POLY FIBER MANUAL Flashcards
(157 cards)
1
Q
What is POLY-TAK?
A
A proprietary fabric cement used to cement fabric together and to the airframe.
POLY-TAK is essential for ensuring strong bonds in fabric applications.
2
Q
What is the purpose of POLY-BRUSH?
A
It is a fabric sealer used for closing the pores of bare fabric and preparing it for subsequent coatings.
POLY-BRUSH is also used to attach finishing tapes.
3
Q
What does POLY-SPRAY do?
A
It is a silver coating applied before the final color paint to protect the fabric against UV rays.
POLY-SPRAY ensures longevity of fabric by shielding it from sun damage.
4
Q
Describe POLY-TONE.
A
The final color paint with a satin-gloss finish, easy to repair when used over fabric.
Not ideal for metal surfaces without proper preparation.
5
Q
What is the base material for POLY-TAK, POLY-BRUSH, POLY-SPRAY, and POLY-TONE?
A
Vinyl
All four products are chemically compatible and won’t separate over time.
6
Q
What is MEK?
A
A universal solvent that cuts the four vinyl products and removes bonds between fabric and airframe.
MEK is too harsh to be used as a reducer.
7
Q
What temperature range is R 65-75 REDUCER used for?
A
Between 65 and 75°F.
It is used to thin Poly-Brush, Poly-Spray, and Poly-Tone.
8
Q
What is the purpose of RR 8500 REDUCER?
A
To thin products at temperatures above 85°F.
It serves the same purpose as R 65-75 but for higher temperatures.
9
Q
What type of finish does AERO-THANE provide?
A
A high-gloss high-tech ‘wet-look’ finish.
It is a two-part product requiring its own catalyst and reducer.
10
Q
What is RANDOLPH RANTHANE?
A
A two-part polyurethane similar to Aero-Thane with its own catalyst and reducer.
It works well over fabric, primed metal, or composites.
11
Q
What does the term ‘dope’ mean in the context of Poly-Fiber?
A
It does not exist; there is no dope in Poly-Fiber.
This term is rejected in the Poly language.
12
Q
What is EP-420 EPOXY PRIMER?
A
A two-part catalyzed epoxy primer for steel and aluminum, essential for the Poly-Fiber system.
Other primers like zinc chromate will peel off when in contact with Poly-Fiber products.
13
Q
What is EV-400 EPOXY VARNISH used for?
A
For wood, serving the same purpose as EP-420.
It provides a protective layer on wooden surfaces.
14
Q
What is BR-8600 BLUSH RETARDER?
A
Used to slow down drying time of coatings to reduce blush in high-humidity environments.
It also enhances the glossiness of Poly-Tone paint.
15
Q
What does the term ‘dope’ refer to in aviation?
A
Cellulose-based coatings
The term goes back to the earliest days of aviation.
16
Q
Which type of dope was first used in aviation?
A
Nitrate dope
17
Q
What type of dope gradually replaced nitrate dope during World War II?
A
Butyrate dope
18
Q
Why did butyrate dope become the predominant product?
A
It was somewhat less flammable than nitrate
19
Q
What fabric was introduced in the late ’50s that saved time in aircraft construction?
A
Heat-tightened polyester fabric
20
Q
What covering system became predominant after the introduction of polyester fabric?
A
Ceconite
21
Q
What was the issue with butyrate dope sticking to raw Ceconite?
A
Butyrate dope would not stick to raw Ceconite
22
Q
What combination system was introduced in the ’60s for Ceconite?
A
Nitrate/butyrate dope with Ceconite
23
Q
What serious drawbacks did nitrate and butyrate dope have?
A
- Dope burned readily
- Dope shrank over the years
- Delaminated from polyester fabric
- Became brittle and cracked
- Sensitive to humidity in application
24
Q
In what year did Ray Stits introduce a new process for aircraft covering?
A
1965
25
What did Ray Stits use to design his new polyester fabrics?
His own specially-designed polyester fabrics
26
What is a key difference between the Poly-Fiber system and the nitrate/butyrate/Ceconite system?
