Section 18F, Covering Flying Surfaces - Stabilizer, SeaRey, LSA

Progressive Aerodyne, Inc.

3801 State Rd 19
Tavares, FL 32778

Revision Description Remarks Date

01 Initial Creation 01/27/2012
02 Update Added grommet installation to section 07/09/2012
03 Update Pg 9, additional notes about applying Poly-Brush 09/06/2013

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 Section 18F, Covering Flying Surfaces - Stabilizer, SeaRey, LSA
1.0 Scope
This document will detail the steps necessary to cover wings with fabric.

2.0 Applicable Documents

N/A

3.0 Requirements
3.1 Equipment
3.1.1 The following tools will be necessary to perform this procedure:
 Clamps
 Cloth Masking Tape (Stits Anti-Chafe Tape)
 Deburring Tool
 Diagonal Cutters
 Felt Fabric or Poly Pad (optional)
 Files
 Iron
 Linear Tape, 2”, 3”, 4”
 MEK
 Paint Brushes
 Pinking Shears
 Poly-Brush
 Poly-Fiber Reducer
 Poly-Spray
 Poly-Tak Cement
 Pop Rivet Gun, Manual or Pneumatic
 Scissors
 Soldering Iron or Hot Knife
 Squeegee
 Stits Reinforcing Tape
 Tape Measure

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 Section 18F, Covering Flying Surfaces - Stabilizer, SeaRey, LSA
3.2 Materials
The following general supplies will be necessary to perform this procedure:

 Lacquer thinner (Cleaning labels off of parts)

 Protective gloves

3.3 Procedure (See the following pages)

It is recommended to read the “Poly Fiber How To Cover” manual and/or watch the installation video prior to doing this work.

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 Section 18F, Covering Flying Surfaces - Stabilizer, SeaRey, LSA

Cloth Tape all

sharp edges

Debur and file Install Rubber

all sharp edges Filler Tape

Figure 58. Preparing the Stabilizer for Covering

Note: Cover a left and right Stabilizer so the bottom surface has the final finished seam showing

58.1 Prepare the Stabilizer on both sides by cleaning the surface with M.E.K., Gallon (#0620-001) removing any oils or construction
markings.
58.2 Make sure all the sharp edges on the Stabilizer are deburred and filed on both sides.
58.3 Install Roll Cloth Masking Tape (Anti-Chafe) P-66 1” x 60 YD (#0620-012) onto any sharp edges that can come into contact with the
Stits Fabric, 3.16oz, 70” wide, 1 YD (#0620-020). There is no right or wrong when it comes to using the Roll Cloth Masking Tape
(Anti-Chafe). If you think it needs the tape, use it. Do this to both sides.
58.4 Install Rubber Filler, 3/4 x 3/8” (#5510-011) on the (4) center ribs on both sides.
.

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 Section 18F, Covering Flying Surfaces - Stabilizer, SeaRey, LSA

Stits
Poly-Fiber
Fabric Fabric Half
Way up to
top edge

Leading
Edge
Stabilizer

Figure 59. Covering the Stabilizer with Fabric

Note: The Stits Fabric weave pattern needs to run square in the direction of the Leading Edge Tube

59.1 Start unrolling the roll of Stits Fabric, 3.16oz, 70” wide, 1 YD (#0620-020) onto a table larger than the surface of the Stabilizer by
6” on each end in the length direction, total 46”. When covering the Stabilizer it will be done in two pieces of material. It should
take a piece of Stits Fabric, 3.16oz, 70” wide, 1 YD (#0620-020) that is approximately 70” x 46” on each side. Line up the clean
edge of the Stits Fabric with the leading edge of the Stabilizer and extend out about 2”. Make some initial cuts in the Stits Fabric at
the ends of the Stabilizer Leading Edge tube.
59.2 Using the Poly-Tak Cement, Quart (#0620-008), apply a base coat to the leading edge tube with a 1” brush and let dry for 10
minutes
59.3 Using the Poly-Tak Cement, Quart (#0620-008), cement fold over the Stits Fabric, 3.16oz, 70” wide, 1 YD (#0620-020) half way
up onto the top edge of the leading edge tube. Re-wet the leading edge tube with Poly-Tak Cement, Quart (#0620-008) and push
the fabric into the cement while applying more cement to the top surface of the fabric. Smooth out the fabric using the brush until
the entire leading edge of the tube is glued down in place.

