18A SeareyLSA - Covering Wings 2013-08-27 PDF

Section 18A, Covering Wings, 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 Note to skip this section if “Fast Build Kit” was Purchased 06/12/2012
03 Update Pg 8 & 17, procedure 5.2 & 14.2, temp should be 350 degrees 08/02/2012
04 Update Corrected covering using complete Stits Method 08/29/2012
05 Update Added step 9.3 to page 12 11/30/2012
06 Update Added Page 24, AOA Inspection Hole 08/27/2013
Page 1 of 24
1.0 Scope
This document will detail the steps necessary to cover wings with fabric. If the “Fast Build Kit” is purchased the builder will skip this section.
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
Page 2 of 24
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.
Page 3 of 24
Anti-Chafe
Tape
Debur and file

rivet holes
Remove
this Bolt
Figure 1. Preparing the Wing for Covering
1.1 Prepare the Wing on both sides by cleaning the surface with M.E.K., Gallon (#0620-001) removing any oils or construction markings.
1.2 Make sure all the rivet holes on the ribs are deburred and filed on both sides.
1.3 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.
1.4 Remove the Bolt/Nut on the outboard end of the wing on the Trailing Edge Wing Cuff.
Note: Prior to covering the fiberglass wing tip, scuff up the surface with sandpaper and clean with MEK.
Page 4 of 24
Optional Poly Stits

Pad or Felt Poly-Fiber Trailing
Fabric (Not Fabric Edge
supplied in Kit) Wing Cuff
Figure 2. Covering the Bottom of the Wing with Fabric
2.1 Installation of Poly Pad or Felt Fabric on the Leading Edge is not required. The Poly Pad or Felt Fabric is not supplied in the kit.
This step can cover any imperfections of the Leading Edge Wing Cuff aluminum and hide the rivet heads, giving the leading edge
a smoother look. (Poly Pad or Felt Fabric was not installed on this wing.)
2.2 Install the Poly Pad or Felt onto the leading edge by cutting a piece of material the same length and width as the Leading Edge
Cuff. Apply contact cement to the Poly Pad or Felt and to the Leading Edge Cuff. Let the contact cement set up for a bit and then
apply the Poly Pad or Felt to the Leading Edge Cuff.
2.3 Start on the underside of the wing. Unroll the roll of Stits Fabric, 3.16oz, 70” wide, 1 YD (#0620-020) across the entire surface
and clamp to the frame. Leave 12 inches of overhang on the inboard and outboard ends of the wing. Line up the clean edge of
the Stits Fabric with the bottom edge of the Trailing Edge Wing Cuff. (This is really the top edge of the Trailing Edge Wing Cuff.)
Make some initial cuts in the Stits Fabric to allow the trailing edge to hang smoothly over the Trailing Edge Wing Cuff.
2.4 Using the Poly-Tak Cement, Quart (#0620-008), cement in place the Stits Fabric to all of the surface area the Fabric comes in
contact with on the Trailing Edge Wing Cuff.
Page 5 of 24
Stits
Poly-Fiber
Fabric
Leading
Edge Cement Wing Rib
Wing Cuff Wing Cuff Inboard
Surface
3.1 Pull the Stits Fabric, 3.16oz, 70” wide, 1 YD (#0620-020) over the Leading Edge Wing Cuff so it lays smoothly over the Leading
Edge Wing Cuff. Make a line on the Fabric that is 1” past the apex point of the Leading Edge Wing Cuff and cut the Fabric on the
line.
3.2 Using the Poly-Tak Cement, Quart (#0620-008), cement in place the entire Leading Edge Wing Cuff surface using the brush and
squeegee to get the fabric to adhere securely.
3.3 Using an iron at 250 degrees F., pull down on the 12” overlap fabric on the Wing Rib Inboard (#5710-010) and apply heat from the
iron to the edge, forming the fabric around the lip of the Wing Rib Inboard. Trim the Stits Fabric so the Fabric covers the entire
side of the wood of the Wing Rib Inboard all the way to the top edge.
3.4 Prime the wood surface of the Wing Rib Inboard (#5710-010) with Poly-Tak Cement, Quart (#0620-008) to make a good contact
surface for the wood. Let dry. Cut slits in the Stits Fabric to allow the Aileron Torque Tube (#2710-003) to protrude through. Now
cement the Stits Fabric to the Wing Rib Inboard.
Page 6 of 24
Stits
Poly-Fiber
Cement Fabric
Wing Tip
Surface
Cut the
Fabric at an
angle here
Trailing
Edge
Wing Cuff
4.1 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 Leading
Edge Wing Cuff. Cut a 45 degree angle out of the fabric at the end of the wing cuff across the fiberglass wing tip.
4.2 Using the Poly-Tak Cement, Quart (#0620-008), cement fabric to the entire wing tip surface using the brush and squeegee to get
the fabric to adhere securely.
4.3 Using an iron at 250 degrees F., pull down on the 12” overlap fabric on the wing tip and apply heat from the iron to the edge,
forming the fabric around the curved edge. Trim the curved tip so there is 1” fabric past the apex of the edge and cement in place.
Note: Do not Iron the Fabric that is glued to the fiberglass wing tip surface.
Page 7 of 24
Stits
Poly-Fiber
Fabric
Trailing
Edge
Wing Cuff
Figure 5. Ironing the Bottom of the Wing Fabric
5.1 Iron the surface at 250 degrees F. as follows: Start with the trailing edge, then leading edge, then wing tip, then inboard end.
5.2 Now iron the main surface at 350 degrees F. Start at the inboard rib area first. Then go to the outboard end first rib area.
Alternate back and forth between rib sections until you reach the middle of the wing.
Page 8 of 24
Rib
Figure 6. Cementing the Fabric to the Wing Ribs
6.1 Place enough weight on the Stits Fabric, 3.16oz, 70” wide, 1 YD (#0620-020) to help the Fabric form over each rib and lay firmly
on top of the rib.
6.2 Apply Poly-Tak Cement, Quart (#0620-008) to each rib. Leave the weight on and let dry. Remove the weights when dry.
Page 9 of 24
Check position with Horn

