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WhiskeyVictor36(at)aol.co Guest
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Posted: Thu Jan 22, 2009 12:57 pm Post subject: fabric rubbing on cage tubes |
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In a message dated 1/15/2009 10:51:00 P.M. Eastern Standard Time, cristalclearwaters(at)gmail.com writes:
Quote: | Have any of you ever seen anything similar to what I have attached here in the photos?
When you build these planes is there any instruction to put anything between the tubes and fabric?
Cristal,
Your pictures show what looks like a black, oily residue, forming around the aluminum tubes. I have seen this on my original style FireStar a few times and cleaned it off with a de greaser. It always appeared after I spilled pre-mix fuel when topping off my fuel tank. That fuselage side fabric does a lot of 'drumming' when the engine is running.
The instructions for building did not say anything about gluing, rib stitching or riveting the fabric to these tubes. I suppose when I applied the Polybrush coating, some of it did glue the fabric to the tube, but it would have been just a narrow strip on the apex of the tube and the drumming could have caused it to become loose.
I believe John Haucks suggestion to use the fabric rivets to secure the fabric to the aluminum faring tubes is a good idea and I may even do this to my Kolb because it also is beginning to show some signs of wearing a hole through the fabric.
Bill Varnes
Original Kolb FireStar
Audubon NJ
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cristalclear13

Joined: 19 Sep 2007 Posts: 363 Location: Southeast Georgia
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Posted: Thu Jan 22, 2009 1:42 pm Post subject: Re: fabric rubbing on cage tubes |
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WhiskeyVictor36(at)aol.co wrote: | Your pictures show what looks like a black, oily residue, forming around the aluminum tubes. I have seen this on my original style FireStar a few times and cleaned it off with a de greaser. It always appeared after I spilled pre-mix fuel when topping off my fuel tank. That fuselage side fabric does a lot of 'drumming' when the engine is running.
The instructions for building did not say anything about gluing, rib stitching or riveting the fabric to these tubes. I suppose when I applied the Polybrush coating, some of it did glue the fabric to the tube, but it would have been just a narrow strip on the apex of the tube and the drumming could have caused it to become loose.
I believe John Haucks suggestion to use the fabric rivets to secure the fabric to the aluminum faring tubes is a good idea and I may even do this to my Kolb because it also is beginning to show some signs of wearing a hole through the fabric.
Bill Varnes
Original Kolb FireStar
Audubon NJ
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Thank you for sharing that Bill, That sounds exactly like what I'm seeing. Although I didn't spill any fuel, I did wash my plane and some of the water (and probably dirt and dust) probably ran down the inside and probably settled between the tubes and fabric contributing to the fretting corrosion.
I've got a friend who helped me with some small fabric repairs when I first got the plane so maybe he can help me with this.
Thank you also John, Mike and Mike for your suggestions. Now if I only had a shop with all these supplies and tools I'll need.
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_________________ Cristal Waters
Kolb Mark II Twinstar Rotax 503 DCSI Sept 2007 - sold Sept 2012
Private Pilot Aug 2008
ELSA Repairman for N193Y April 2008
Rotax 2 stroke maintenance April 2009 |
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rlaird

Joined: 10 Jan 2006 Posts: 373 Location: Houston
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Posted: Thu Jan 22, 2009 2:18 pm Post subject: fabric rubbing on cage tubes |
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Cristal --
I recently learned how to do the Polyfiber system for a repair, and, it's not hard at all! The only "special" tools you'll need are some pinking shears and a calibrated iron. (Some people get away with calibrating their own iron, but I didn't feel very good about doing that, so I used one that came with temp-control dial.. And even then I didn't trust it, and used a digital thermometer to make sure it was at the right temp.)
Everything else is easy to come by. The trick I learned -- for repairs... you wouldn't want to use them for an entire covering job -- is to use the disposable sprayers. Here's a link:
http://store.fastcommerce.com/PaintProsUSA/prod-ff80808117344aab01175583b1ca6bf5.html
They were worth their weight in gold... Not only easy to use and inexpensive, but you don't have to buy or fool with the entire HVLP sprayers.
