Aircraft Paint - Shop challenges removing Flight Controls (Elevator and Flaps)

[steve_falconer]

Heads up that my aircraft is currently being painted at Artcraft who does a high volume of painting (painting 10+ at a time in various stages) other aircraft big and small but very few Diamond DA40s. They do have one they show on a Youttube Video, but apparently removing the elevator and to a lesser degree flaps can be harder on our aircraft as instruction to remove are not in the AMM. Some older DA40s like mine don’t have access holes to more easily remove the elevator and a special tool may be needed??? I’m not sure, but was asked to perform OSB 40-061 to make the process to remove or install the elevator easier. Jonathan from the AeroCity Maintenance Diamond Service Center in Long Beach (https://aerocitygroup.com/contact/)was knowledgeable about the process and helped Artcraft A&Ps with good advice.

I’m not sure what the challenges are removing the Ella-a, but that was mentioned, as well.

I recommend if anyone does a full paint to make sure the paint shop knows the scope of that work and an access to mechanics familiar with the process to make sure it goes smoothly. I had some challenges with the shop operations manager, Kevin, which required looking at my contract, conferring with others, and ultimately talking with the owner, Teresa to figure out a fair approach. SThey’ve been great to work with since, so glad we’re past that now. Post surface prep is done and now they’re working on filler primer to address pinholes before starting paint. They are very quality craftsmanship focused.

21 years old and the aircraft has spent most of its life outside In the Sun before I got it. I think it’s gonna look great, and am excited when I can get flying again.

[steve_falconer]

Does anyone have anything else to share about removing and reinstalling the flight controls?

[TomO]

On my last annual, corrosion was found on one flap mass balance arm requiring its replacement.
I have a 2005 da-40 with the flaps never removed. Unfortunately, the flap has to be removed to replace the balance arm.

On my model there is a steel roll pin securing a stainless pin in the aluminum flap hinge. A great setup for corrosion!!

The roll pin must be removed to pull the stainless pin to detach the flap.
The roll pin is 1.5 mm and had to be pounded out resulting in broken punches and little progress on 50% of the hinges.

After several hours and multiple failures, my mechanic suggested cutting the hinges with a dremel cut off wheel and just replacing hinges. Within a short period of time the flap was off.

Hinge replacement was no problem since there is clear access.
The new roll pins are stainless which may be better corrosion wise.

If I need to remove a flap again, I will just cut the hinge and replace it if there is any problem removing the roll pins.

[steve_falconer]

Thanks Tom. Great advice!

[DerekM]

How did this project turn out? What is a typical price to pay to repaint a DA 40?

[DerekM]

I own a cabinetry company with a high end spray paint department. Any thoughts / comments on my team doing this job in-house? Construction very slow in Toronto these days so it would keep my staff busy and maybe save some money. I’d take the wings off and truck my plane to our shop. Good idea? Bad idea? All comments and knowledge appreciated!

[jwx96]

The control surfaces are usually removed and apparently this isn’t easy on a DA40. There’s another recent post about this. DA40’s have an antistatic primer layer that has to be preserved or replaced as part of the process. Unless the old paint is removed the new paint will add weight. I’ve heard as much as 40 lbs. The airframe has a lot of small drain holes and some vents that need to be preserved. I’ve heard that the factory paint is thick enough to withstand buffing a few times. This is just what I’ve heard. I hope it’s helpful. I’ve had cabinets sprayed by a high end shop and they really look good.

[DerekM]

Very helpful thanks! My 2003 was painted a little too soon before the epoxy had finished off gassing and there are thousands of very tiny bubbles in the paint, like sand paper finish. A shop tried to buff and epoxy coat it a few years back and smoothed the roughness but in the process removed too much of the paint layer so you can see tiny spots of primer in certain spots where these bubbles were. The ceramic coat didn’t last long nor did it look amazing, maybe because I put a wing cover on too soon after application and the plane lived on a windy ramp for a winter during Covid.

Bottom line it would look much better with a high end careful prep and paint job. I wonder if I can sand off enough of the paint and keep enough of the anti static primer in place. I’ll talk to Diamond.

[Karl]

I own a cabinetry company with a high end spray paint department. Any thoughts / comments on my team doing this job in-house? Construction very slow in Toronto these days so it would keep my staff busy and maybe save some money. I’d take the wings off and truck my plane to our shop. Good idea? Bad idea? All comments and knowledge appreciated!

They should be aware of flght control balance requirements.

Ensure all flight controls are balanced before refitting and that a full weight and balance is carried out before flight.

[jwx96]

Also possibly talk to XU-Aviation in London, ON.