Covering of the Wings Begins

The covering process has generated a lot of questions. Here are some basic facts:

• I'm covering the plane with what is referred to as the Poly-Fiber process. This is the old "Stits" process. It is the process that has been used to cover planes since the 50's. The Poly-Fiber process is an FAA approved process for certified aircraft. If there is a fabric covered plane at your local airport, chances are it is covered with the same materials I'm using.
  
• The cloth weighs 1.6 oz. per square yard. It is made of polyester and shrinks tight when you heat it with an iron.
  
• The covering is held onto the plane with glue and rivets.
  
• It will take over 36 square yards of fabric to cover the plane.
  
• After covering, all places where the aircraft frame touches the fabric get reinforcement tape added to them.
  
• The fabric gets sealed with 2 to 3 coats of "Poly-Brush" (sort of like dope). Then, it gets two coats of aluminum pigmented UV blocker. The UV blocker is sandable and allows you to fill in the weave and achieve a glossy finish. My plane will not have a dull canvas look. Contrary to popular expectations, it will be shiny.
  
• The covering and paint will add about 25 pounds to the weight of the plane.
  
• The fabric, chemicals, and paint will end up costing about $900 (plus I had to purchase a spray gun, fresh-air respirator,...expensive).
  
• The covering kit comes with a 1/2" thick manual and a 1 hour and 45 minute video.

This is the last picture of the plane assembled before it gets taken apart to begin the covering process.

These are the required chemicals and some of the personal protective equipment needed. The UV protectant isn't included in this entree of healthy substances. Gotta add paint to the list also.

You start with the bottom of a wing. Anti-chafe tape has to be put on all of the rivet heads and sharp edges that protrude into the fabric. Then, you brush cement along all of the outer edges and let it dry. After the cement dries you drape the fabric over the wing and wet the fabric with MEK (Methyl Ethyl Ketone) to activate the cement underneath. You work about 6 to 8 inches at a time. Hold it about 20 seconds, press out the wrinkles with your hands and then move on.

Applying the MEK to activate the cement. The fabric is gently held in place on the four corners by clamps. Mike, my technical advisor, is behind the camera.

At this point I've glued the fabric down around the perimeter of the wing, including the root rib in the foreground. It still must be wrapped further around the leading and trailing edges and then trimmed neatly. The fabric is pulled only snug at this point. The wrinkles you see will come out when it is shrunk with a calibreted household iron.

The fabric has to be carefully slit and worked around corners and protrusions. It has a tendency to unravel when cut and handled excessively.

The structures you see under the fabric are ribs. Notice how you can see them through two layers of fabric (thin stuff)! All rib tops and other structures will get the 2" pinked edge reinforcement tape shown here. The fabric will also be riveted to the top and bottom of the ribs on a 4" spacing. Look closely and you can see the pre-drilled rivet holes in the ribs under the fabric.

The covering and sealing process is going to take weeks and weeks! My mid-September completion date could be in Jeopardy. We'll see.