Buy the Polyfiber book and read it... read it twice! It's worth the time. If you're worried, then nail four boards together and "cover it" and play with the process needed... The first time you do it, you might make a couple of minor mistakes... the 2nd time, you won't. It's very easy.
Good luck!
-- Robert
P.S. You can also read my blog entries about my repair job:
http://blogs.chron.com/lightflight/archives/2008/08/repairing_fabri.html
http://blogs.chron.com/lightflight/archives/2008/08/repairing_fabri_1.html
http://blogs.chron.com/lightflight/archives/2008/08/repairing_fabri_2.html
http://blogs.chron.com/lightflight/archives/2008/09/repairing_fabri_3.html
You'll notice that I --didn't-- test the process first, and ended up with lumpy results... that's how I know to tell you to do a test covering first! If I wasn't so lazy, I'd go back and re-do it (another big advantage of the Polyfiber system, is that you -can- undo it all).
On Thu, Jan 22, 2009 at 3:42 PM, cristalclear13 <cristalclearwaters(at)gmail.com (cristalclearwaters(at)gmail.com)> wrote:
[quote]--> Kolb-List message posted by: "cristalclear13" <cristalclearwaters(at)gmail.com (cristalclearwaters(at)gmail.com)>
WhiskeyVictor36(at)aol.co wrote:
> Your pictures show what looks like a black, oily residue, forming around the aluminum tubes. I have seen this on my original style FireStar a few times and cleaned it off with a de greaser. It always appeared after I spilled pre-mix fuel when topping off my fuel tank. That fuselage side fabric does a lot of 'drumming' when the engine is running.
>
> The instructions for building did not say anything about gluing, rib stitching or riveting the fabric to these tubes. I suppose when I applied the Polybrush coating, some of it did glue the fabric to the tube, but it would have been just a narrow strip on the apex of the tube and the drumming could have caused it to become loose.
>
> I believe John Haucks suggestion to use the fabric rivets to secure the fabric to the aluminum faring tubes is a good idea and I may even do this to my Kolb because it also is beginning to show some signs of wearing a hole through the fabric.
> Bill Varnes
> Original Kolb FireStar
> Audubon NJ
>
>
>
Thank you for sharing that Bill, That sounds exactly like what I'm seeing. Although I didn't spill any fuel, I did wash my plane and some of the water (and probably dirt and dust) probably ran down the inside and probably settled between the tubes and fabric contributing to the fretting corrosion.
I've got a friend who helped me with some small fabric repairs when I first got the plane so maybe he can help me with this.
Thank you also John, Mike and Mike for your suggestions. Now if I only had a shop with all these supplies and tools I'll need.
--------
Cristal Waters
Kolb Mark II Twinstar
Rotax 503 DCSI
Read this topic online here:
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Robert Laird
formerly: MkIIIc w/ 912ULS & Gyrobee
current: Autogyro Cavalon w/ 914ULS
Houston, TX area
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WhiskeyVictor36(at)aol.co Guest
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Posted: Thu Jan 22, 2009 8:34 pm Post subject: fabric rubbing on cage tubes |
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Robert,
Thanks so much for informing us about this portable paint sprayer. Looks like it would be easy to use and clean up.
Bill Varnes
In a message dated 1/22/2009 5:18:51 P.M. Eastern Standard Time, rlaird(at)cavediver.com writes:
Inauguration '09: Get complete coverage from the nation's capital.
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williamtsullivan(at)att.n Guest
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Posted: Fri Jan 23, 2009 5:09 pm Post subject: Fabric rubbing on cage tubes |
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Cristal- I happened to look at my cage tubes today, and noticed a flat spot worn on one of the aluminum tubes. The fabric is off for the re-build, but I remember seeing exactly what you describe. I thought it was an oil stain, or some kind of mold. By the looks of it, it was probably abrasion from the Dacron. It's quite a flat spot, so good catch. Fix it like the guys said. you might even be able to feel a flat spot on the tube. Dacron must be pretty strong stuff to do that to aluminum.
