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Top 10 Essential Tools Every Aircraft Mechanic Should Have
- June 06th, 2025
- Categories: Uncategorised
In the high-stakes world of aerospace maintenance, precision, reliability, and efficiency are paramount. Aircraft mechanics rely on a suite of specialised tools to ensure that every component—from rivets to fasteners—is installed and maintained to exacting standards.
Applied Fasteners and Tooling (AFT Systems) stands at the forefront of this industry, offering a comprehensive range of tools designed to meet the rigorous demands of aerospace maintenance.
This blog delves into ten essential tools that every aircraft mechanic should have for general maintenance and repair, highlighting their technical specifications and the role they play in ensuring aircraft safety and performance. After all, you want to use the best tool for your project.
What Tools Should an Aircraft Mechanic Have in Their Toolkit?
Many speciality fasteners meet approved standards, and the same is said for aerospace tooling and consumables.
Cleco Pins
Cleco Fasteners make fabrication work easier than ever before with versatile, handy fastening tools (which are sometimes spelled Celko or called Skin Pins). They are an indispensable tool which can save you a lot of labour time!
These are used extensively in aviation for temporary fastening solutions and securely hold multiple sheets of material together and ensure a perfect alignment before permanent joining processes such as welding, bonding, or riveting.
As a user-friendly design for engineers and efficient operation, Plier Operated Cleco Fasteners are always going to be part of an aircraft mechanic’s toolkit.
The Plier Operated Cleco Fasteners is a game-changer, providing a strong grip and stopping movement and misalignment during assembly or repair operations. You can expect a seamless final assembly.
Likewise, the KK1/8 Extra Short 0-1/4” Grip Plier Operated Cleco Fasteners is a sheet holder clamp that is simple, cost-effective and adaptable to many processes. The plier-operated design allows for quick installation and removal, which is non-negotiable for projects that are time sensitive. Other categories include Long, Extra Long, Heavy Duty, and Standard.
Countersink Cages
Zephyr Tool Group meets the demands of the commercial and military markets for a range of countersink cages, which is critical to countersink tooling. What are some of the tools engineered to perform?
ZT680-SW Swivel Shaft
The ZT680-SW Swivel Shaft is machined for continuous operation at speeds up to 6,000 RPM without ever overheating!
Countersink with up to 5 degree off angle between the spindle and the cutter axis. It is designed for use on all standard materials as well as the latest composite materials in the most demanding applications.
ZT691/ZT692 High Precision Microstop Cage
These countersink cages are designed for continuous operation at any speed up to 6,000 RPM and are suitable for metallic, graphite, and composite materials used in the airframe industry today. They offer .0005” depth adjustment and are available in a full range of foot pieces. Other features include:
- Heavy-duty construction
- Improved thrust system which increases run time between adjustments and product life
- Fail-safe positive stop design for accurate repeatability and eliminating the chances of workpiece damage
- 1” to 2” cutter capacity
- And more!
Countersink Cutters
Zephyr’s Swivel Shaft High Speed Microstops allows you to countersink with up to 5 degree off angle between the spindle and the cutter axis. The ZT666, ZT667 and ZT668 series use a common body design, making all footpieces, footplates and spare parts interchangeable.
They are designed for use on all standard materials as well as the latest composite materials in the most demanding applications. Other series include the ZT575 Series 2 Flute, ZT576 Series 3 Flute and more. The ZT576 Series 3 Flute is a Standard polit cutter with M8 x 1:00 metric male threaded shank for use with Recoules (-M8) series Microstop Cages.
FSI Cordless CherryMax Riveter Kit
This PT:4500 Cordless Blind Riveter drill by Fastening Systems International is a new, higher capacity that offers a sheet material technician the capability for installation of most all ¼” diameter blind rivets.
Both aerospace and industry quality blind rivets are installable with the PT-4500 which include the CherryMax “A” and more.
Powered by a slide-on 18 VDC Li-Ion battery pack with fuel gauge,the PT-4500 brushless motor drives a mechanical ball screw gear system that provides capability for the most demanding of applications for the air.
Aircraft Rivet Squeezer Sets
Featuring an all-steel construction, this adjustable set holder accepts all sets with a 3/16” shank and long handles for increased force.
