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How to Rebuild a Fabric Aircraft Wing

Rebuilding the fabric wing of an aircraft is a time-consuming and delicate process; however, some hobbyists enjoy the challenge and take pride in their ability to restore a favorite aircraft rather than replace it when the wing is damaged beyond repair. It is important to have all the proper tools and review the steps several times before attempting fabric wing reconstruction. Rebuilt wings done correctly will last an average of 20 to 30 years, even in constant weather exposure.

Things You'll Need

Poly-fiber fabric
Iron
Fabric cement
Fabric sealer
Pop rivets
Finishing tape
Reinforcing tape
Anti-chafe tape
Silver spray
Aircraft topcoat paint

Instructions

- 1
  Determine the weight of the other fabric components of the aircraft, and purchase one to match. Poly-fiber fabric typically comes in three weights: heavy, which is generally intended for agricultural and bush aircraft; medium, which is recommended for normal service; and light uncertified, which should only be used over plywood surfaces or on uncertified ultralight aircraft.
- 2
  Calibrate the iron to 350 degrees F to achieve the best performance from the fabric.
- 3
  Glue the fabric to the wing frame with fabric cement. Apply the iron over the entire fabric surface to tighten the fabric against the frame. The poly-fiber material will reach its maximum shrink potential of approximately 10 percent, preventing flapping, shrinking and tearing once the aircraft is in flight.
- 4
  Apply one coat of fabric sealer to the entire wing. Secure the fabric to the rib structure with pop rivets and tapes.
- 5
  Brush on two coats of fabric sealer, allowing time for drying between each coat.
- 6
  Block ultraviolet radiation by spraying three cross coats of silver spray over the fabric.
- 7
  Apply two coats of topcoat paint. Although many aircraft owners frequently substituted auto paint, recent FAA changes to the supplemental type certificate now prohibit any paint other than Poly-Tone or Aero-Thane.

Aviation