When modern synthetic fabric is used, an

adequate bond is created when the adhesive

flows around the non-absorbing fibres to encapsulate them. Without two initial coats of PolyBrush there is insufficient adhesive present to
encapsulate the fabric fibres and create a good
bond.

Poor bonding

Fabric doping
Use the wrong method of
doping synthetic fabric and
you could come unstuck.

HE NATIONAL TRANSPORTATION
Safety Board (NTSB) recently released
its report on the April 1995 accident
that took the lives of aviation legend Steve
Wittman and his wife.
The NTSB report found that while in cruise
flight, the fabric covering the plywood skin of
the right wing the Wittman aircraft debonded
immediately ahead of the aileron and ballooned up. The pulsing of the ballooned fabric is then believed to have initiated aileron
flutter, which in turn caused the wings to flutter and separate from the aeroplane simultaneously.
The surface of the aircraft's plywood covered wings were coated with a layer of Stits
HS150X Poly-Fiber that had completely
delaminated from the right wing. The fabric
was recovered and was intact, although the
overlying doped finish had largely been shed.
Investigation determined that the fabric
had been bonded to the plywood skin by an
estimated two coats of clear nitrate dope,
brushed into the weave of the fabric from the
top or outer surface. The nitrate dope was followed by five or six coats of clear butyrate
dope, a coat or two of Poly-Spray silver and
finally, several coats of yellow Poly-Tone. The
plywood skin had not been treated in any
manner prior to the application of the fabric
and liquid finishing materials.

Microscopic
A microscopic examination of the surface of
the plywood revealed a thin film of nitrate

dope, which the NTSB believes was forced

through the weave of the fabric when the first
two coats of nitrate dope were brushed on.
The imprint of the weave pattern of the fabric could be seen in the film of dope, indicating that the fabric had delaminated from the
nitrate dope rather than the plywood itself.
Synthetic fibres such as
polyester usually require
different materials and
application procedures to
natural fibres.
Compliance with Stits
:.
(now Poly-Fiber) STC
1008wE requires that two
coats of Poly-Brush be
applied to the surface to
be covered (in this case
the plywood skin) before
'
the Poly-Fiber fabric is
applied. The aim is to
provide a base for com
plete fabric bond to the
wood.
After the fabric is adhered to the plywood
using the fabric cement (Poly-Tak) the covering is heat taughtened. The first coat of PolyBrush is brushed on to ensure good penetration through the fabric. This attaches to the
underlying layers to give a good bond. The
next coat of Poly-Brush is usually sprayed on
to promote a smooth surface and fill the
weave. It is then finished with further coats of
the aluminium pigmented Poly-Spray followed by the final colour coat.
Note that Stits/Poly-Fiber finishing materials do not include nitrate or butyrate dope.
In the older procedures involving natural
fibres, a bond is created when the material
being used as an adhesive is absorbed or
wicked into the fibres.

Poor bonding procedures can be discovered

by testing the bond on a small surface of the
aircraft. I know of a wooden motor glider,
about 20 years old, which was in need of recovering. The Stits method was selected. Following removal of the old covering, the plywood
was sanded down and washed with acetone.
To gain experience in the Stits method, an
elevator was covered first as an experiment.
The plywood was coated with two coats of
Poly-Brush thinned down to provide penetration. The fabric was glued down using
Poly-Tak and tensioned using a hot iron.
A brush coat of Poly-Brush was applied followed by a spray coating. The Poly-Spray was
then applied.
The result looked good. The next day the
experiment was tested for adhesion - there was
none, or at the best, very little. Most of the PolyBrush stuck to the Poly-Fiber, and not the ply-

wood. The material lifted away and the base

coat of the Poly-Brush lifted off the plywood.
A telephone call to a Stits agent revealed
that even a small trace of Nitrate Dope
applied 20 years ago can stop Poly-Brush from
sticking to the plywood. The answer is to seal
over the embedded dope with Stits Epoxy Varnish (or use a system based on Nitrate dope
instead of the Poly-Brush system).
These two examples of failed bonding of
synthetic fibres illustrate how important it is
to pay careful attention to manufacturers
directions, or do some tests that meet or
exceed the manufacturers requirements
before you fly.
Tex Chalson is district airworthiness manager based
at Paralleld Airport.
FLIGHT SAFETY AUSTRALIA AUTUMN 1997 33