Temporarily on Aileron
Torque Tube
20”
Optional Inspection Hole –

5”
Access to AOA Sensors
Rib # 10
Figure 7. Laying out the Wing Inspection Covers
7.1 Lay out the (6) Inspection Hole Ring(s) (#5720-016) and (2) Fabric Reinforcement Plate(s) (#5720-001) on the bottom
side of the Wing per the diagram above.
Page 10 of 24
Inspection
Hole Ring
Inspection
Hole Ring
Fabric
Reinforcement
Plate
Fabric
Reinforcement
Plate
Figure 8. Cementing the Wing Inspection Hole Rings and Fabric Reinforcement Plates
8.1 Apply Poly-Tak Cement, Quart (#0620-008) to each Inspection Ring (#5720-016) and Fabric Reinforcement Plate (#5720-001)
and set in place per the dimensions on Figure 7.
Page 11 of 24
Jury Strut Jury Strut

Doily Doily
Doilies
Installed
Doily
Figure 9. Installing Doilies on the Inspection Hole Rings and Fabric Reinforcement Plates
9.1 For the Inspection Hole Ring(s) (#5720-016) and Fabric Reinforcement Plate(s) (#5720-001) cut out Doilies from the Stits Fabric,
3.16oz, 70” wide, 1 YD (#0620-020), 1” larger in dimension than the ring and plate. Use pinking shears to cut doilies.
9.2 Apply Poly-Brush Tinted, Gallon (#0620-003) to each Ring Doily and Plate Doily and set in place over the Inspection Hole Ring(s)
and Fabric Reinforcement Plate(s), making sure they are centered and overlap 1”.
9.3 Cut a 2” round Doily for two spots on each wing at the Wing Jury Strut Eyebolt locations. The Leading Edge Jury Strut location is
51 3/8” outboard from the Root Rib and 5 ½” from the leading edge. The Trailing Edge Jury Strut location is 51” outboard from the
Root Rib and 4 ½” from the trailing edge. Apply Poly-Tak Cement, Quart (#0620-008) to each Doily and set in place on the wing
fabric.
Page 12 of 24
Stits
Reinforcing
Tape
Start Stits
End Rivet
Tape Reinforcing
Tape ABL4-2A
Here Tape
Here
Figure 10. Installation of the Reinforcing Tape on the Ribs
10.1 Install the Roll Stits 3/8” x 60 YD Reinforcing Tape (#0620-013) by applying the tape on each rib. Apply the Stits Reinforcing Tape
from the edge of the Leading Edge Wing Cuff to the edge of the Trailing Edge Wing Cuff.
10.2 Locate the rivet holes drilled in the ribs underneath the Stits Reinforcing Tape and use a soldering iron or hot knife to burn through
the tape, opening up each rivet hole.
10.3 Install a Rivet ABL4-2A (#L-42) in each hole that was drilled in all of the ribs.
10.4 Flip the wing over to the top side.
Page 13 of 24
Stits
Poly-Fiber
Fabric
Trailing
Edge
Wing Cuff
Figure 11. Covering the Top of the Wing with Fabric
11.1 Unroll the roll of Stits Fabric, 3.16oz, 70” wide, 1 YD (#0620-020) across the entire surface and clamp to the frame. Leave 12
inches of overhang on the inboard and outboard ends of the wing. Line up the clean edge of the Stits Fabric with the bottom edge
of the Trailing Edge Wing Cuff. Make some initial cuts in the Fabric to allow the trailing edge to hang smoothly over the Trailing
Edge Wing Cuff.
11.2 Using the Poly-Tak Cement, Quart (#0620-008), cement in place the Stits Fabric to all of the surface area the Fabric comes in
contact with on the Trailing Edge Wing Cuff.
Page 14 of 24
Stits
Poly-Fiber
Fabric
Wing Rib
Inboard Leading Cement
Edge Wing Cuff
Wing Cuff Surface