There is no dope in Ray’s system
27
What are the components of the liquid products in the Poly-Fiber system?
Made from vinyl, not from cellulose dope
28
What are the advantages of Poly-Fiber vinyl coatings over traditional dope?
* Never shrink or tighten fabric
* Remain flexible
* Do not support combustion
* Easily removed with MEK for repairs
29
When was the Poly-Fiber system awarded its STC?
1965
30
How many years of service experience has proven the Poly-Fiber system's ease of application and longevity?
Forty years
31
What should be used to cut away old fabric?
Razor blades or an Exacto knife
## Footnote
MEK can be used to loosen cemented areas.
32
What protective gear should be worn when using MEK?
Protective equipment and goggles
## Footnote
MEK is hazardous and can cause harm if it splashes into eyes or onto skin.
33
What should be done before pulling fabric from ribs?
Cut old rib laces
## Footnote
If rib rivets are installed, they must be carefully drilled out.
34
What should be noted when removing old fabric?
Positions of inspection rings, fairleads, and drain grommets
## Footnote
A photographic record of the old installed fabric is helpful.
35
What is crucial for the preparation process before spraying?
Thorough, meticulous preparation
## Footnote
The time spent preparing will enhance the final results.
36
What type of primers or varnishes should not be used?
One-part zinc chromate primers or 'spar' varnishes
## Footnote
These can cause wrinkling and lifting of fabric cements and dopes.
37
What type of primers or varnishes should be used instead?
Two-part epoxy primers or varnishes
## Footnote
They are unaffected by cements and dopes.
38
What should be done to old flaking varnish on wood surfaces?
Dry-sand the loose parts
## Footnote
It's not necessary to remove all old varnish.
39
What solvent should be used after sanding wood surfaces?
Poly-Fiber C-2210 Paint Cleaning Solvent
## Footnote
This removes grease and contamination before applying new finishes.
40
What should be done before applying primer to steel tubing?
Remove old cement, paint, primer, and rust
## Footnote
This must be done without damaging the underlying metal.
41
What is the recommended method for removing paint from tubing?
Blasting with suitable media
## Footnote
Test a painted tubing scrap first for the right combination.
42
What must be done immediately after blasting metal?
Protect the metal by priming as soon as possible
## Footnote
Delaying can invite new rust formation.
43
What should be used to clean bare areas before priming?
Poly-Fiber C-2200 Metal Surface Cleaner
## Footnote
This ensures removal of oil, grease, and contamination.
44
What epoxy primer is recommended for metal?
Poly-Fiber EP-420 Epoxy Primer
## Footnote
Use EP-430 Catalyst and thin with E-500 Epoxy Reducer.
45
What should be done to fiberglass parts with big holes?
Fill them with SuperFil
## Footnote
Sand until smooth with 180-grit sandpaper.
46
What should be sprayed over fiberglass after sanding?
White EP-420 Epoxy Primer
## Footnote
This seals the surface before applying topcoats.
47
What should be used to clean old aluminum before etching?
E-2310 Phosphoric Acid Etch and Brightener
## Footnote
This should be diluted with two parts water.
48
What is the next step after washing aluminum with etch?
Rinse thoroughly with clean water
## Footnote
Ensure no etch is trapped in seams or under rivet heads.
49
What should be done to new aluminum before priming?
Wipe with MEK, Acetone, or Toluene
## Footnote
This removes packing oils.
50
What should be used to scuff the surface of new aluminum?
Ultrafine Scotch-Brite pad or 320-grit sandpaper
## Footnote
Care should be taken not to leave noticeable scratches.
51
What is the final step before priming aluminum?
Prime with epoxy primer
## Footnote
Follow the same instructions as for old aluminum.
52
What is the main issue with having dents and old damage visible on a new covering job?
It detracts from the appearance of the airplane and can result in negative impressions from onlookers.
53
What should you do if the damage is severe or extensive?
Replace the material instead of attempting to repair it.
54
What is SuperFil used for?
To fill dents and imperfections on wood, fiberglass, steel, and aluminum.
