fuelsalage envelope ?????

[jsf74]

what exactly needs anti chafe tape on it before i slide my envelope on. was thinking the tops of all the stringers and the corner's on the top and bottom of the tail. also do i put any polybrush or polytack on the tail tubes or anything else first? thanks everyone.

[Champ Dreamer]

I recently covered my Champ fuselage, and was unable to get any advice here (which is , to me , really unusual). I used Polyfiber, and assume you are also doing so?
I am definitely no expert, but I did not use chafe tape on any wood or tube, only on the steel parts of the horz. stab (where screws went), and a couple of other sheet metal areas. I would suggest (based on the mistakes I made) that you glue the upper envelope to the front structure and horz stab, then drape everything and glue to the fabric which (I assume) you already have on the bottom tubes. Then cut out door and window openings and glue at the perimeter of each of those. I tried to "work my way down", cutting and glueing at top front, then windows and doors and finally the bottom tubes. It didn't work very well that way, causing a few "fishmouths" (roofing term) in the fabric. Remember, only glue to "structure", which basically means steel. Also, when I started to shrink, I was convinced that there was absolutely no way the fabric was going to shrink that much...but, it did! I skipped around a bit, gave up on the top and moved to the sides. That tightened the top, and eventually it was all "tight as a drum". I thought the wings were a lot easier.

Best of luck, perhaps some real experts will chime in.

Brian Walker
NC1197E '46 7AC..DC

[jsf74]

thanks for the reply. i have to admit i am super nervous about this step. i have done a few wings with no problems but i just cant seem to get the nerve up to start glueing and cutting the fuelsalage envelope. trying to get as many tips as possible and hear from others on their mistakes.

[jsf74]

sorry i may have put this in the wrong topic.

[MikeB]

Hardly an expert but the first envelope I used had the bottom sewn in. It tightened up OK but it was hard to keep the lower seams straight. I pretty much concentrated on keeping the upper seams over the upper stringers straight. The next two I ordered with bottom separate and installed that first. Keeping the upper seams straight takes a lot of concentration. Especially if it has one up top center of the fuselage.

The interesting thing is, if you watch the Aeronca factory film, you'll notice them using blanket material and wrapping one piece of the fabric around a upper stringer......a "no...no" according to Poly Fiber, etc. Personally, I can't think it would make that much difference but....................

MikeB

[cmacveigh]

Jason,
E-Mail me direct at cmacveigh AT hotmail DOT com

I took a bunch (couple 100) pictures when I did my '39 Chief. I think I could guide you around a few pitfalls. I'll burn them on a disk for you. The fuselage is tricky but nothing to lose sleep over. The hard part is being mindful of keeping the seams straight and where you want them. Careful balance of where to work the iron. Start with it pretty cool to start gently taking up the slack.

Speaking of slack. Leave some in. You said you've done wings, so you have some experience to fall back on.

If you see any of the structure being bent... Stop shrinking the fabric!!!! You're done in that area!!!

What are you using for cover? Stitts?? Ceconite??

Look at my picture. The front legs work well. Put wheels on the top so that you can roll it around easier.

Craig
26 years with "Uncle Sam's Misguided Children"

[joea]

Looking great Craig!

[jsf74]

i sent you a pm and my e-mail is 1946aeronca AT gmail DOT com

[Champ1]

Approx. how much does it cost in materials to recover the wings and fuselage on a Champ or Chief?

Thanks

[MikeB]

Much depends on what process is used. But I'd figure $5000 give or take a little for basic material. If I were to do another I'd seriously look at the Stewart (water borne)System. Everything I've heard about it is positive and it's not so nasty to work with.

On another note: once you open things up you'll undoubtly find some "gremlins" (unanticipated work and expense) that need to be taken care of. These planes are 60+ years old and some have had a hard life but almost anything is fixable.

MikeB

[Champ1]

Much depends on what process is used. But I'd figure $5000 give or take a little for basic material. If I were to do another I'd seriously look at the Stewart (water borne)System. Everything I've heard about it is positive and it's not so nasty to work with.

On another note: once you open things up you'll undoubtly find some "gremlins" (unanticipated work and expense) that need to be taken care of. These planes are 60+ years old and some have had a hard life but almost anything is fixable.

MikeB

Wow! I had no idea it cost that much. I thought it was more like $2,000 for the materials. Is there a more cost effective way to do it?

[MikeB]

I might be a little high, but it's better to figure high than low when you're estimating a job and it depends on what process you use. I happened to use the Superflite process. I looked at a couple of other websites and they advertise the Poly-fiber materials from $2500-3500. Depends on when the price list was posted, I guess. If you want an accurate price call Jim or Dondi Miller at 1-877-877-3344. They're very nice to talk to and should be able to answer your questions. I tend to buy just enough material and product for the task at hand rather than have a bunch of stuff sitting around as it usually winds up being a fairly long term process (work and $$$ get in the way). A kit may be cheaper, too. Didn't mean to scare you away and some others may jump in with their costs.

MikeB

[Kif]

Talked to Jim awhile back and he said around $3500 to do a Champ thru paint. Not sure if that was with envelopes or just a roll of fabric. Speaking of rolls, does anyone know if you can get a large roll or do they come in a set length like 50 yds. My brother inlaw is recovering a Reliant (single place airplane with a Rotax engine) and we were thinking of getting enough fabric to do his and mine. Would a roll be cheaper than certain length (ie 45 yds)?

[Champ1]

Thanks for the info Mike and Keith.

[MikeB]

Keith,l
My wing order from Superflite came in a roll of raw (ceconite) material. I'm pretty sure the Poly-Fiber would do the same.
Mike