Top 5 Aviation Tools You Can Find at a Hardware Store

Flying doesn’t have to drain your wallet, many useful aviation tools are actually simple hardware store items. General aviation can be expensive, but everyday gadgets from your local hardware shop can be both cheap and extremely useful. Whether you’re prepping for a flight, doing light maintenance, or organizing your cockpit, here are five budget-friendly tools every thrifty pilot should consider. (IMPORTANT: Always ensure any maintenance or modifications comply with FAA rules and safe operating practices.)

1. Flashlights and Headlamps

A hands-free LED headlamp is perfect for preflight inspections at night, keeping your hands free for checks.

A reliable light source is indispensable for pilots, especially for night operations. Imagine trying to do a walk-around or check the oil in the dark, how will you conduct your preflight in the dark without a flashlight? A compact LED flashlight or, even better, a headlamp lets you illuminate hard-to-see areas (like under the cowling or inside the cockpit) while keeping your hands free. Many hardware stores sell headlamps with both white and red LEDs, so you can preserve night vision in the cockpit. In fact, a white-light flashlight is recommended for night preflight inspections, and having a red light option helps when reading instruments or charts without dazzling yourself. Look for a light that’s robust (all-metal or impact-resistant plastic) and runs on common batteries. Store it in your flight bag or around your neck during evening flights, you’ll be glad to have it if the panel lights fail or for that post-sunset tie-down. As a bonus, pilots often carry a small flashlight at all times, making this one of the most critical tools you can buy for just a few dollars.

2. Multi-Tool or Basic Tool Kit

A multi-function tool like this Leatherman Crunch packs pliers, screwdrivers, blades and more in one compact device, ideal for minor fixes on the fly.

Instead of an expensive aviation tool kit, a quality multi-tool from the hardware store can handle many small tasks. Pilots swear by tools like a Leatherman or Swiss Army knife because you never know when you’ll need to cut a piece of tie-down rope, tighten a loose screw, or open a can of oil. A good multi-tool typically includes pliers (great for pulling a cotter pin or tightening a nut), screwdrivers (for loose panel screws or removing a battery compartment cover), a knife blade, and even mini-scissors or a file. These tools are compact enough to keep in your flight bag and can save the day during an unexpected repair or adjustment. For example, if a headset screw comes loose or a piece of fairing is rattling, you can address it on the spot. One traveler quipped that a “Leatherman and a pocket flashlight” are all you need for most little fixes, and it’s true that this combo empowers you to handle many minor issues. Just remember: for anything beyond basic tightening or cosmetic fixes (especially on certified aircraft), defer to a certified mechanic. But for pilots who are also aircraft owners, many preventive maintenance tasks (like changing a landing light or replacing cowling fasteners) are allowed by the FAA, and having a set of basic tools will let you tackle those jobs confidently. A small wrench set or screwdriver set from the hardware store can complement your multi-tool, giving you a capable DIY kit for common needs without breaking the bank.

3. Duct Tape (Speed Tape’s little cousin)

A roll of sturdy duct tape, a staple in every toolkit, can serve as an emergency fix for minor issues. Just remember it’s a temporary solution.

It’s often joked that “if it moves and shouldn’t, use duct tape.” In aviation, duct tape isn’t holding airplanes together (airlines use certified speed tape for minor exterior fixes, not common duct tape), but a roll of good duct tape in your flight bag or hangar is still incredibly handy. Use it for quick, temporary fixes: securing a loose interior trim piece, taping down a frayed carpet corner, or labeling things in a pinch. For example, if an inspection panel cover is slightly loose, a bit of tape can keep it secure until you can properly fasten it. Got a small crack in a plastic fairing or a loose wheel pant on a long cross-country? Duct tape can prevent further damage by holding it in place so it doesn’t flap in the slipstream (of course, only as a get-home measure). Pilots in the field often include “a few feet of duct tape” in their onboard tool kits for exactly these scenarios. Choose a high-quality tape (like Gorilla Tape or a brand-name duct tape) for better adhesion and strength. A bright color (or even reflective tape) can also double as a visibility aid if needed (for instance, marking an obstacle or making an improvised signal). Always replace tape fixes with a proper repair as soon as possible, think of duct tape as your short-term friend to save a flight or protect your plane until the mechanic can take over. Used wisely, this cheap tool can be a real lifesaver for minor issues, all without violating any rules (just avoid slapping it on anything that requires an FAA-approved fix later!). In short, duct tape often rounds out a pilot’s field toolkit alongside tie-wraps, embodying that “be prepared” mindset every aviator needs.