55
Why should you avoid using Bondo?
Bondo is heavy, shrinks over time, separates from the surface, and is made from polyester.
56
How should SuperFil be applied?
With a squeegee, worked into the desired shape.
57
How long does it take for SuperFil to be ready to sand and smooth?
12 hours.
58
What should you apply to SuperFil used on aluminum?
Primer.
59
What should you apply to SuperFil used on wood?
Varnish.
60
What is a critical step before mixing SuperFil components?
Thoroughly stir each of the two parts before mixing.
61
What is Poly-Fiber polyester padding used for?
To hide minor dents and glitches, commonly on wing leading edges.
62
What is a drawback of using polyester padding?
It can collect Poly-Brush and cause a mottled effect.
63
What type of seams must be used over leading edge padding?
Sewn seams or envelopes.
64
What should you avoid using as padding instead of Poly-Fiber polyester padding?
Felt or cheap padding from a fabric store.
65
What is the purpose of inter-rib bracing?
To keep the ribs straight when the fabric is heat tightened.
66
What material is used for inter-rib bracing?
Twill tape.
67
How does inter-rib bracing look when completed?
It looks like a series of 'Xs' in each rib bay.
68
What should be covered with anti-chafe tape?
Any sharp edge or structural feature that might cut through the fabric.
69
What should you avoid using instead of genuine Poly-Fiber anti-chafe tape?
Paper masking tape, duct tape, or aluminum-faced tape.
70
What is the caution regarding the use of anti-chafe tape?
Avoid excessive use that could affect the appearance and bonding of the fabric.
71
What happens if you cement something to anti-chafe tape?
The bond is only as strong as the adhesive on the tape.
72
Fill in the blank: SuperFil is used to fill dents and imperfections on _______.
wood, fiberglass, steel, and aluminum
73
What is the only authorized heat source for accurate temperature control when working with fabric?
A CALIBRATED CLOTHING IRON
## Footnote
Heat guns are not suitable as they cannot be calibrated.
74
Why should you avoid using a heat gun for fabric work?
It cannot be calibrated and temperature changes with distance from fabric
## Footnote
This can lead to permanent damage to the fabric.
75
What wattage is recommended for an iron used in fabric work?
1100 watts or higher
## Footnote
This ensures adequate heat for effective fabric treatment.
76
What is the purpose of a small 165-watt heat sealing iron?
To smooth edges of trim tapes and patches in non-load carrying areas
## Footnote
It is not suitable for areas subjected to flight loads.
77
What temperature is used to smooth the edges of finishing tapes and patches?
225°
## Footnote
This temperature is also used to heat form fabric around corners.
78
What is the temperature for initial tightening and smoothing wrinkles from seams?
250°
## Footnote
This step is crucial before final heat tightening.
79
What is the maximum temperature for final tightening of fabric?
350°
## Footnote
Temperatures above this can permanently loosen the fabric.
80
At what temperature do polyester filaments start to thermo-soften?
375°
## Footnote
At this point, they begin to lose measurable tension.
81
What is the first step in calibrating your iron?
Obtain an accurate thermometer with a stem that contacts the iron plate
## Footnote
Silicone heat sink compound is also needed for calibration.
82
How do you check the calibration of a thermometer?
In boiling water (212° at sea level)
## Footnote
This step ensures the thermometer gives accurate readings.
83
What is the recommended method to secure the calibration card of a thermometer?
With cement
## Footnote
This ensures the calibration remains intact during use.
84
What is the recommended overlap for wing leading edge seams?
2˝ fabric overlap
## Footnote
This is crucial for maintaining structural integrity.
85
How wide must finishing tape be for cemented seams?
At least 2˝ wide
## Footnote
Wider tape can also be used for added security.
86
What should be used to cut all fabric edges for cemented seams?
STRAIGHT SCISSORS
## Footnote
This prevents loose threads and ravels.
87
What is the drying time for Poly-Tak cement in hot weather?
As fast as five minutes
## Footnote
Normal drying time is about 15 to 20 minutes.