The yoke is made of the highest quality tool steel; all an aircraft mechanic needs to do is remove 3 pins to change the yoke to match riveting or dimpling applications.
Note: the ram that holds one of the sets rotates to adjust the set up or down, and new units can be a bit stiff and need a small pin or nail to make the first few turns. You also cannot buy the squeezer without the yoke.
Air Drill
An alloy egg cup bush holder is premium and allows you to drill perfectly straight holes into curved or flat surfaces. Made of solid aluminium with a steel lock in a life, this product is a strong choice for any mechanic’s tool kit.
Egg cup bush holders use an industry standard ½” Ø slip bushes and are available in either a 3 or 4 leg configuration. You can also acquire a 10 piece plastic drill cup and bushing kit which allows you to repair mismatches or crooked holes. The cup is made of plastic with steel liner and uses ½: O.D slip bushings.
The Aluminium Pen Reamer 316-1 by Bahco helps aircraft mechanics with deburring tubes, internal deburr, is extra lightweight, has an aluminium body, and a HSS-blade.
You can also use a Plastic Pen Reamer 316-2 for deburring tubes, internal deburrs as it has a plastic body and extra HSS-blade inside. There are also spare blades suitable for the 316-2 pen reamer/deburr tool!
If you would like to know more, AFT has deburring tools, hand tools, and rivet tooling you can invest in!
Hilok Ratchet
Hi-Lok Tooling such as Hi-Lok Hand Ratchets are a must-have in the general maintenance toolkit. The Omega Technologies ATHR-MINI Small Hi-Lok ¼” Hand Ratchet is manufactured from high-quality materials and nickel-plated for strength.
These hand ratchets are available in a variety of sizes and are suitable for a number of applications, including Hi-Lok systems. Hi-Lok hand ratchets are durable, easy to reverse, compatible with other Hi-Lok systems and engage with minimal movement.
Protrusion Gauges
Manufactured for use on all types of frangible and torque-control fasteners, these gauges determine if the correct length pin has been installed by determining if the pins project is between the allowable minimum and maximum ranges shown on the gauge.
The OM2-1522 Large Diameter Hi-Lok Protrusion Gauge Black Markings by Omega Technologies measures 1.8” square and are easy to handle and provide plenty of reach to inspect larger fasteners. .020” full hard stainless steel ensures long gauge life and a large footprint helps stabilize gauge against work surface.
Gauges are available for Hi-Lok, Hi-Lite, and Ho-Tique systems; exceeding the max limit requires a shorter pin, and falling short the minimum limit requires a longer pin. The correct pin will be between the maximum and minimum limitations, giving the proper ratio of grip to protrusion.
These complete sets include gauges for -5 to -12 fasteners. Constructed of full-hard, electro-chem etched, 301 stainless steel for durability, these gauges are assembled on a chain for easy selection and use.
Offering technical support through the product lifecycle working with design, procurement, production, quality, maintenance and repair, what are some of our services at AFT?
- Application engineering support, such as valuable solutions to complex manufacturing and maintenance problems.
- Product development and training, as we have access to innovative fastening and tooling manufacturers. We support the training of new products and techniques to deliver maximum value to customers.
- Program management and VMI, including design, procurement and delivery of all fastener and assembly/repair products.
- Repair and maintenance support, such as after-sales support for specialised equipment in aerospace, defence and industrial applications.
If you would like to learn more, have a read of why countersink cages are a critical tool in aerospace manufacturing!
Need Aerospace Fasteners? Get a Quote at AFT Today!
Are you looking for a specific tool? Registered and AS9120 quality certified in 2014, we were founded to supply the aerospace and defence industries with specialised fastening products and technical support. Emerging as a leader in the fastening supply chain, we work closely with you and push the boundaries of what is possible.
From Dotco tooling to Eddie Bolt tools, Nutplate tooling, Clecos and Temporary fasteners, spares, and cold working fasteners and tooling, AFT has everything an aircraft mechanic needs.
With same-day global shipping, quality certifications and OEMs approvals, custom manufacturing capability, inspection and quality control and stocking over 60,000+ products, contact us today to shop in stock. Our customers depend on us as a reliable partner for our flexibility, collaboration responsiveness, and on-time delivery.
