in BFE.

I carry one of those basic toolkit/ratchet sets. This is making me think I should bring safety wire, pliers, and a spark plug socket -- perhaps in lieu.

 

[Ed Haywood]

I do feel like an uber to and fro the nearest harbor freight settles a lot of this. Even for values of "nearest" that might be >100mi in BFE.

A mere one hour drive. But TBH I probably could have fixed that hinge with a scrounged up paperclip.

 

[Brad W]

For an aircraft bag, I think I'd be
a) focusing on pure basic emergency jury-rig repairs to minimize what I'm carrying...just enough to tighten a loose fastener even if it buggers up the head and needs to be replaced sort of thing. Simple basic spark plug wrench as opposed to a real mechanic's socket and ratchet, etc....
and b) ultralight tools made from lightweight alloys &/or with lightening holes (something like this...)


I don't own one ....yet...but I've seen good things about the Knipex Pliers Wrench in place of an adjustable. A pair of these might not replace proper open end/box end wrenches for tight areas, but they might replace the crescent wrenches and the standard pliers

Not for aircraft use....I have a single pair of these knipex pliers and it has become my go-to. Even used quite a few times to tighten hex heads in a pinch. Works better than standard channel locks for almost everything

 

[sourdough44]

It’s a trade off, weight & complexity add up. Then one could have an issue where it takes a real mechanic to make things right. People around most airports often are willing to assist also.

 

[Tools]

Really like these parallel jaw knipex. Those others pictured rock as well. These are exceptional for the back up wrench like when ya need two.

 

[Ed Haywood]

Not for aircraft use....I have a single pair of these knipex pliers and it has become my go-to.

Really like these parallel jaw knipex. Those others pictured rock as well. These are exceptional for the back up wrench like when ya need two.

Dammit, now I gotta buy one. You guys are in trouble with my wife.

 

[Tools]

Hmmm… those little parallel jaw… work GREAT on a Kitchen Aid/horse tack/Singer… help me out here. We’ll save ya!

 

[bonefishpete]

My kit is very similar. I also have a small funnel, a spare airplane key, a tire pressure guage, a small flashlight, a couple of rags, and some hand cleaner.

For a mechanic to work on an airplane legally, he must have a copy of the plane's maintenance manual. I can't count on an A&P at any out-of-the-way field to have documentation for my Musketeer, so I have the manuals and IPCs for the plane and engine stored on a thumb drive in my tool bag.

Everything fits into one of these bags from HF:

https://www.harborfreight.com/12-in-tool-bag-with-21-pockets-61467.html

Come on that’s a stretch isn’t it?

 

[Ed Haywood]

I always despised crescent wrenches. But recently discovered they are not all equal. Wrenches with more threads on the worm gear are more precise and slip less. Bought this Tekton recently to meet the two wrench requirement in my travel bag for inverted oil system hoses, many of which have larger fittings. With 5 threads vs the usual 3, it has zero slop. Note it has a hole for a 3/8" ratchet if needed. I have not used it yet.

 

[Roger Wilco]

For an aircraft bag, I think I'd be
a) focusing on pure basic emergency jury-rig repairs to minimize what I'm carrying...just enough to tighten a loose fastener even if it buggers up the head and needs to be replaced sort of thing.

Brad, maybe I have misunderstood your meaning, but I strongly recommend doing the job right or not doing it at all. At the risk of sounding too much like Robert Pirsig*, before putting a tool to the airplane, one must first have respect for the machine. Buggering thigs up is the antithesis of good workmanship and can make life unnecessarily difficult for the next person who has to work on that assembly. If I don't have the right tool for the job, I buy one or find someone who has one. I apologize for writing what sounds like a lecture--it's just my opinion.

Simple basic spark plug wrench as opposed to a real mechanic's socket and ratchet, etc....
and b) ultralight tools made from lightweight alloys &/or with lightening holes (something like this...)
View attachment 153646

Those are very cool. I couldn't find them in SAE, but they could be perfect for the motorcycle.


*Robert Pirsig was the author of the pop philosophy book, Zen and the Art of Motorcycle Maintenance that was very popular in the 1970s.

 

[Ed Haywood]

Brad, maybe I have misunderstood your meaning, but I strongly recommend doing the job right or not doing it at all. At the risk of sounding too much like Robert Pirsig*, before putting a tool to the airplane, one must first have respect for the machine. Buggering thigs up is the antithesis of good workmanship and can make life unnecessarily difficult for the next person who has to work on that assembly. If I don't have the right tool for the job, I buy one or find someone who has one. I apologize for writing what sounds like a lecture--it's just my opinion.


Those are very cool. I couldn't find them in SAE, but they could be perfect for the motorcycle.


*Robert Pirsig was the author of the pop philosophy book, Zen and the Art of Motorcycle Maintenance that was very popular in the 1970s.

I found some thin wrenches at Walmart that are surprisingly good for the price. Very light weight for the larger nut sizes, which I need because of inverted oil fittings. Most of my hoses are 1" or 15/16".

