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Rudder Covering - How to?

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WhiskeyVictor36(at)aol.co
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Posted: Fri Oct 29, 2010 8:39 pm Post subject: Rudder Covering - How to?

Guys,

  

 I am in the process of recovering some of the components on my  FireStar.  I don't recall how I did the rudder the first time (it's been  more than 16 years ago) but I am having trouble.  I'm using the  Poly-Fiber process.

  

 Attempting to use one piece of fabric, I glued one edge to the L.E. spar,  wrapped it around the trailing edge and back to the L.E. spar and glued it in  place.  Now I have a lot of fabric at both the top and bottom, where the  rudder is curved and I don't know how to handle it.

  

 It looks like if I glue one of the fabric sides to the curved tubing and  cut off the excess, then I would wrap the other side over it, but there is  so much fabric I don't think the iron could shrink it enough to get rid of  the wrinkles.  Also, where the fabric wraps around the small diameter  trailing edge, even to cut the one side to wrap down onto the tube for  gluing becomes close to the other side, almost like a slit to separate the  two, which would almost make a place where it could come  apart.  I thought about using two separate pieces of fabric and after  installing them, run a  2 or 3 inch tape on the TE.

  

 Any suggestions?

  

 Bill  Varnes

Original Kolb FireStar

Audubon  NJ



 [quote][b]

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Richard Pike

Joined: 09 Jan 2006
Posts: 1671
Location: Blountville, Tennessee

Posted: Sat Oct 30, 2010 6:40 am Post subject: Re: Rudder Covering - How to?

Here's how I did this rudder early this summer: I cut the fabric just like you did. At the top curve, I cut the fabric so that I had a good overlap and then cut a bunch of slits in it as I wrapped the first side of fabric around the small diameter tube and used lots of glue to tack it in tight. I didn't worry about the fabric from the first side laying back on itself on the inside, a little MEK laid onto the surface of the fabric as you iron it out will make it disappear.



Then the second side was wrapped around and also had a lot of slits cut into it, you overlay one little width of slit fabric over it's neighbor as you work your way around the corner. 



Then you cover it with bias ply tape, I think I used 4" width to get plenty of overlap. You can pull or stretch the bias ply as you lay it on and it will conform nicely. The iron will take care of any details.



You can sort of see the overlapped and slit fabric under the curved bias tape in the photo. (There are lots of bugs in the paint because little growing Firestars need their protein)



Richard Pike

MKIII N420P (420ldPoops)

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herbgh(at)nctc.com
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Posted: Sat Oct 30, 2010 6:54 am Post subject: Rudder Covering - How to?

Jim Miller used an iron  and elbow grease to stretch and iron the 

fabric around curved areas...He then trimmed the excess and glued...Herb



At 09:40 AM 10/30/2010, you wrote:

 	  Quote: 	
		  



Here's how I did this rudder early this summer: I cut the fabric 

just like you did. At the top curve, I cut the fabric so that I had 

a good overlap and then cut a bunch of slits in it as I wrapped the 

first side of fabric around the small diameter tube and used lots of 

glue to tack it in tight. I didn't worry about the fabric from the 

first side laying back on itself on the inside, a little MEK laid 

onto the surface of the fabric as you iron it out will make it disappear.



Then the second side was wrapped around and also had a lot of slits 

cut into it, you overlay one little width of slit fabric over it's 

neighbor as you work your way around the corner.



Then you cover it with bias ply tape, I think I used 4" width to get 

plenty of overlap. You can pull or stretch the bias ply as you lay 

it on and it will conform nicely. The iron will take care of any details.



You can sort of see the overlapped and slit fabric under the curved 

bias tape in the photo. (There are lots of bugs in the paint because 

little growing Firestars need their protein)



Richard Pike

MKIII N420P (420ldPoops)





Read this topic online here:



http://forums.matronics.com/viewtopic.php?p=317486#317486





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WhiskeyVictor36(at)aol.co
Guest

Posted: Wed Nov 03, 2010 5:53 am Post subject: Rudder Covering - How to?

Herb, Richard & Bill,

  

 Thanks for the response to my rudder covering question.  It has  already helped me get it done.

   

 Bill  Varnes

Original Kolb FireStar

Audubon NJ

Do Not  Archive



  

   	  Quote: 	
		     --> Kolb-List message posted by: Herb herbgh(at)nctc.com (herbgh(at)nctc.com)



Jim Miller    used an iron  and elbow grease to stretch and iron the 

fabric around    curved areas...He then trimmed the excess and    glued...Herb



   --> Kolb-List message posted by: "Richard Pike"    <richard(at)bcchapel.org>



Here's how I did this rudder    early this summer: I cut the fabric just like you did. At the top curve, I cut    the fabric so that I had a good overlap and then cut a bunch of slits in it as    I wrapped the first side of fabric around the small diameter tube and used    lots of glue to tack it in tight.

    

    From Bill Sullivan



   Bill- Go to the EAA Video Player and look under "Tube and Fabric".     They have a video called "Forming fabric around a tight radius".     

                                                         





	


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