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  • Stewart Systems covering process discussion

    Ok, as Hank suggested, I'd like to open a thread on the Stewart Systems process and include some pictures/links and stories and comments.

    Stewart Systems process is the only covering process as of now, that meets the very stringent FAR Part 23 standards.

    From their website ( www.stewartsystems.aero )

    "Solvent based products are facing scrutiny from the EPA and more regulations are predicted to come. We know there are health concerns using solvent based products. What if you could have an aircraft finishing product that provided excellent results AND was safe to use?
    The wait is over: Learn more about Stewart Systems revolutionary products...
    Available from Stewart Systems:

    * FAR Part 23 and STC Approved and People-Safe Aircraft Fabric Covering process
    * High Performance Catalyzed Waterborne Coatings for the Aerospace Industry
    * EPA compliant, non-hazardous, and non-flammable, safe to use aircraft finishing products"





    I've been using this system since the late '90's, before it became "Stewart Systems" and have had great luck with it. The system is easy to use, but different in a few ways from the more traditional solvent borne/based systems. I must admit, after years of using "traditional" paints and glues, I had some "unlearning" to do...but every time I thought there was a problem, I could trace it back to ME, and all I had to do was follow the directions to the letter and it worked the way it was supposed to. The glue used is much stronger than anything out there, but is a bit slower drying, so you need to be able to plan and work ahead of yourself just a bit, but it's also very forgiving. All the products have a light pleasant smell to them, so at the end of the day, you can still go out to dinner and taste that steak in all it's glory, and come in the house without the rest of the household being able to tell just what you've been doing! The main thing that attracted me to this system to start with was the health aspects, and I'll get into them at a later date. It's no where near as dangerous as the solvent borne systems to you or your loved ones, pets, or passers-by. It ships non-hazmat, and can even be overnight shipped.

    Check out their website www.stewartsystems.aero and if you have questions, they are second to none in the customer service department!
    Last edited by N96337; 02-18-2012, 17:33.
    I'm so far behind, I think I'm ahead

  • #2
    Re: Stewart Systems covering process discussion

    One of the most amazing aspects of the Stewart Systems waterborne system is the topcoat. The next few pictures will show some samples that I made in 1999 and will demonstrate the flexibility of that system today, in 2012. I've worked with most of the other covering systems out there and haven't found any that will compare to this flexibility, and flexibility is a huge factor in a long lived covering system!

    Here's the sample, covered in June of 1999, as it appeared on my table today, 02/18/12.



    Notice the gloss of the topcoat. You can still see some weave, but the fabric is fully UV protected at this point.



    Now, let's abuse it just a little.... has your airplane had it's fabric crumpled this bad?



    Now, we'll flatten it back out by hand, not gently, but stretching and pulling to see how it holds up and if it cracks...



    Remember, this is 13 year old finish. Normally, your fabric wont see this kind of abuse...at least I would hope not!

    2024 Shows SUN 'n FUN Aerospace Expo in Lakeland, FL: April 9-14, 2024 (Workshop Opportunity) The Great Alaska Aviation Gathering in Anchorage, AK: May 4-5, 2024 EAA AirVenture in Oshkosh, WI: July 22-28, 2024 (Workshop
    I'm so far behind, I think I'm ahead

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    • #3
      Re: Stewart Systems covering process discussion

      I know I used to know this, but what did they used to call the Stewart System?
      Hank

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      • #4
        Re: Stewart Systems covering process discussion

        Their used to be Blueriver, I thought there was also another name. I have not used this process so I may learn something here. My first question. What is used to attach the fabric that makes the system different than when it was used by Piper when it caused structural failure of the longerons due to the water based system leaching through the primer (i am sure it was zinc primer at the time known to absorb water) and Piper having to recover many Supercubs and thus ending production?

        Comment


        • #5
          Re: Stewart Systems covering process discussion

          Originally posted by N96337 View Post
          One of the most amazing aspects of the Stewart Systems waterborne system is the topcoat. The next few pictures will show some samples that I made in 1999 and will demonstrate the flexibility of that system today, in 2012. I've worked with most of the other covering systems out there and haven't found any that will compare to this flexibility, and flexibility is a huge factor in a long lived covering system!

          Here's the sample, covered in June of 1999, as it appeared on my table today, 02/18/12.