Bill Sullivan
Windsor Locks, Ct.
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Possums
Joined: 03 Nov 2007 Posts: 247
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Posted: Fri Jan 23, 2009 8:05 pm Post subject: Fabric rubbing on cage tubes |
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At 08:07 PM 1/23/2009, you wrote:
Quote: | Cristal- I happened to look at my cage tubes today, and noticed a
flat spot worn on one of the aluminum tubes. The fabric is off for
the re-build, but I remember seeing exactly what you describe. I
thought it was an oil stain, or some kind of mold. By the looks of
it, it was probably abrasion from the Dacron. It's quite a flat
spot, so good catch. Fix it like the guys said. you might even be
able to feel a flat spot on the tube. Dacron must be pretty strong
stuff to do that to aluminum.
Bill Sullivan
Windsor Locks, Ct.
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don't think they use Dacron
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Dana

Joined: 13 Dec 2007 Posts: 1047 Location: Connecticut, USA
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Posted: Fri Jan 23, 2009 8:16 pm Post subject: Fabric rubbing on cage tubes |
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At 11:05 PM 1/23/2009, possums wrote:
Quote: | don't think they use Dacron
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Stits IS Dacron, as is Ceconite. All three are trademark names for
polyester fabric.
-Dana
--
A day without sunshine is like, night.
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Possums
Joined: 03 Nov 2007 Posts: 247
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Posted: Fri Jan 23, 2009 8:26 pm Post subject: Fabric rubbing on cage tubes |
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At 08:07 PM 1/23/2009, you wrote:
Quote: | Cristal- I happened to look at my cage tubes today, and noticed a
flat spot worn on one of the aluminum tubes.
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I don't think you should have had a problem if it was done right to begin with.
You glue the fabric, shrink/iron the fabric.
When you dope or seal the fabric, put on the reinforcement tapes,
spray the silver & paint,
it pretty much goes thru the fabric & cements it to those tubes.
Least that's what I thought.
Mines 11 years old.
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Possums
Joined: 03 Nov 2007 Posts: 247
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Posted: Fri Jan 23, 2009 8:40 pm Post subject: Fabric rubbing on cage tubes |
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At 11:11 PM 1/23/2009, you wrote:
Quote: | --> Kolb-List message posted by: Dana Hague <d-m-hague(at)comcast.net>
At 11:05 PM 1/23/2009, possums wrote:
Quote: | don't think they use Dacron |
Stits IS Dacron, as is Ceconite. All three are trademark names for polyester fabric.
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I think you might be wrong, I've used both on different Uls - My old 1983 CGS Hawk used Dacron coverings - right?? Like sail cloth?
The Poly-Fiber method uses Poly-Brush followed by Poly-Spray, which includes a silver coat for UV protection and the final color coats for the desired color.
These products are essentially the same airplane dope as the adhesive and are completely compatible.
EkoFill by Stewart Systems is water-based with a high level of solids that will fill the weave of the Dacron fabric while including sufficient UV inhibitors to protect the fabric.
but that is just an extra.
[quote][b]
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ceengland(at)bellsouth.ne Guest
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Posted: Fri Jan 23, 2009 9:09 pm Post subject: Fabric rubbing on cage tubes |
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william sullivan wrote:
Quote: | Cristal- I happened to look at my cage tubes today, and noticed a
flat spot worn on one of the aluminum tubes. The fabric is off for
the re-build, but I remember seeing exactly what you describe. I
thought it was an oil stain, or some kind of mold. By the looks of
it, it was probably abrasion from the Dacron. It's quite a flat spot,
so good catch. Fix it like the guys said. you might even be able to
feel a flat spot on the tube. Dacron must be pretty strong stuff to
do that to aluminum.
Bill Sullivan
Windsor Locks, Ct.
|
Haven't followed this thread closely, but do have a comment about fabric
wearing aluminum. It's likely not the covering doing the damage, but
grit carried by the covering as it moves relative to the tube.
