Section 18C, Covering Flying Surfaces - Elevator, 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 07/05/2012
03 Update Pg 4, changes to not removing bolts 09/04/2013

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 Section 18C, Covering Flying Surfaces - Elevator, 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 18C, Covering Flying Surfaces - Elevator, 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 18C, Covering Flying Surfaces - Elevator, SeaRey, LSA

Debur and file

all sharp edges

Cloth Tape all

sharp edges

Figure 39. Preparing the Elevator for Covering

39.1 Make sure all the sharp edges on the Elevator are deburred and filed on both sides. Remove all of the shavings.
39.2 Prepare the Elevator on both sides by cleaning the surface with M.E.K., Gallon (#0620-001) removing any oils or construction
markings.
39.3 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.

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 Section 18C, Covering Flying Surfaces - Elevator, SeaRey, LSA

Stits
Poly-Fiber
Fabric

Fabric Half
Way up to
top edge

Slit the
Fabric
around
bolt heads

Leading
Edge
Elevator

Figure 40. Covering the Elevator with Fabric

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

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

40.1 Start unrolling the roll of Stits Fabric, 3.16oz, 70” wide, 1 YD (#0620-020) onto a table larger than the surface of the Elevator by 6”
on each end in the length direction, total 70”. When covering the Elevator it will be done in one piece of material that will roll
completely around the leading and trailing edge. It should take a piece of Stits Fabric, 3.16oz, 70” wide, 1 YD (#0620-020) that is
approximately 35” x 70”. Line up the clean edge of the Stits Fabric with the leading edge of the Elevator and extend out about 2”.
Make some initial cuts in the Stits Fabric at the ends of the Elevator Leading Edge tube.
40.2 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.
40.3 Where the Stits Fabric covers a Bolt/Allen Bolt on the Leading Edge, slit the fabric allowing the bolt head to pass through the
fabric.
40.4 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 18C, Covering Flying Surfaces - Elevator, SeaRey, LSA

Slit the
Cement Fabric
Leading Edge around
Surface bolt heads
Fold up onto
top surface

Leading
Stits Edge
Poly-Fiber Elevator
Fabric

Figure 41. Covering the Elevator with Fabric

41.1 Roll the Elevator over onto the Stits Fabric, 3.16oz, 70” wide, 1 YD (#0620-020) covering the other side. Pull the remainder of the
material over the leading edge tube. Using a pencil place marks on the fabric at the top apex of the leading edge tube al the way
down the length of the tube. Using a straight edge draw a line connecting the marks on the fabric. Cut off the material on the line.
41.2 Make some initial cuts in the Stits Fabric at the ends of the Elevator Leading Edge tube.
41.3 Where the Stits Fabric covers a Bolt/Allen Bolt on the Leading Edge, slit the fabric allowing the bolt head to pass through the
fabric.
41.4 Using the Poly-Tak Cement, Quart (#0620-008), apply a wet coat to the leading edge tube with a 1” brush working in small areas.
41.5 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 leading 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 leading edge of the tube is glued down in place.

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 Section 18C, Covering Flying Surfaces - Elevator, SeaRey, LSA

Cement all Stits

contact Poly-Fiber
Surfaces Fabric

Cement all
Overlapping contact
End Flaps Surfaces

Figure 42. Covering the Ends of the Elevator with Fabric

Note: There are two methods to covering radius corners. You can use heat to mold the Poly-Fiber fabric to the radius or you can cut
slits in the fabric to work around a bend.

42.1 Start making cuts in the Stits Fabric, 3.16oz, 70” wide, 1 YD (#0620-020) so there is a flap of fabric hanging over the end of the
Elevator from the bottom side.
42.2 Now make cuts in the Stits Fabric, 3.16oz, 70” wide, 1 YD (#0620-020) so there is a flap of fabric hanging over the end of the
Elevator from the top side.
42.3 Using the Poly-Tak Cement, Quart (#0620-008), cement with a 1” brush, one of the end flaps to the Elevator End Tube.
42.4 Using the Poly-Tak Cement, Quart (#0620-008), cement with a 1” brush, the other end flap over the previously glued end flap
42.5 Using the Poly-Tak Cement, Quart (#0620-008), cement with a 1” brush, make sure all fabric that comes in contact with any
structural frame is bonded in place such as the trailing edge and the perimeter of the end tubes.