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 Section 18F, Covering Flying Surfaces - Stabilizer, SeaRey, LSA

Stits Leading
Poly-Fiber Edge
Fabric Stabilizer
Cement
Leading Edge
Surface

Fold up onto
top surface

Figure 60. Covering the Stabilizer with Fabric

60.1 Proceed to covering the Trailing Edge tube keeping the Poly-Fiber fabric smooth and free of any large wrinkles.
60.2 Make some initial cuts in the Stits Fabric at the ends of the Stabilizer Trailing Edge tube. Using the Poly-Tak Cement, Quart
(#0620-008), fold over the Stits Fabric, 3.16oz, 70” wide, 1 YD (#0620-020) half way up onto the top apex edge of the trailing edge
tube and brush down the fabric into the wet cement. Re-wet the top side with Poly-Tak Cement, Quart (#0620-008) and push the
fabric into the cement getting the fabric to adhere to the fabric below. Smooth out the fabric using the brush until the entire trailing
edge of the tube is glued down in place.
60.3 Now proceed to the lower tube and then to the upper tube cementing the edge over the tube in the same manner as the leading
and trailing tubes.
60.4 When the Stabilizer is dry, iron the completed side with a 250 degree iron taking out the wrinkles and getting an initial tightening
done on the Fabric. Start with the center area and then work to either end rotating back and forth so the fabric stretches evenly
and is wrinkle free and taught. Iron the edges on the tube at 225 degrees getting out all the bubbles and making sure it has a
smooth finish to the tube.

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 Section 18F, Covering Flying Surfaces - Stabilizer, SeaRey, LSA

Cement all
contact Initial Iron
Surfaces at 250 Stits
degrees Poly-Fiber
Fabric

Cement all
contact
Surfaces

Figure 61. Covering the Opposite Side of the Stabilizer with Fabric

Note: The Stits Fabric weave pattern needs to run square in the direction of the Leading Edge Tube

Note: Prior to Ironing make sure the Poly-Tak is completely dry

61.1 Using the other piece of Stits Fabric, 3.16oz, 70” wide, 1 YD (#0620-020) that is approximately 72” x 46”, lay the . Line up the
clean edge of the Stits Fabric with the leading edge of the Stabilizer and extend out about 2”. Make some initial cuts in the Stits
Fabric at the ends of the Stabilizer Leading Edge tube.
61.2 Proceed to covering the Trailing Edge tube keeping the Poly-Fiber fabric smooth and free of any large wrinkles.
61.3 Continue covering in the same manner as the first side and also working from the leading edge to the trailing edge to the bottom
then the top.
61.4 When the second side of the Stabilizer is dry, iron the completed side with a 250 degree iron taking out the wrinkles and getting an
initial tightening done on the Fabric. Iron the edges on the tube at 225 degrees getting out all the bubbles and making sure it has a
smooth finish to the tube.

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 Section 18F, Covering Flying Surfaces - Stabilizer, SeaRey, LSA

Figure 62. Ironing the Fabric on the Stabilizer

Note: Prior to Ironing make sure the Poly-Tak is completely dry

62.1 Now it is time to turn the iron temperature up to 350 degrees. Iron every inch of the fabric thoroughly.
62.2 Iron the edges on the tube at 225 degrees getting out all the bubbles and making sure it has a smooth finish to the tube.
62.3 Repeat the process and iron again at 350 degrees.

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 Section 18F, Covering Flying Surfaces - Stabilizer, SeaRey, LSA

Poly-Brush

Poly-Brush

Figure 63. Preparation of the 3” Linear Tape on the Seams

Note: Application of additional Linear Tape in other areas such as the ribs is totally up to the builder if they feel the need for
reinforcement of protrusions or sharp edges.

63.1 Prior to installing the Linear Tapes it is necessary to apply Poly-Brush Tinted, Gallon (#0620-003) to the areas that the Linear Tape
will be applied to. In the case of the Stabilizer it will be the Leading Edge, Trailing Edge and Inboard Tube.
63.2 Hand application of the Poly-Brush Tinted, Gallon (#0620-003) is required in the areas mentioned in the previous step. Mix together 3:1
Poly-Brush to Poly-Fiber Reducer RR8500, Gallon (#0620-005) thinning it out so it can apply evenly and penetrate into the Stits Fabric. To
apply the Poly-Brush you must use a paint brush. Coat the area that the Linear Tape will be applied to. The perimeter surface on both sides
will need at least 1 1/2” on the top surface. Let these areas dry.
63.3 Apply a generous coat of Poly-Brush Tinted, Gallon (#0620-003) to the area where the Stits Fabric lays on the Rubber Filler, 3/4 x 3/8”
(#5510-011) of each of the (4) ribs so the fabric is glued to the foam.

