Musings from the Combat Pits

A carrier for Combat planes

November 2025

The rack holds nine Combat planes of various sizes. All photos by Buzz Wilson.

By Buzz Wilson

For years I used old produce boxes from the grocery store with the sides notched out to carry airplanes. Several years ago I decided to build a custom carrier using PVC tubing and fittings. The carrier had to be easy to handle and fit into my Rav 4. The one that I built holds nine Combat-type models. The original design used foam pipe insulation over the vertical dividers to protect the planes. I soon learned that they were more trouble than they were worth and removed them. The carrier has never damaged a plane.

A couple of weeks ago I was delivering some planes to John Knoppi and he wanted to know if it came with the carrier. I told him no. On my way home, I decided to build a carrier for John. In this article I am detailing the construction process.

Here is the bill of materials and quantities. When buying the Tees check for contractor packs. This will save you a lot of money. Speaking of money, the materials will cost you about $90.

The first step is to cut the PVC connectors that will connect the PVC fittings. To determine the connector length, measure the distance from the inside stop of the fitting to the end of the fitting. Multiply by two and subtract 0.1 inches. For the fittings that I used this is 1.5 inches. I used a band saw with a stop at 1.5 inches to get the correct length.

Once they are cut, check for squareness.

If not square, use a disc sander to square the ends. Use the disc sander and put a slight taper on each end. A total of 22 connectors is required for the project.

Next the vertical hold pieces are cut. Lengths are marked on a piece of PVC and each cut. These are stacked vertically and lengths compared and adjusted using the disc sander. Using a belt sander, a slight taper is put on each end.

Next cut eight pieces 11.5 inches long. Check them to make sure they are identical lengths and taper the ends. Here are all the pieces cut and ready to assemble.

The above process take about four hours.

With all the pieces cut, it is time to do dry fits. The PVC tees are joined together using the couplers. The couplers are a tight fit and all must be aligned straight.

Dry fit the entire assembly to make sure the couplers are correct. I found that some of the couplers needed to be thinned down. I did this by rotating them on the belt sander. Once everything is checked, insert and glue couplers in place. Because you have limited time to adjust pieces before the PVC cement sets, the couplers are glued into the PVC tees. You will notice that some have two couplers and others just one. The next step is to join two tees together. Glue is put in one tee and the other tee with the coupler pushed into it and the two tees forced flat onto a flat surface. This is done to make sure that when all couplers are joined together that they are straight. At this point you will have four sets of two tees. Next you will glue two tees to a group of two tees. This completes one side piece. Repeat and make the second side. Check to make sure the two side pieces are equal.

Take one of the 11.5 inch pieces and glue a tee to it. Repeat with another 11.5 inch piece of PVC. Once the glue is dry, take one piece and glue a tee to  the other end. Press the tees against a flat surface to insure squareness. Once dry insert a coupler into the one end of each tee. Now take the piece with the horizontal piece and tee and attach it to the connector on the completed horizontal piece. Take a tee and place it on the other end of the second horizontal piece and then onto the coupler. If everything is correct you will have two identical pieces. Now remove the unglued piece and apply glue and re-assemble.

It is time to assemble the unit. You will need a flat surface and straight edges. I used a heavy metal ruler for one side. Insert photo 0071 I then used framing squares for  the two sides. Insert photo 0072& Insert photo 0073 The photos show the dry fit assembly.

Now disassemble and carefully glue and reassemble.

The vertical dividers are now put in place. Any misalignment will be obvious. Adjust them to bring into alignment. I used a piece of straight wood to align them.

Once they are aligned they can be glued. You may notice a vertical piece with a 90 degree fitting. This is a piece of the handle that is dry fit to help with the alignment.

The next step is to assemble the handle assembly. Dry fit and make sure the two assemblies are identical. Once identical then glue the assembly making sure that it is square.

One final step is to add sheet metal screws to the ninety degree fittings.

This is insurance that if the glue joint fails that the assembly will remain in place.

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This page was updated Nov. 1, 2025