12.1 Pull the Stits Fabric, 3.16oz, 70” wide, 1 YD (#0620-020) over the Leading Edge Wing Cuff so it lays smoothly over the Leading
Edge Wing Cuff. Make a line on the Fabric that is 1” past the apex point of the Leading Edge Wing Cuff and cut the Fabric on the
line.
12.2 Using the Poly-Tak Cement, Quart (#0620-008), cement the Fabric in place on the entire Leading Edge Wing Cuff surface, using
the brush and squeegee to get the Fabric to adhere securely.
12.3 Using an iron at 250 degrees F., pull down on the 12” overlap fabric on the Wing Rib Inboard (#5710-010) and apply heat from the
iron to the edge forming the fabric around the lip of the Wing Rib Inboard (#5710-010). Trim the Stits Fabric so the Fabric covers
the entire side of the wood of the Wing Rib Inboard all the way to the bottom edge.
12.4 Cut slits in the Stits Fabric to allow the Aileron Torque Tube (#2710-003) to protrude through. Now using Poly-Tak Cement,
cement the Stits Fabric to the Wing Rib Inboard (#5710-010)
Page 15 of 24
Stits
Poly-Fiber
Fabric
Trailing
Edge
Wing Cuff
Cement
Cut the Wing Tip
Fabric at an Surface
angle here
13.1 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 Leading
Edge Wing Cuff. Cut a 45 degree angle out of the fabric at the end of the wing cuff across the fiberglass wing tip.
13.2 Using the Poly-Tak Cement, Quart (#0620-008), cement fabric in place over the entire wing tip surface, using the brush and
squeegee to get the fabric to adhere securely.
13.3 Using an iron at 250 degrees F., pull down on the 12” overlap fabric on the wing tip and apply heat from the iron to the edge,
forming the fabric around the curved edge. Trim the curved tip so there is 1” material past the apex of the edge and cement in
place.
Page 16 of 24
Stits
Poly-Fiber
Fabric
Trailing
Edge
Wing Cuff
Figure 14. Ironing the Top of the Wing Fabric
14.1 Iron the surface at 250 degrees F. as follows: Start with the trailing edge, then leading edge, then wing tip, then inboard end.
14.2 Now Iron the main surface at 350 degrees F. Start at the inboard rib area first. Then go to the outboard end first rib area.
Alternate back and forth between rib sections until you reach the middle of the wing.
Page 17 of 24
Rib
Figure 15. Cementing the Fabric to the Wing Ribs
15.1 Place enough weight on the Stits Fabric, 3.16oz, 70” wide, 1 YD (#0620-020) to help the Fabric form over each rib and lay firmly
on top of the rib.
15.2 Apply Poly-Tak Cement, Quart (#0620-008) to each rib. Leave the weights on and let dry. Remove the weights when dry.
Page 18 of 24
Start
Tape
Here
Rivet
ABL4-2A
Stits
Reinforcing Reinforcing
Tape Tape
End
Tape
Here
Figure 16. Installation of the Reinforcing Tape on the Ribs
16.1 Install the Roll Stits 3/8” x 60 YD Reinforcing Tape (#0620-013) by applying the tape on each rib. Apply the Stits Reinforcing Tape
from the edge of the Leading Edge Wing Cuff to the edge of the Trailing Edge Wing Cuff.
16.2 Locate the rivet holes drilled in the ribs underneath the Stits Reinforcing Tape and use a soldering iron or hot knife to burn through
the tape, opening up each rivet hole.
16.3 Install a Rivet ABL4-2A (#L-42) in each hole that was drilled in all of the ribs.
Page 19 of 24
Top Wing 2” Linear

