covering part 1 (Tail Feathers)

I started covering the tail surfaces. The rudder was first. This is the first time I am using the Stewart system Eco Bond adhesive. As usual there is a learning curve to go down. I will eventually re-cover the rudder, but I learned a few good lessons. The Eco bond is really good stuff, but it needs to be applied with a foam brush. The natural fiber paint brush I was using does not apply the adhesive evenly. This will make for a lumpy covering job. In the Stewart manual, they give a lot of good tips, one of them was the use of this disposable cup method.

Chinette plate and Dixie cup holder

this is a holder for the Eco bond adhesive. In the middle is a cut down Dixie cup that has been bonded with 5 minute Epoxy to the center of a Heavy duty Chinette paper plate. A fresh Dixie cup is used for the actual adhesive. Its placed in the Dixie Cup holder. This way it wont spill on you. about 1/3 a cup is all the adhesive you work with at a time. That's the length of out time you have available.
The Eco Bond is water soluble, but once it cures, its set for good.

pre coating the structure

The method I finally settled on is to pre-coat the entire structure and let it fully dry. The Eco Bond is heat activated. The fabric is placed into position and then ironed onto the frame with a iron set and calibrated to 200 degrees. The heat of the irons is extremely important. Its very important to use a good IR thermometer when you calibrate the Irons. The normal main shrink temp is 250 degrees, on a certified plane with heavier structure, the shrink is accomplished in three steps, 250 degrees, 300 and finally 350 degrees. that is way too much for an ultralight airframe.  This is the main reason I am recovering the rudder. I used the higher temp and I bent the trailing edge. Its slightly scalloped. All ultralights stop the shrink at 300 degrees.

Rudder

I am using a single wrap piece of cloth for the rudderThe first wrap will attach to the trailing edge The cloth will be wrapped over the trailing edge. The opposite side will wrap over the railing edge and attach to the cloth only. All ribs are also bonded,








 

Ribs being bonded

 once the adhesive dries, the fabric is tacked on using a heated iron, after everything is in place, additional Eco bond is brushed into the surface to adhere to the previous coat. Once this sets, its really on there.










 

beginning of the Horizontal

The horizontal came out really well. I used two separate pieces to cover this surface. Both pieced will over wrap the leading edge.

Finished Horizontal

So far the covering process added only 2.5 ounces, the real weigh gain will be the finish. Tomorrow I will finish the elevator and the ailerons. My buddy Ed will come by tomorrow and we will pull the wings. I can cover the R/H wing immediately, the L/H wing needs some repair on a plywood piece that was damaged during storage. But I should have both wings covered by Saturday. Then its on to the fuselage. after I cover the fuselage and finish the plane, I need to re assemble the wings and then build a root fairing. I decided it would be easier once I figure out where the fuselage fabric is placed.