Most of the guys flying bigger experimentals know not to use nylon wire
ties directly on motor mounts because they can eat through the 4130
steel. Dirt & grit get embedded in the nylon & if it moves, it acts like
a saw. This is a very real issue with any soft material moving against
metal in an a/c; I've had a fabric covered starter cable cut through an
aluminum oil drain-back tube on a Lyc.
Charlie
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Dana

Joined: 13 Dec 2007 Posts: 1047 Location: Connecticut, USA
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Posted: Sat Jan 24, 2009 6:46 am Post subject: Fabric rubbing on cage tubes |
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At 11:39 PM 1/23/2009, possums wrote:
Quote: | I think you might be wrong, I've used both on different Uls - My old
1983 CGS Hawk used Dacron coverings - right?? Like sail cloth?
The Poly-Fiber method uses Poly-Brush followed by Poly-Spray...
|
Well, I should have been more precise. The fabric you use in the Stits
_process_, that you buy from Stits (Poly-Fiber, now) is polyseter
fabric. Same for Ceconite, same fabric, though you have to buy it from
Ceconite for the process to be "legal". I don't know if Stits and Ceconite
do anything further to the base fabric (sizings or coatings) before selling
it. Dacron is just another trade name for polyester fabric made by Dupont
Corporation, though we use it interchangeably (and incorrectly) whether it
was actually manufactured by Dupont or not, and sailcloth is usually
polyester... lots of other ultralights use polyester sails, but without the
"process" coatings. Same fabric, different process.
-Dana
--
"A dress makes no sense unless it inspires men to want to take it off you."
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slyck(at)frontiernet.net Guest
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Posted: Sat Jan 24, 2009 7:04 am Post subject: Fabric rubbing on cage tubes |
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and you can save money by using the generic dacron from ACS. Works
the same.
BB
On 24, Jan 2009, at 9:43 AM, Dana Hague wrote:
Quote: |
At 11:39 PM 1/23/2009, possums wrote:
> I think you might be wrong, I've used both on different Uls - My
> old 1983 CGS Hawk used Dacron coverings - right?? Like sail cloth?
> The Poly-Fiber method uses Poly-Brush followed by Poly-Spray...
Well, I should have been more precise. The fabric you use in the
Stits _process_, that you buy from Stits (Poly-Fiber, now) is
polyseter fabric. Same for Ceconite, same fabric, though you have
to buy it from Ceconite for the process to be "legal". I don't
know if Stits and Ceconite do anything further to the base fabric
(sizings or coatings) before selling it. Dacron is just another
trade name for polyester fabric made by Dupont Corporation, though
we use it interchangeably (and incorrectly) whether it was actually
manufactured by Dupont or not, and sailcloth is usually
polyester... lots of other ultralights use polyester sails, but
without the "process" coatings. Same fabric, different process.
-Dana
--
"A dress makes no sense unless it inspires men to want to take it
off you."
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jbhart(at)onlyinternet.ne Guest
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Posted: Sat Jan 24, 2009 10:05 am Post subject: Fabric rubbing on cage tubes |
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At 11:08 PM 1/23/09 -0600, you wrote:
Quote: |
Haven't followed this thread closely, but do have a comment about fabric
wearing aluminum. It's likely not the covering doing the damage, but
grit carried by the covering as it moves relative to the tube.
Most of the guys flying bigger experimentals know not to use nylon wire
ties directly on motor mounts because they can eat through the 4130
steel. Dirt & grit get embedded in the nylon & if it moves, it acts like
a saw. This is a very real issue with any soft material moving against
metal in an a/c; I've had a fabric covered starter cable cut through an
aluminum oil drain-back tube on a Lyc.
|
Charlie, Cristal, and Kolbers,
One thing to remember is that iron oxide and aluminum oxide are both
abrasives, where aluminum oxide is the champ. This why if the fabric is
fretting over aluminum tubing, a black powder will form. Add a little water
or oil and it will run down the fabric. When you can see the black, it is
the alumni oxide caught in the fabric that will rapidly wear or fret the
aluminum tube over which the fabric has been stretched.