Tape 2” Linear
Tape
End
Tape Start
1” past Tape
apex
Bottom Wing
Figure 17. Installation of the 2” Linear Tape on the Ribs
17.1 Perform the following on both top and bottom of wings: Apply 3:1 Poly-Brush Tinted, Gallon (#0620-003) mixed with Poly-Fiber
Reducer RR8500, Gallon (#0620-005) on each rib in a 2” strip. Let dry.
17.2 Apply the Roll 2” Linear Tape x 50 YD, Poly-Fiber P-106 (#0620-009) starting from the center point of the Trailing Edge Wing Cuff
and ending at 1” past the Leading Edge Wing Cuff apex. Wet the area again under the 2” Linear Tape and also brush it in with
more Poly-Brush on the top side.
Page 20 of 24
2” Linear 2” Linear
Tape Bottom Tape
Wing
3” Linear
Edge Tape
Figure 18. Installation of the 2” and 3” Linear Tape on the Inboard Rib and Tip
18.1 Install the Roll 2” Linear Tape x 50 YD, Poly-Fiber P-106 (#0620-009) by applying Apply 3:1 Poly-Brush Tinted, Gallon (#0620-003)
mixed with Poly-Fiber Reducer RR8500, Gallon (#0620-005) on the Inboard Rib. Apply the 2” Linear Tape starting from the Trailing
Edge Wing Cuff and ending at the Leading Edge Wing Cuff apex. The edge of the 2” Linear Tape will be 1” on the top side of the
wing and fold over the other 1” portion over the side of the inboard edge of the wood Rib. Repeat on the bottom edge.
18.2 Install 2” Linear Tape over the 45 degree angled cut that runs from the end of the Trailing Edge Wing Cuff across the fiberglass
wing tip. Do this on the top and bottom side.
18.3 To clean up the edges of the wing tip on the fiberglass you can install 3” Linear Tape x 25 YD, Poly-Fiber P-106 (#0620-010).
Apply Poly-Tak Cement to the 3” Linear Tape and install to the desired areas.
Page 21 of 24
Bottom
Wing
4” Linear
Tape
Top Wing
Reinstall
this Bolt
4” Linear
Tape
Figure 19. Installation of the 4” Linear Tape on the Wing Leading and Trailing Edge
19.1 Install the Roll 4” Linear Tape x 25 YD, Poly-Fiber P-106 (#0620-011) by applying Apply 3:1 Poly-Brush Tinted, Gallon (#0620-003)
mixed with Poly-Fiber Reducer RR8500, Gallon (#0620-005) on the Trailing Edge Wing Cuff. Start the 4” Linear Tape at the inboard
end of the wing and run the tape across the entire length to the inside edge of the wing tip where the Aileron would end. Center
the tape top-to-bottom on the Trailing Edge Wing Cuff. There should be 1” wrapping over on the top side and 1” wrapping over on
the bottom side.
19.2 Install the Roll 4” Linear Tape by applying Apply 3:1 Poly-Brush Tinted, Gallon (#0620-003) mixed with Poly-Fiber Reducer RR8500,
Gallon (#0620-005) on the Leading Edge Wing Cuff. Start the 4” Linear Tape at the inboard end of the wing and run the tape
across the entire length, going around the curved outboard leading edge of the Wing Tip until you reach the very end. Center the
tape on the Apex of the Leading Edge Wing Cuff. There should be 2” wrapping over on the top side and 2” wrapping over on the
bottom side.
19.3 Reinstall the Bolt on the outboard end of the wing on the Trailing Edge Wing Cuff that was removed in Step 1.4. Using a soldering
iron or hot knife, open up the existing hole in the Trailing Edge Wing Cuff where the Bolt use to be and reinstall Bolt and Nut.
Page 22 of 24
Top Wing Bottom

