Zlin Aviation
Section 1
Maintenance Manual Aircraft Maintenance Manual
Issued: 01/02/2006
QAP-AMM-Rev02
Date of latest Revision: 23/01/2013
Page Number: 1-58
1.11 Painting and coatings
Savage aircrafts are covered with standard dacron fabric. The covering procedure is absolutely
traditional, as outlined in different specific literature, and is described in chapter 2.3.3..3. Trained
A&P or LSRMA should be able to repair a tear on the dacron without any particular problems.
Little or bigger tears in fabric covering need at first to be cleaned from the external finishing paint.
In case for example of an L-shaped tear, you have to clean an area around the L tear of about 3
inches along the tear.
Only later you can glue a finishing tape (pinked edged) over the cleaned area. Later this tape will be
brushed, manually at least 4 times, before to be painted with final desired paint. You can use a
standard Poly-Brush product or similar product.
We use the PPG system and components for final painting. A complete list of components and
colour codes is available on request .These components should be available locally in your town, or
ZA can supply them. They are polyurethane type components. The use of our elastic component,
will avoid the risk of any crack in the final paint during the years.
You can clean your plane as you would clean your car starting from the top and working your way
downwards using a soft sponge and a car shampoo. Don't use a sponge that could be contaminated
with particles e.g.bud, fine sands etc). This will avoid to grind the surface. Use a separate sponge to
clean the bottom of the fuselage, since it is normally more greasy than the rest of the plane. Don't
direct the water over the fuel reservoir caps, wing fuselage joining section etc..Always water the
shampooed surface again before they become dry. Thereafter wipe the whole of the aircraft dry
using a drying towel, or a leather skin.
For the lexan use only clean water and really clean drying towel. If the surface are dusty (dacron
and fuselage), remove at first the dust with clear water.
Write to our customer service department to receive a complete list of components for your
reparation or service, at
customer.service@zlinaero.com
For surface preparation you can also refer to the book “How to Cover An Aircraft Using the Poly-
Fiber System”: ZA does not use Poly Fiber products but recognizes the process and materials to be
an acceptable method for performing repairs on the Savage Aircraft.
Use the following instructions for preparing a surface for painting, after the minor repair has been
performed following instructions of other chapters.
Preparation of metal
1.
Sand surfaces with 180-320 grit sandpaper & very fine red Scuffpads.
2.
Degrease components with DX330 per manufacturer’s instructions.
3.
Mix and apply PPG Metal Primer DX1787 and DX1788 per manufacturer’s instructions.
4.
Allow primer to dry at 140°F for 20 minutes.
5.
Sand primed surface. Use 400 grit sandpaper in areas where DUHS will be used, or 600 grit
sandpaper where PolyTone will be used.
Preparation of composites