Since you cannot get away from the fabric contacting the aluminum tube oxide
coating, the only way to stop the fretting is to make sure the fabric cannot
move. In Cristal's case I would blow the dust away from the tube and fabric
and then lightly brush poly tack thinned with some MEK above the tube an on
the inside of the fabric. This combination should help to re attach the
fabric to the tube. Brushing it lightly will prevent a run down on the
inside of the fabric that may show through. Then I would follow up with a
second brushing of full strength poly tack. Then I would air brush the
paint on the out side and go fly.
Snowing a little
Jack B. Hart FF004
Winchester, IN
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cristalclear13

Joined: 19 Sep 2007 Posts: 363 Location: Southeast Georgia
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Posted: Thu Feb 19, 2009 1:43 pm Post subject: Re: Fabric rubbing on cage tubes |
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I appreciate everyone's input on this. I'm sorry it has taken me so long to follow up, but it has taken me a while to get out and work on it and then test it. I used my shop vac on the inside where the fabric joins the tubing and cleaned up any loose dirt I could. The outside oily substance I had already just wiped away when I first saw it. Then I put some goop as a filler so that more substance (water, dirt, etc.) wouldn't fall down between the fabric and tubing. I put the goop only in a couple test areas that seemed to have a problem.
I've flown and flown and it is not doing it again anywhere, so here's hoping either one or both the cleaning and/or goop helped.
I'll keep you informed (for those inquiring minds...whose initials are Carlos).
jbhart(at)onlyinternet.ne wrote: | At 11:08 PM 1/23/09 -0600, you wrote:
Quote: |
Haven't followed this thread closely, but do have a comment about fabric
wearing aluminum. It's likely not the covering doing the damage, but
grit carried by the covering as it moves relative to the tube.
Most of the guys flying bigger experimentals know not to use nylon wire
ties directly on motor mounts because they can eat through the 4130
steel. Dirt & grit get embedded in the nylon & if it moves, it acts like
a saw. This is a very real issue with any soft material moving against
metal in an a/c; I've had a fabric covered starter cable cut through an
aluminum oil drain-back tube on a Lyc.
|
Charlie, Cristal, and Kolbers,
One thing to remember is that iron oxide and aluminum oxide are both
abrasives, where aluminum oxide is the champ. This why if the fabric is
fretting over aluminum tubing, a black powder will form. Add a little water
or oil and it will run down the fabric. When you can see the black, it is
the alumni oxide caught in the fabric that will rapidly wear or fret the
aluminum tube over which the fabric has been stretched.
Since you cannot get away from the fabric contacting the aluminum tube oxide
coating, the only way to stop the fretting is to make sure the fabric cannot
move. In Cristal's case I would blow the dust away from the tube and fabric
and then lightly brush poly tack thinned with some MEK above the tube an on
the inside of the fabric. This combination should help to re attach the
fabric to the tube. Brushing it lightly will prevent a run down on the
inside of the fabric that may show through. Then I would follow up with a
second brushing of full strength poly tack. Then I would air brush the
paint on the out side and go fly.
Snowing a little
Jack B. Hart FF004
Winchester, IN |
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_________________ Cristal Waters
Kolb Mark II Twinstar Rotax 503 DCSI Sept 2007 - sold Sept 2012
Private Pilot Aug 2008
ELSA Repairman for N193Y April 2008
Rotax 2 stroke maintenance April 2009 |
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JetPilot

Joined: 10 Jan 2006 Posts: 1246
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Posted: Thu Feb 19, 2009 5:42 pm Post subject: Re: fabric rubbing on cage tubes |
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I use Goop for some areas in building model airplanes where I can not use a brittle glue. Goop is incredibly strong and durable ! The only thing that seems to kill good is constant everyday exposure to the sun. I bet that Goop inside will outlast the fabric !
Mike
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_________________ "NO FEAR" - If you have no fear you did not go as fast as you could have !!!