88
What should you do if Poly-Tak cement gets thick in the soup can?
Add pure MEK to restore original consistency
## Footnote
MEK also cleans up spills and dried Poly-Tak.
89
What is the best way to achieve a strong cement bond?
Brush a 1˝ wide strip of wet Poly-Tak and immediately lay fabric wrinkle-free
## Footnote
This ensures good penetration of the cement.
90
What should you do if you make a mistake with a cemented seam?
Wet the seam with MEK, pull apart, and re-cement correctly
## Footnote
MEK can fix any mistakes made during the process.
91
True or False: Ribs are considered structural parts of an airplane.
False
## Footnote
Only certain parts like leading edges and longerons are structural.
92
What is the first step in covering a wing?
Cement the new fabric to the wing
93
What is the purpose of heating the fabric in stages?
To heat-tighten the fabric
94
What is the first coat applied to the wing after cementing the fabric?
1st coat of Poly-Brush
95
What is rib-lacing used for?
To attach the fabric to the ribs
96
What materials are used for the blanket method of covering the wing?
Poly-Fiber Heavy and Medium fabrics
97
What is the recommended width for Poly-Fiber fabrics?
About 70 inches wide
98
What should be done if the wing has an unusually wide chord?
Sew two pieces of fabric together
99
What is the best way to hold the wings for covering?
Rest them upon specially modified sawhorses
100
How should the sawhorses be modified for covering wings?
Fasten two pieces of wood perpendicular to the top beam
101
What is the overlap requirement for joining top and bottom fabric pieces?
2-inch overlap at the leading edge, 1-inch overlaps at the trailing edge, tip bow, and butt rib
102
What should be done to the leading edge before cementing the fabric?
Brush on two coats of thinned Poly-Brush
103
What is the recipe for thinned Poly-Brush?
3 parts Poly-Brush to 1 part Poly-Fiber Reducer
104
What tool is used to mark guidelines on the leading edge?
Chalk line
105
What should be done with selvage before covering the wing?
Trim it off carefully
106
What are scallops in the context of wing covering?
Troughs that form between the ribs
107
How can scalloping be minimized?
Use Poly-Fiber Medium fabric or a pre-sewn wing envelope
108
What tension should the fabric have when cementing?
Snug but not tight
109
What is the recommended temperature for the iron used in heat-tightening?
225° to 250°
110
What should be done if strut fittings are less than 2 inches above the wing surface?
Leave the fabric intact and tighten it around the protrusion
111
What should be done if strut fittings are 2 inches or more above the surface?
Make a cut to let the protrusion through
112
What is the purpose of heat-forming fabric around the trailing edge?
To create a permanent crease and ensure overlap
113
What should be done to the butt rib after cementing the bottom fabric?
Heat-form the extra fabric around the butt rib
114
Why should only soft lead pencils or chalk lines be used on fabric?
Other markers will bleed through the final paint
115
What is the process for aileron and flap recesses?
Heat-form the fabric into the recess and cement it securely
116
What should be made to assist in heat-forming at the wingtip?
A small ironing board out of cardboard
117
What is the final step after cementing the bottom fabric around the perimeter?
Let the Poly-Tak dry for about 15 minutes
118
What is the recommended tool for trimming fabric?
Single edge razor blade
## Footnote
Hold it firmly on the surface, and pull the fabric into the blade.
119
How long should Poly-Tak dry after applying the bottom fabric?
About 15 minutes
## Footnote
This is after the bottom fabric is cemented all around the perimeter of the wing.
120
What temperature should the iron be set to when working on cemented areas?
Lower than 250°
## Footnote
Never apply an iron hotter than this to a cemented area.
121
What is the purpose of ironing the cemented areas before attaching the top fabric?
To take out all wrinkles or imperfections
## Footnote
Smoother cemented areas will look better when covered with the top piece of fabric.
122
What should you use to smooth out lumps in the cemented areas?
The tip of the iron
## Footnote
The iron softens the Poly-Tak below the fabric, allowing for re-smoothing.