Wing
Figure 20. Application of the Poly-Brush to the Wing
20.1 Hand application of the Poly-Brush Tinted, Gallon (#0620-003) is required for the first coat on the wing 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.
20.2 Wing is ready for (2) more sprayed-on coats of the Poly-Brush and then Poly-Spray, Gallon (#0620-007) before finish-color paint is
applied.
Page 23 of 24
Bottom Rib # 10
Wing
20”
AOA Insp.
Hole 5”
Rib # 10
Figure 21. Cutting Out the Inspection Hole for the AOA
21.1 Layout the dimensions on the bottom side of the wing tip for the Inspection Hole to be cut. From the Leading Edge of Rib #10
measure back 20” and from the center line of the rib measure over 5”.
21.2 Using a Hole Saw , cut a 3 ½” hole centered on the above dimensions.
21.3 Cut out a 4 ½” Doily from the Stits Fabric, 3.16oz, 70” wide, 1 YD (#0620-020) use pinking shears. Prior to applying the doily to
the wing, coat the top side of the doily with Poly-Brush. Apply Poly-Brush Tinted, Gallon (#0620-003) to the edges around the
inspection hole and then place the doily over the Inspection Hole, making sure it is centered and overlap 1”.
Page 24 of 24

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Section 18A, Covering Wings, SeaRey, LSA

Progressive Aerodyne, Inc.

Revision Description Remarks Date

2.0 Applicable Documents

 Lacquer thinner (Cleaning labels off of parts)

3.3 Procedure (See the following pages)

Debur and file

Figure 1. Preparing the Wing for Covering

Optional Poly Stits

Figure 2. Covering the Bottom of the Wing with Fabric

Figure 3. Covering the Bottom of the Wing with Fabric

Figure 4. Covering the Bottom of the Wing with Fabric

Figure 5. Ironing the Bottom of the Wing Fabric

Figure 6. Cementing the Fabric to the Wing Ribs

Check position with Horn

Optional Inspection Hole –

Figure 7. Laying out the Wing Inspection Covers

Jury Strut Jury Strut

Figure 10. Installation of the Reinforcing Tape on the Ribs

Figure 11. Covering the Top of the Wing with Fabric

Figure 12. Covering the Top of the Wing with Fabric

Figure 13. Covering the Top of the Wing with Fabric

Figure 14. Ironing the Top of the Wing Fabric

Figure 15. Cementing the Fabric to the Wing Ribs

Figure 16. Installation of the Reinforcing Tape on the Ribs

Top Wing 2” Linear

Figure 17. Installation of the 2” Linear Tape on the Ribs

Top Wing Bottom

Figure 20. Application of the Poly-Brush to the Wing

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