          Remember, this is 13 year old finish. Normally, your fabric wont see this kind of abuse...at least I would hope not!

          www.stewartsystems.aero
          I can do that with Airtech as well

          Comment


          • #6
            Re: Stewart Systems covering process discussion

            No, this isn't Blue River. This system was called Aircraft Finishing Systems before Stewart's bought it.
            The Blue River system that was used on some of the had a problem with the cement they used, from what I remember. This uses a TOTALLY different glue than that. This uses more of a "contact" type of cement. No corrosion problems. The topcoat is also TOTALLY different. This uses a pure polyurethane.
            I'm so far behind, I think I'm ahead

            Comment


            • #7
              Re: Stewart Systems covering process discussion

              I am really looking forward to following this thread. I saw a staggerwing at Blakesburg in 2007 and the restorer was really sold on the stewart process. His plane was a midnight blue color. He showed me where he had patched about a 4 foot section of the lower wing after the paint had been on for 2 years. The color match was perfect. the only detectable feature about the patch as visible to the naked eye was the mask line, which I would not have seen if the man hadn't pointed it out.

              These 1999 samples are impressive. Very flexible still. My father in law's '39 BC65 was covered in 1999 with poly-fiber. It just started showing a very few signs of cracking about a year ago in some places where there has been some extra ordinary flexing of the fabric. My 46 BC12D covered in 1984 with Ceconite/Randolph has some places with cracks showing up. I would like to try rejuvinator sometime. But not planning to this calendar year.
              Terry Bowden, formerly TF # 351
              CERTIFIED AERONAUTICAL PRODUCTS, LLC
              Consultant D.E.R. Powerplant inst'l & Engines
              Vintage D.E.R. Structures, Electrical, & Mechanical Systems
              BC12D, s/n 7898, N95598
              weblog: Barnstmr's Random Aeronautics
              [email protected]

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              • #8
                Re: Stewart Systems covering process discussion

                Originally posted by N96337 View Post
                No, this isn't Blue River. This system was called Aircraft Finishing Systems before Stewart's bought it.
                The Blue River system that was used on some of the had a problem with the cement they used, from what I remember. This uses a TOTALLY different glue than that. This uses more of a "contact" type of cement. No corrosion problems. The topcoat is also TOTALLY different. This uses a pure polyurethane.
                I actually have a bunch of AN yellow an old neighbor bought to paint his PT-26 with. This was 10 plus years ago, but had nothing but hell with it, so he gave up and painted it with Aerothane I think. I wonder if it is still good?

                Comment


                • #9
                  Re: Stewart Systems covering process discussion

                  Shelf life is usually about a year, and even though it may look ok, I wouldn't push that with ANY paint. Been there, and saw the results down the road.
                  I'm so far behind, I think I'm ahead

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                  • #10
                    Re: Stewart Systems covering process discussion

                    I can attest that while it is a little differant to work with,the end results are excellent.I had some hail last summer and it never ringwormed or came unstuck.
                    PV

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                    • #11
                      Re: Stewart Systems covering process discussion

                      I'm having fun working with it in the basement - MIke
                      Mike Horowitz
                      Falls Church, Va
                      BC-12D, N5188M
                      TF - 14954

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                      • #12
                        Re: Stewart Systems covering process discussion

                        The Stewart system looks pretty attractive. But I like the satin "dope look" as opposed to the wet look of polyurethane finishes. Is the some way to dull the Stewart final gloss down to look more like dope ?

                        Dick

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                        • #13
                          Re: Stewart Systems covering process discussion

                          The gloss finish is about the only thing I don't like about it at this time. I just love the deep satin look of rubbed dope. I can get the smell while I work with a nice banana smothie.
                          Hank

                          And without the head ache!

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                          • #14
                            Re: Stewart Systems covering process discussion

                            Absolutelly you can have a "satin" finish!!! You can get anything from a gloss finish to a total flat finish and anything in between. That's not a problem at all...just ask for that finish in your paint.
                            I'm so far behind, I think I'm ahead

                            Comment


                            • #15
                              Re: Stewart Systems covering process discussion

                              I am starting to paint my third plane with the Stewarts system. The first one was a complete restoration of my Taylorcraft. The second a repaint of another Taylorcraft. I am now in the process of recovering a Tripacer.

                              I am sold on the system. I too had to learn the differences in solvent based vs. waterborn.

                              If you would like to look at my web site www.RestoredRunwayClassics.com you can see some of the pictures of my restoration. I will soon have a gallery of the one that I repainted on there as well.

                              Mark

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