Hyper Tough 8-Piece Thin Open-End Wrench Set with Organization Pouch (SAE) - Walmart.com

Buy Hyper Tough 8-Piece Thin Open-End Wrench Set with Organization Pouch (SAE) at Walmart.com

www.walmart.com

 

[Brad W]

Brad, maybe I have misunderstood your meaning, but I strongly recommend doing the job right or not doing it at all. At the risk of sounding too much like Robert Pirsig*, before putting a tool to the airplane, one must first have respect for the machine. Buggering thigs up is the antithesis of good workmanship and can make life unnecessarily difficult for the next person who has to work on that assembly. If I don't have the right tool for the job, I buy one or find someone who has one. I apologize for writing what sounds like a lecture--it's just my opinion.

I agree with your point.
and yeah, maybe I wasn't clear enough with my off-the-cuff comment.
What I meant was every repair in the field doesn't have to be pristine. Think emergency type stuff

Considering the weight and space penalty of bringing along a proper set of tools
my focus would be primarily emergency troubleshooting and repair type stuff. Not on doing regular maintenance. It's get me out of there kind of things...such as putting it down on a field with no services and nobody around for miles because weather was closing in...and a loose electrical connection prevents a restart after it clears. In that case, I'd be willing to bugger up the battery terminal with a pair of channel locks to get back out of there. I can replace the terminal when I get back to civilization and use the proper wrench then, so as not to bugger up the new one.

Another example might be pulling plugs to clean a fouled one. I'm not going to have a proper torque wrench in my tool bag, so a basic, crude spark plug wrench will do.... and if I'm on a field with people and services, then I'd try to borrow the correct tools or I'd hire it out

 

[iamtheari]

I went with a Tool Roll with mostly straight wrenches to keep in the RV. I often fly routes without a Harbor Freight so I erred on the side of capability, but not redundancy or necessarily convenience. No torque wrench or sockets other than spark plug sockets, that can be turned with a straight wrench.

If I had to point to the most critical tool, though, it’s a very stubby Phillips screwdriver. My wheel pants sit low enough to inspire a Flo Rida song and you can’t get to the lowest screws with just any screwdriver. I use a 1/4” ratchet with a #2 Phillips socket in the hangar.

So that’s my advice: Find the tools you had to pick up special for your plane and pack those.

 

[RyanShort1]

For not-so-stubborn bolts and nuts, a pair of these are reasonably useful...

https://amzn.to/4bqkCfB

 

[mondtster]

FWIW, I don’t regularly use much more than a 1/4” socket set, combination wrenches, and screwdrivers to work on aircraft for 8-10 hours a day. There’s no need to haul all that stuff around in an aircraft all the time.

To me, parts would be the bigger concern on a cross country trip, especially if they’re something unique to the aircraft. That will stop you far quicker than not having a tool will. There are plenty of places around to borrow or buy enough tools from to get by, and they’re not all named Harbor Freight.

 

[Lama1125]

Being an IA has its perks when you're an owner.
Complete set of serviced plugs, small container of anti-sieze and new gaskets.
Spark plug socket, rachet, 3/4" wrench
Various bulbs, screws, nuts, washers
Safety wire and pliers
1/4" Socket set from 1/4" to 9/16"
Adjustable hammer (Combination wrench)
6 in 1 screwdriver from Harbor Freight (Love this one, I have one in my work toolbox I use more than my Snap-On drivers)
(On long XCs I carry a spare tire/tube with tools for it)
Spare brake linings, tool, o-rings and hydraulic fluid. (I've had a caliper pop when my brake linings failed)
9mm Tarus Millenium G2

I usually only have the bag in the plane if I'm going more than an hour or so away. The spark plugs are in a separate bag in the back because those are most valuable to have.

 

[Lama1125]

Come on that’s a stretch isn’t it?

The Beech Mouse is a weird airplane that not a lot of people work on anymore. I've been an AP for 10 years and only worked on one. I wish more pilots had copies of their aircraft MM and IPC to share. Saves me a lot of time digging through the internet or purchasing one if it isn't readily available.

 

[Ed Haywood]

6 in 1 screwdriver from Harbor Freight (Love this one, I have one in my work toolbox I use more than my Snap-On drivers)

Harbor Freight has upped their game over the years. Still have the cheap Chinesium crap, but their upper tier brands are decent and make good travel bag stuffers. I just picked up a composite 3/8" ratchet for 10 bucks. Just has to survive one project.

 

[farmrjohn]

The Beech Mouse is a weird airplane that not a lot of people work on anymore. I've been an AP for 10 years and only worked on one. I wish more pilots had copies of their aircraft MM and IPC to share. Saves me a lot of time digging through the internet or purchasing one if it isn't readily available.

I'd like to have a better MM. The one for my plane is 66 pages and that includes the current ADs and the related service bulletins that I've included, otherwise it's only 21 pages. Traveling with a digital version makes sense though.

 

[Roger Wilco]

FWIW, I don’t regularly use much more than a 1/4” socket set, combination wrenches, and screwdrivers to work on aircraft for 8-10 hours a day. There’s no need to haul all that stuff around in an aircraft all the time.

