The main methodological difficulties and specifics of creation of free flying dynamically similar models (FDSM) of full-scale aircraft are related to the necessity of correct resolution of complex contradictions between the requirements of adequate representation of the investigated events on FDSM and the conditions of its technical feasibility. For this purpose, it is necessary to perform a set of works that constitute the main content of the stages of general design and manufacturing preparation of FDSM. At these stages, the problem of modelling the phenomena and modes of flight of a full-scale aircraft is formulated, similarity conditions are defined and requirements for the quality of a FDSM, methods of manufacturing and linking of technological equipment, production base and research complex to perform a full cycle of work on a FDSM are formed. The formation of the required quality of a FDSM is directly related to the determination of its geometrical parameters (and, accordingly, the scale of linear dimensions) during design for subsequent implementation in model manufacturing. One of the technological tasks to be solved during design is to establish such requirements to the accuracy of all design elements and basic parameters of the FDSM, which correspond to the real possibilities of the used manufacturing methods, and their fulfilment ensures the intended purpose of the FDSM. From these positions the author of the article considers theoretical and practical aspects of influence of existing methods of manufacturing, assembly of units and linkage of technological equipment on the choice of scale of linear dimensions, and also analyses and evaluates new methods of manufacturing of units in the production of FDSM.