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 Section 18F, Covering Flying Surfaces - Stabilizer, SeaRey, LSA

3” Linear
Tape

3” Linear
Leading Edge Tape
of Stabilizer

Figure 64. Application of the 3” Linear Tape on the Seams

Note: When applying the Linear Tapes make sure it is applied to the surface as it comes off the roll with the bottom side on the Stits
Fabric. This helps to keep the Pinked edges from curling up.

64.1 Re-wet the same area on the ends with the Poly-Brush Tinted, Gallon (#0620-003) using 3:1 Poly-Brush to Poly-Fiber Reducer
RR8500, Gallon (#0620-005). Using the Roll 3” Linear Tape x 50 YD, Poly-Fiber P-106 (#0620-010) cut a strip that will go along the
trailing edge. Center the tape and affix it to the end surface. Wet the center with Poly-Brush leaving the radius corners with out
any Poly-Brush.
64.2 Apply the Poly-Brush Tinted, Gallon (#0620-003) using 3:1 Poly-Brush to Poly-Fiber Reducer RR8500, Gallon (#0620-005) to the
remainder of the edges of the 3” Linear Tape x 25 YD, Poly-Fiber P-106 (#0620-010) making sure it is securely adhering the pinked
edges to the Poly-Fiber Fabric below. Repeat the steps above for the Inboard Tube.
64.3 Flip the Stabilizer over and install 3” Linear Tape x 25 YD, Poly-Fiber P-106 (#0620-010) on the full length of the leading edge.
Wet the center with Poly-Brush leaving the radius corners with out any Poly-Brush. Trim the remainder of the Linear Tape so it
does not extend past the ends.
64.4 Use the iron at 250 degrees to get the radius of the Linear Tape to form around the tube.
64.5 Apply the Poly-Brush Tinted, Gallon (#0620-003) using 3:1 Poly-Brush to Poly-Fiber Reducer RR8500, Gallon (#0620-005) to the
remainder of the edges of the 3” Linear Tape x 25 YD, Poly-Fiber P-106 (#0620-010) making sure it is securely adhering the pinked
edges to the Poly-Fiber Fabric below.

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 Section 18F, Covering Flying Surfaces - Stabilizer, SeaRey, LSA

Poly-Brush Iron edges

at 250
degrees

Figure 65. Hand Application of the Poly-Brush

Note: Make sure all edges of the Linear Tape are laying flat and are bonded properly onto the Stits Fabric.

65.1 Hand application of the Poly-Brush Tinted, Gallon (#0620-003) is required on the entire surface. Mix together 3:1 Poly-Brush to Poly-
Fiber Reducer RR8500, Gallon (#0620-005) thinning it out so it can apply evenly and penetrate into the Stits Fabric. To apply the Poly-
Brush you must use a paint brush and squeegee. Apply small areas at a time with the brush and then pull the Poly-Brush across the
surface of the Fabric with the squeegee. Let the entire Stabilizer dry completely.
65.2 Using the Iron at 250 degrees work on sealing all of the edges of the Linear Tape and removing any wrinkles or bubbles out of the
Linear tape.

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 Section 18F, Covering Flying Surfaces - Stabilizer, SeaRey, LSA

Drain
Grommet Burn 3/8” hole

Drain
Grommet

Trailing Edge
of Stabilizer

Figure 66. Installing the Drain Grommets

66.1 Locate where the Drain Grommet AN231-4 (#5720-014) will be placed on the bottom Inboard Trailing Edge of the Stabilizer. On
the Trailing Edge center at 1 1/2” in and from the Inboard bottom edge center at 1 1/2”.
66.2 Using a hot knife/soldering Iron burn a 3/8” diameter hole into the Poly Fiber material where the location has been marked.
66.3 Next using Poly-Tak Cement, Quart (#0620-008) or Loctite 401 Instant Adhesive apply a little of the cement onto the rim edge of
the Drain Grommet AN231-4 (#5720-014). Face the opening of the Drain to the aft end of the plane or in this case toward the
trailing edge. Push the Drain Grommet AN231-4 (#5720-014) down firmly onto the Poly-Fiber surface and make sure it adheres
properly.
66.4 The Stabilizer is now ready for (2) more sprayed-on coats of the Poly-Brush and then Poly-Spray, Gallon (#0620-007) before finish-color
paint is applied.

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