Kolb MK-III Xtra, 912-S |
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ElleryWeld(at)aol.com Guest
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Posted: Thu Feb 19, 2009 6:06 pm Post subject: fabric rubbing on cage tubes |
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What in heck is wrong with using poly tack something that we all know is compatible with the poly fiber material
Ellery
do not archive
In a message dated 2/19/2009 8:43:27 P.M. Eastern Standard Time, orcabonita(at)hotmail.com writes:
Quote: | --> Kolb-List message posted by: "JetPilot" <orcabonita(at)hotmail.com>
I use Goop for some areas in building model airplanes where I can not use a brittle glue. Goop is incredibly strong and durable ! The only thing that seems to kill good is constant everyday exposure to the sun. I bet that Goop inside will outlast the fabric !
Mike
--------
"NO FEAR" - If you have no fear you did not go as fast as you could have !!!
Kolb MK-III Xtra, 912-S
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slyck(at)frontiernet.net Guest
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Posted: Thu Feb 19, 2009 6:42 pm Post subject: fabric rubbing on cage tubes |
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Nothing wrong with polytack. Goop can be bought down at the corner store and is just as good if not better.It holds the 1/8" lexan wing fences on my MkIII.
BB
On 19, Feb 2009, at 9:04 PM, ElleryWeld(at)aol.com (ElleryWeld(at)aol.com) wrote:
[quote] What in heck is wrong with using poly tack something that we all know is compatible with the poly fiber material
Ellery
do not archive
In a message dated 2/19/2009 8:43:27 P.M. Eastern Standard Time, orcabonita(at)hotmail.com (orcabonita(at)hotmail.com) writes:
Quote: | href="http://www.matronics.com/Navigator?Kolb-List">http://www.matronics.com/Navigator?Kolb-List href="http://forums.matronics.com">http://forums.matronics.com href="http://www.matronics.com/contribution">http://www.matronics.com/contribution [/b] | [b]
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cristalclear13

Joined: 19 Sep 2007 Posts: 363 Location: Southeast Georgia
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Posted: Thu Feb 19, 2009 6:58 pm Post subject: Re: fabric rubbing on cage tubes |
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ElleryWeld(at)aol.com wrote: | What in heck is wrong with using poly tack something that we all know is compatible with the poly fiber material
Ellery |
Some people wanted to know what I did so I let everyone know. Was it the best solution? Probably not. I'm not sure I like the way it looks on the outside where the goop bonded with the fabric. But luckily I only put it in a couple small places.
Whoever did the fabric on the cage on this plane didn't follow standard procedures for poly-fiber. They used automotive paint and didn't apply the silver coat for UV protection. I will probably have to do a recovering of the cage soon enough.
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_________________ Cristal Waters
Kolb Mark II Twinstar Rotax 503 DCSI Sept 2007 - sold Sept 2012
Private Pilot Aug 2008
ELSA Repairman for N193Y April 2008
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Ralph B

Joined: 14 Apr 2007 Posts: 367 Location: Mound Minnesota
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Posted: Thu Feb 19, 2009 7:10 pm Post subject: Re: fabric rubbing on cage tubes |
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As an alternative, brushing polybrush and polytone with a paint brush instead of using a sprayer works pretty well. I painted everything on my Firestar wings with a roller and paint brush. It's not messy and there's no concern about over-spray. It makes adding patches and repairs easy.
Ralph B
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_________________ Ralph B
Kolb Kolbra 912uls
N20386
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John Hauck

Joined: 09 Jan 2006 Posts: 4639 Location: Titus, Alabama (hauck's holler)
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Posted: Thu Feb 19, 2009 7:13 pm Post subject: fabric rubbing on cage tubes |
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> Whoever did the fabric on the cage on this plane didn't follow standard
procedures for poly-fiber. They used automotive paint and didn't apply the
silver coat for UV protection. I will probably have to do a recovering of
the cage soon enough.
Quote: |
--------
Cristal Waters
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Cristal:
If it was mine, and auto paint had been used, I'd make sure fabric on all
flying surfaces, especially the wings, were inspected and a punch tested.
Couple years ago I helped pull old fabric from a Kolb that had been finished
with auto paint. The fabric had little to no tear resistance.
I make it a habit never to mix products when covering an airplane with the
Polyfiber process.
john h
mkIII
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_________________ John Hauck
MKIII/912ULS
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