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 Section 18C, Covering Flying Surfaces - Elevator, SeaRey, LSA

Initial Iron
at 250
degrees

Figure 43. Ironing the Fabric on the Elevator

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

43.1 Iron the surface at 250 degrees F. as follows: Start with the center area on one side and switch to the center area on the other
side. Then work your way outward rotating from end to end until the entire surface area is wrinkle free and taught.
43.2 Now iron the edge surface at 250 degrees F. Take the iron and rock it back and forth working your way down the end surfaces.
Also pay close attention to the seam areas pulling the iron out away from the seam edge trying to get the area as smooth as
possible.
43.3 Now it is time to turn the iron temperature up to 350 degrees. Iron every inch of the fabric thoroughly. Repeat the process and iron
again at 350 degrees.

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 Section 18C, Covering Flying Surfaces - Elevator, SeaRey, LSA

Poly-Brush

Poly-Brush

Figure 44. Preparation of the 2” and 3” Linear Tape on the Seams

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

44.1 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 Elevator it will be the Leading Edge and both ends.
44.2 Hand application of the Poly-Brush Tinted, Gallon (#0620-003) is required in these areas. 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 two ends will need at least 1” on the top surface,
1” on the bottom surface and also the entire end. The Leading Edge will be covered with 1 ½” on the top and bottom side. Let these
areas dry.

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 Section 18C, Covering Flying Surfaces - Elevator, SeaRey, LSA

3” Linear
Tape 3” Linear
Tape Leading Edge
of Elevator

Figure 45. Application of the 2” and 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.

Note: There are two methods to covering radius corners. You can use heat to mold the Poly-Fiber fabric to the radius or you can cut
slits in the fabric to work around a bend.

45.1 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 2” Linear Tape x 50 YD, Poly-Fiber P-106 (#0620-009) cut a strip that will go from
leading edge center to the trailing edge center. Take 1” of the width of the tape and affix it to the top surface. Wet the side with
Poly-Brush and now fold the remaining 1” of the tape over and brush it down with more Poly-Brush completely adhering the tape
down to the whole side and top. Trim the remainder of the Linear Tape so it does not extend past the side.
45.2 Flip the Elevator over and work from the bottom side. 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 2” Linear Tape x 50 YD, Poly-Fiber P-
106 (#0620-009) cut a strip that will go from leading edge center to the trailing edge center. Take 1” of the width of the tape and
affix it to the bottom surface. Wet the side with Poly-Brush and now fold the remaining 1” of the tape over and brush it down with
more Poly-Brush completely adhering the tape down to the whole side and bottom. Trim the remainder of the Linear Tape so it
does not extend past the side.
45.3 Install 3” Linear Tape x 25 YD, Poly-Fiber P-106 (#0620-010) to the Leading Edge. Wet the area of the leading edge that the 3”
Linear Tape will be applied to. Cut a strip of 3” Linear Tape x 25 YD, Poly-Fiber P-106 (#0620-010) for the whole length of the
Elevator leading edge. Lay the 3” Linear Tape centered on the leading edge. Brush the 3” Linear Tape down with more Poly-Brush
completely adhering the tape down.

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 Section 18C, Covering Flying Surfaces - Elevator, SeaRey, LSA

Poly-Brush

Iron edges
at 250
degrees

Figure 46. 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.

46.1 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 Elevator dry completely.
46.2 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
tape.

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 Section 18C, Covering Flying Surfaces - Elevator, SeaRey, LSA

Burn 3/8” hole

Drain Drain
Grommet Grommet

Drain
Grommet

Figure 47. Installing the Drain Grommets

47.1 Locate where the Drain Grommet AN231-4 (#5720-014) will be placed on the bottom Trailing Edge of the Elevator. On the Inboard
end center at 2 1/2” in and 2 1/2” from the trailing edge. On the Outboard end center at 1 1/2” in and 2 1/2” from the trailing edge.
47.2 Using a hot knife/soldering Iron burn a 3/8” diameter hole into the Poly Fiber material where the location has been marked.
47.3 Locate the center hinge mounting hole on the leading edge tube at 23-1/2” (from inboard end) and burn out the hole.
47.3 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.

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 Section 18C, Covering Flying Surfaces - Elevator, SeaRey, LSA

Bolt AN4 Allen Head Bolt

Figure 48. Completed Elevator Ready for Final Poly-Brush Applications

48.1 The Elevator 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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