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Covering
the Fuselage
We covered our aircraft using the blanket method. After coating all attaching points with two coats of adhesive, we applied the fabric to the fuselage sides. This will allow the belly fabric to be easily removed/replaced, in future if necessary, without disturbing the integrity of the side fabric. We operate our aircraft mainly on floats and the belly takes a real beating. GYF also sits outside so we wanted a very durable coating. We decided to use Air-Tech polyurethane fabric covering system and found our supplier, Phil Kite of KiteAir, very helpful. We only have prior experience with conventional butyrate/dacron finishing so my opinion should be taken accordingly. That said, Storm and I both found the system quicker and easier to use than butyrate. There are safety concerns with polyurethane but the same can be said for all paints. For more on painting see the appropriate title in the menu bar to the left.
Close pins work great for securing the fabric. Trim leaving excess sufficient for final adjustment of the covering.
Thinned adhesive is applied to the fabric to secure it to the previously glued structure.
We worked from the front to the back of the plane, tacking the fabric every half a foot while keeping the fabric taut and relatively wrinkle free.
The fabric was then final trimmed and wrapped around the longerons, a job best done from inside the fuselage. Lots of rubbing required to get any bubbles out, then apply a second coat of thinned adhesive to saturate the fibers.
After letting the glue dry overnight we shrunk the Dacron with an iron.
A few passes at increasing heat levels, as per covering manual.
After the sides are taut, we moved to the top. Creating a smooth compound arch at the fin was the source of quite a bit of stress, so we started securing the fabric there and figured if we "pooched" it, we would simply cut out the error, drag the fabric back and start again.
As it turned out, this wasn't necessary. As recommended to us by other Stinson aficionados, we started by applying 2 tapes from the fin to the rear-former bow.
I sliced the fabric to allow it to wrap around the fin, then secured it in place.
Trimming excess material will help get a relatively smooth glueing surface; however, wrinkles... big wrinkles will exist!
Fabric secured along to fin and fuselage sides. Now remove the wrinkles with heat. Avoid ironing directly on folds as it tends to leave a crease in the fabric - instead draw the fabric out with your hands and iron slowly with the tip.
Wouldn't have thought it was possible, but there you go - wrinkle free.
Upper fuselage fabric secured and taut.
The first real challenge is the belly fabric. This would be a non-issue if you could role the aircraft over. This won't be an option for most so get lots of help.
This was a game the whole family could play.
Securing the belly fabric. Working on your back means lots of adhesive running down your arms. Dave Miller |
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