123
What is the recommended method for cementing the top fabric's leading edge?
Align it to the lowest chalk guide line
## Footnote
Re-chalk the line if it is hard to see due to the bottom fabric covering it.
124
What is the minimum overlap required for a trailing edge seam?
1 inch
## Footnote
This can be achieved by heat-forming the top fabric around both sides of the trailing edge.
125
What should you do if the trailing edge fairing is at least 1 inch wide?
Cement the fabric to the top of the trailing edge and trim flush
## Footnote
This also makes a legal 1 inch overlap.
126
What is crucial to remember before starting to iron the wing fabric?
A calibrated iron is the only approved source for tightening
## Footnote
Heat guns or uncalibrated irons can damage the project.
127
What will happen if you use heat guns or uncalibrated irons?
You could end up with permanently loose fabric
## Footnote
This can lead to cracked paint or fabric deformation during flight.
128
Will Poly-Brush or Poly-Spray tighten the fabric further?
No
## Footnote
Whatever is done with the iron is the finished product.
129
What must be ensured at the wingtip bow when applying the top fabric?
A 1 inch overlap with the bottom fabric
## Footnote
Trim the top piece neatly with scissors.
130
What should be used in tight places when sealing?
The little sealing iron
## Footnote
This ensures precision in tight areas.
131
What is the recommended method for trimming the top piece of fabric?
Use scissors as neatly as possible
## Footnote
Razor blades are dangerous and can cut the bottom fabric.
132
What temperature should you start with when heat tightening?
250°
## Footnote
This temperature helps to spread the tension evenly across the fabric surface.
133
What is the purpose of starting at one end of the wing during heat tightening?
To spread the increasing tension evenly and symmetrically across the surface.
134
What should you do if you see fabric pulling tight around the iron?
Move the iron slowly around the fabric to take out the big wrinkles.
135
What should you avoid while tightening the fabric on the wing?
Starting at one end of the wing and working toward the other.
136
What can happen if you exert asymmetrical force while tightening the fabric?
You could put unwanted dihedral in your wing or wind up with deep troughs in the fabric.
137
What should you do after tightening one end of the wing?
Go to the opposite end of the wing and do the same thing.
138
At what temperature should you turn the wing over and tighten opposing areas?
250°.
139
What should you do around strut fittings while tightening?
Iron right around them; they won’t break through.
140
What is the peak temperature for tightening fabric?
350°.
141
What happens if you exceed 350° while tightening fabric?
It starts permanently loosening the fabric.
142
What should you ensure while ironing the fabric at 350°?
Iron every inch of the fabric.
143
What is the danger of ironing over a cemented seam at temperatures over 250°?
A 350° iron can pop cemented seams.
144
What should you do if you're covering an ultralight aircraft?
Tighten at 250° and monitor for structural deformation.
145
What does applying Poly-Brush do?
* Seals the fabric
* Acts as a cement that secures the fabric to the airframe
146
What is the recommended thinning ratio for Poly-Brush?
3 parts Poly-Brush to 1 part reducer.
147
What should you use above 85° for thinning Poly-Brush?
RR 8500 Reducer.
148
What should you scrub the fabric with before applying Poly-Brush?
MEK or reducer.
149
What type of rags should be used when applying Poly-Brush?
New cotton rags.
150
What should you do after scrubbing the fabric?
Pass a tack rag lightly over the surface.
151
What is the best type of brush for applying Poly-Brush?
Natural-bristle brushes.
152
How should Poly-Brush be applied to the fabric?
Liberally over all the fabric.
153
What should you monitor for during the application of Poly-Brush?
Drips on the bottom fabric.
154
What should you do if you see runs pooling on the underside of the top fabric?
Wipe these drips away with MEK and a clean rag.
155
What is the drying time for Poly-Brush in hot weather?
As little as 5 minutes.
156
Is it recommended to spray on the first coat of Poly-Brush?
No, brushing does a much better job.
157
Can you sand drips or flaws in Poly-Brush?
Page 42 - Rib Lacing
No, Poly-Brush doesn’t sand.