4. Zip Ties (Cable Ties)

Assorted zip ties in various lengths, perfect for tidying up wires or making quick fixes. Opt for UV-resistant or heat-resistant ties for aviation use.

Right next to duct tape in the hall of fame of “quick fixes” are zip ties (also known as cable ties). These simple plastic straps can be used to secure almost anything: bundling loose wires or headphone cords, re-attaching a dangling wiring harness under the panel, or even temporarily securing a loose knob or sun visor. Pilots have found endless uses for zip ties. For example, if your cowl flap linkage clip breaks, a few zip ties can hold it in position until repair. Need to strap a flashlight to a strut for a makeshift landing light? Zip tie it. In fact, zip ties are so handy that many pilots say they carry “a handful of them because they’re almost as handy as duct tape”. They weigh virtually nothing, cost pennies, and tuck into any pocket. However, choose quality ties, the cheap ones can get brittle, especially in hot engine compartments. Look for ties labeled UV-resistant or heat-stable if you plan to use them near the engine or in sunlight. It’s also smart to carry a mix of sizes (small, medium, large) and even a few reusable Velcro ties for gentler applications. A fellow DIY enthusiast noted “zip ties are actually really useful… common for a quick and dirty repair”, and that’s the key: they’re a temporary assist, not a permanent solution for critical components. Always trim the tails with flush cutters (no one likes sharp edges in tight spaces) and inspect them regularly if left in place. Used properly, zip ties can secure a rattling throttle cable, keep your headset cords neatly managed, or even serve as an emergency belt loop (don’t ask!). For just a few dollars per pack, this is a hardware store gem you should always have on hand as a pilot.

5. Portable Step Stool or Ladder

When you’re flying a high-wing airplane (like a Cessna 172 or 182) or even some low-wing planes, a compact step stool can be your best friend on the ramp. Many pilots discover that checking fuel or oil on taller aircraft can be a stretch, quite literally. A lightweight folding step stool from the hardware store makes it easy to peek into fuel tanks, check the wing surfaces, or reach the oil dipstick on engines set high off the ground. Verifying fuel quantity is critical for preflight, but it can be a hassle on high wings; a sturdy step stool “makes checking the fuel and other parts of the pre-flight easy.” Instead of dragging over a large ladder (or worse, standing on a strut or tire), you can carry a small two-step folding stool in your hangar or baggage area. Look for one that is lightweight but rated for your weight (many are under 5 lbs and rated for 250-300 lbs). For example, some pilots use a plastic folding step that collapses flat, it barely takes up space but gives about a foot of extra height when needed. This is especially useful at remote airstrips where ladders aren’t available, or when self-fueling from cans. The stool isn’t just for fueling: use it to clean the windshield, cover the aircraft (reaching the top of the cabin), or help shorter passengers board more easily. One popular product, the “AeroLadder,” was basically a custom aviation step stool, but you can achieve the same functionality with a generic hardware store model. Make sure it has non-slip feet and a stable platform for safety. And always secure it in the baggage area so it doesn’t become a projectile in turbulence. By having a portable step stool on hand, you save time and reduce risk, no more standing on tiptoes or wobbling on a makeshift platform. It’s a humble tool that brings big convenience to your flying routine.

Wrapping Up: These five tools, found at any hardware store, can significantly ease your flying life while keeping costs low. From a flashlight that ensures you’re never in the dark, to multi-tools and tape for on-the-spot fixes, and a trusty step stool for safer preflight checks, each item on this list earns its spot through practicality. Importantly, none of these go against FAA regulations or good practices when used appropriately (always use them for minor, legal maintenance or as temporary measures until proper fixes can be done). The spirit of The Thrifty Pilot is all about finding smart, affordable solutions, and these tools exemplify that ethos. By stocking your hangar and flight bag with a few low-cost essentials, you’ll be prepared for the little surprises aviation throws your way, and you’ll do it without emptying your wallet. Stay safe, stay resourceful, and stay thrifty!

Sources: The Thrifty Pilot blogs; Pilot forum discussions (Mooneyspace); Backcountry pilot tips; AOPA Flight Training Magazine; General Aviation News; Reddit r/TravelHacks. This post may contain affiliate links, which means I may earn a commission if you make a purchase through these links, at no extra cost to you. Thank you for supporting this blog!