Abstract: Based on the air channel parts of some aircrats,this paper analyzes and discusses how to fabricate the heavy-thickness and thin-wall aluminum alloy special parts with Wire-EDM,and then puts forward the rebuiliding precept of machining tool wire-shelf and the design precept of Wire-EDM appropriative tongs.Based on the precepts,four type of eight pieces of air channel parts were fab ricated,all sizes of the parts meet the drawing requirements thoroughly.Finally,some practically valuable conclusions of wire-EDM processing methods of the parts are proposed.