Elevator fabric cont

We attached a sheet of fabric to the opposite side of the elevators, and then shrunk the fabric in 3 stages at 250, 300, and 350 degrees.  This is the same procedure we used when covering the horizontal stabilizers.  Next step will be to apply doilies and finishing tapes to these pieces.

Michael is shrinking the fabric with an iron

Fabric attached to both sides of elevator

We also found a tip to pre-shrink fabric that is used to make doilies.  We used a lighter weight fabric for this (per recommendations), and simply attached it to a wood frame with staples.  We then shrunk it over the frame with irons.  This pre-shrunk fabric is now available to us for making protective doilies.  Hours: 3

Elevator covering cont.

We are gluing a sheet of fabric on one side of the elevators.   These parts are more complex than the vertical stabilizers, but we are learning what works.  Takes some time as we are trying to avoid bubbles and creases in the glued areas.   Hours 4.5

Attaching fabric to one side of elevators

Michael and Ed working on Elevators

Started Covering on Elevators

We applied two good coats of U500 adhesive around the perimeter of the two elevators.  Adhesive was also applied on the trim servo mounting/fabric plate.  Hours: 1

Ed Adding Adhesive around Elevator Perimeter

Finished Horizontal Stabilizer Fabric Covering

We had previous cut the finishing tape to be installed on the hinge side of the horizontal stabilizer, including cutting the holes for the hinge points.  We then installed the tapes finishing the fabric covering of the horizontal stabilizers.

Next up are the two elevators.  One elevator is straight forward, but the other one has the trim tab servo mount plate and trim tab cut-out to deal with.  We cut four pieces of fabric that we will using in covering the elevators.  The hardest part in cutting the fabric was trying to arrange the parts to minimize the wasted fabric.  Hours: 2.5

HAPPY NEW YEAR EVERYONE!

Hinge Side Finishing Tape with Hinge Holes Cut

Completed Horizontal Stabilizers

Cutting Fabric for Elevators

H. Stabilizer doilies & tape

We create fabric doilies for added protection at the points where the flying wires will attach to the horizontal stabilizers.  This may be overkill since we already have finishing tape at those points, but we added them anyway.  We pre-shrunk a section of fabric, then traced circles out with a compass, and cut them out with pinking shears.  The doilies were about 3.5" in diameter.

Doilies cut from pre-shrunk fabric

Doilies glued in place (2 on front side, and 2 on back)

We also glued one of the longer horizontal perimeter tapes (at the leading edge) to the horizontal stabilizers.  Ran out of time so will glue on second long tape (hinge side) another day.  Hours: 2.5

More Horizontal Stabilizer Covering Work

We continued to work on our horizontal stabilizers.   We used pencils to mark the area that needed adhesive applied.  Tape was added to make the application of glue easier and cleaner.  Three coats of the U500 adhesive was applied to the outer perimeter and left to dry.  Hours: 1.5

Adding Glue to the perimeter

Finishing Tapes on Horizontal Stabilizers

After completing the top and bottom fabric attachment on the horizontal stabilizers, next up is to attach 2" tapes over the metal support areas to strengthen the areas due to possible rubbing.  The center of the supports were identified and then a 2-1/8" band was drawn centered on the metal supports.  Three coats of the 2:1 thinned U500 adhesive was brushed on the stabilizers making sure we stayed within the drawn lines.  Once the adhesive was allowed to dry, the tapes were added.  The tapes were first attached with adhesive in the center and then worked outward from there toward each end.  Both the top and bottom surfaces were done this way.  Where tapes would overlap, we considered how the air would be passing over the surface and overlapped the areas such that the air stream would not peal up an area.  Hours: 3

Laying out Glue areas in Pencil

Working on Finishing Tapes

Horizontal Stabilizer fabric

Attached 2nd sheet of Superflite fabric to the other side of the two horizontal stabilizers.  The fabric was glued and shrunk using the same process as described in a previous blog entry.  Hours: 3

Horizontal Stabilizer Covering continued

We decided to buy new irons for our covering.  After some research, we decided on the two Toko T14 Waxing Irons.  They get high praise from other builders.  With the new irons, on low heat (250F) we went back over the previously adhered fabric removing all bubbles and glue buildup.  We then shrunk the fabric with temps of 300F and 350F.  It was very rewarding seeing the fabric tighten up.  We then marked the the fabric where we needed to apply U500 adhesive.  Finally we added two coats of  thinned U500 adhesive up to the previous applied marks.  Hours: 1

Horiz Stabilizer Covering Cont.

We finished attaching pieces of Superflite fabric to one side of each horizontal stabilizer.  We had previously attached the fabric to one edge, so finished attaching to the other 3 perimeter tubes of the horiz. stablizers.   The fabric was wrapped around the tubes (which had 2 coats of U500 adhesive applied), and then another coat was applied to the fabric surface which soaked through the fabric and ensured good adhesion.  We went slow since these are the first 2 plane pieces we are covering, and didn't want to screw it up.  The process is a little tricky, but with practice we should get better.  Irons were used to help tame wrinkles and get the fabric to lay nicely against the tubes.  Hours: 2.0

Fabric attached to one side of horizontal stabilizers

Officially Started Covering

We re-calibrated our irons which took a bit of time.  We plan to cover the horizontal stabilizers first.  We first cut the fabric.  Four pieces was cut from the Superflite SF102 fabric.  Next we applied three coats of the U500 adhesive to the outer members of the horizontal stabilizers.  Finally we trimmed and attached the fabric to the rear edge of the stabilizers.  Small bubbles were removed with a iron at 250F.  Hours: 4

Started working on the horizontal stabilizers

Finished Tapes on Practice Parts

Ed and I finished the 3" edge tapes on our practice parts.  We again had to work with curved corners that take a lot of time to get the tapes to lay down nicely.  Once the tapes were worked with the irons to fit correctly a 2:1 Superflite U500 adhesive mixture was added to the tapes to secure them.  Hours: 1.5

Two Practice parts complete with edge tapes

More Fabric Practice

We continued our work on the practice pieces we are covering.  We are now adding the finishing tapes to the center members and we started work on the perimeter tapes.  We are learning a lot,  especially on the curved corners. Hours: 2

Adding perimeter tapes

Fabric covering the practice frames

Today we began covering the practice frames with fabric to get ready for the next stage of our airplane project.  Adhesive was first painted around the edges of the steel frames, and fabric is then applied (glued) to the tubular frames.  We intentionally made the frames with curves on 2 corners because that is a challenge to cover cleanly.  Yeah, we made some mistakes (but hey, that's why these are practice fames), but overall I think they came out pretty nice.  Once the fabric was glued in place, we shrunk it in stages at 250, 300, and then 350 degrees with irons that we calibrated yesterday.   Hours: 5

Two practice frames covered with fabric

Practice Fabric Covering Started

We've been doing a lot of cleaning and straightening of the garage in preparation of doing fabric.   We setup two "covering" tables for the process.  We bought a new wheeled rack for storing chemicals and tools.    And we've had to buy a few things, brushes, strainers, zahn cup (for checking viscosity).  Finally we started working on the practice parts.  We mixed up the U-500 adhesive (1 part glue/2 parts Acetone) and applied 2 coats to the trailing edge of the practice part.  Hours: 2

Glue added to one side of the practice pieces