If you work on aircraft 8-10 hours a day, I'm sure you are pretty handy with safety wire. And you'll want pliers for getting a nice snug twist. That's how the list grows.

To me, parts would be the bigger concern on a cross country trip, especially if they’re something unique to the aircraft.

This is a very good point. I note that a couple of replies included a tire and/or tube. I might start packing a tire patch kit and a small, lightweight bicycle frame pump on certain trips. The list grows fast.

There are plenty of places around to borrow or buy enough tools from to get by, and they’re not all named Harbor Freight.

Not always. It's surprising how many airports do not have a maintenance provider on the field, and it seems that each year there are fewer and fewer. So you're AOG on the ramp at Podunk Regional, and you're eyeballing a row of hangars, at least one of which you just know contains a tool box with just what you need to get going. All you have to do is wait for the hangar tenant/owner to appear, which of course, never happens.

And don't count on the Snap On truck showing up either, at some place like Grant Co. Municipal, Hyannis, NE (1V2), on a Sunday. More likely you will find a ride into town where you will try to beg/borrow/steal (okay, maybe not steal) what you need, which means another ride into town to return it. Which you will. Meanwhile you keep kicking yourself for leaving that tool in your tool chest back home (voice of experience speaking here). And so the list grows.

As for HF, in many places it's the only game in town as far as tool suppliers go. Oh sure, the quality is not consistent and no one will be impressed by your Pittsburgh branded kit, but it will suffice for this purpose.

 

[Lama1125]

I'd like to have a better MM. The one for my plane is 66 pages and that includes the current ADs and the related service bulletins that I've included, otherwise it's only 21 pages. Traveling with a digital version makes sense though.

What plane do you have? I keep mine on the files of my phone/ iPad. If I need anything when I get to a destination I will be staying for a few days, I can look them up and get them coming. Quite convenient and keeps me from lugging around a computer to look things up.

 

[Lama1125]

Harbor Freight has upped their game over the years. Still have the cheap Chinesium crap, but their upper tier brands are decent and make good travel bag stuffers. I just picked up a composite 3/8" ratchet for 10 bucks. Just has to survive one project.

Seriously. I only use their tools in the shop I have at home. When I need a tool for work, HF I go. Why spend so much money on Snap-On or the others? Same warranty, similar quality tools, drastically cheaper prices and easier to exchange. Much better than tracking down a tool truck (we don't have a truck that comes around here, I have several tools that require repair/ replacement)

 

[JRSB]

Spare tailwheel, even if its solid. Having one come apart while away from base isnt fun and it takes up minimal space.

 

[Silvaire]

I went into Harbor Freight to get some zip-ties. I came out with a couple of screwdrivers, a socket set, a pair of hemostats, a pry bar, a pair of 7x50 binoculars and an RC helicopter. Had to go back in again for the zip ties.

 

[mondtster]

If you work on aircraft 8-10 hours a day, I'm sure you are pretty handy with safety wire. And you'll want pliers for getting a nice snug twist. That's how the list grows.

Lock wire can often be done by hand or with a multi tool. I don't see a point to carry a lock wire plier for the minimal amount of stuff on a light airplane that is safetied with lock wire on the extremely unlikely chance that you'd find yourself in the middle of nowhere and need to replace a damaged safety.

Not always. It's surprising how many airports do not have a maintenance provider on the field, and it seems that each year there are fewer and fewer. So you're AOG on the ramp at Podunk Regional, and you're eyeballing a row of hangars, at least one of which you just know contains a tool box with just what you need to get going. All you have to do is wait for the hangar tenant/owner to appear, which of course, never happens.

And don't count on the Snap On truck showing up either, at some place like Grant Co. Municipal, Hyannis, NE (1V2), on a Sunday. More likely you will find a ride into town where you will try to beg/borrow/steal (okay, maybe not steal) what you need, which means another ride into town to return it. Which you will. Meanwhile you keep kicking yourself for leaving that tool in your tool chest back home (voice of experience speaking here). And so the list grows.

As for HF, in many places it's the only game in town as far as tool suppliers go. Oh sure, the quality is not consistent and no one will be impressed by your Pittsburgh branded kit, but it will suffice for this purpose.

Nearly all box stores sell some tools, along with most auto parts stores. The auto parts stores may even have a loaner tool program that could get you by without having to buy anything. It looks like even Hyannis has a potential option to source some basic tools.

But once again, tools aren't really the problem, parts are more of the issue. I spent most of today in a car driving to pick up an aircraft part to cure an AOG situation that took 20 minutes and 3 basic tools to remove and install. Having all the tools in the world wouldn't have gotten things moving any faster than if I had to walk to town to find the tools and walk back again to return them because I would have still been waiting for the part to arrive.

 

[Half Fast]

But once again, tools aren't really the problem, parts are more of the issue.

True. It’s a good idea to bring along a handful of screw, nuts, and washers, a spark plug, a tire tube, a vacuum pump, a mag, a spare cylinder, maybe a camshaft,.....