Stewart Covering System

[Tralika]

I used the Stewart's System on my Highlander. I built and painted the plane in my garage which is attached to my house. I couldn't use any of the solvent based products because even with a good ventilation system there is no way to keep the smell out of the house. You will still need a ventilation system and use a respirator when spraying but there is almost no smell. The glue is the best, very easy to use and very forgiving. I used a four stage turbine sprayer which Stewart's says can work but they do not recommend it. I had trouble getting the paint to flow out smoothly and had to do a lot of trial settings and practice. Since this is the first time I've painted anything with spray equipment I don't know if it would have made any difference what type of paint I used. It still would have been a steep learning curve.

I ended up with a paint job that I look at and can see all the mistakes but everyone else seems to think it looks great. If you use Stewart's follow their recommendations on setting up the compressor and spray equipment. Buy the Stewart's DVD's and watch them closely. Keep in mind that they have re-formulated the paint since the videos were made so it is not mixed or applied exactly the same way. You still want to watch the videos because the basic process is the same and they offer lots of good info and tips. The paint is mixed by weight now which is very easy to do but you will need a digital scale and take your time. The good news is the paint now has a much longer pot life, up to 3 hours, up from 45 minutes.

Follow the written instructions that come with the paint and don't be afraid to ask questions on the Stewart's forum or call them directly. They were very helpful to me. You can look at my build log for details on my covering and painting process. I just had my inspection and received my Airworthiness Certificate yesterday!
John Nealon
mykitlog.com/jnealon