Aircraft Masking: Layout Training Curriculum

• Layout Training Curriculum describes the information, preparations, techniques, and goals for aircraft masking.

Preparations

• Find the Aircraft Production Order (APO) and clock onto the job.
• The APO contains:
  • Customer name (signed or unsigned)
  • Aircraft serial and N-Number
  • Whether numbers are painted or vinyl
  • Layout and color scheme
  • General location of everything
  • Masking order
• Masking is done from largest to smallest areas.
• Typically, trim is sprayed first, then the bottom base.
• The process involves covering what remains white, prepping both colors, cleaning, and covering the bottom base.
• This approach minimizes re-masking when the plane is turned.
• The M Class aircraft sometimes require variations based on layout, but the general process remains similar to smaller planes.
• Begin by covering the bottom, saving the elevator, bottom of wings, and belly.
• Sand the entire plane with 600 grit and Scotch-Brite, then apply the layout.
• The bottom base is typically applied next, followed by trims that sit on top of it.

Tools

• Sharp blade
• Squeegee
• Vis-à-vis marker
• Fine line tape
• Masking tape
• Paper cart

Mylar Application

• When reading the mylar, identify tape types and locate landmarks and hints.
• Determine which side to apply the tape, following the triangles, if necessary.
• The layout indicates the typical size of tape and whether it matters.
• When laying out an archer, generally follow the triangles, but on larger aircraft, stripe alignment may require flipping the line.
• Use the correct tape thickness based on requirements.
• Smaller tape is better for sharper curves.
• Larger tape is ideal for gentle curves or straight lines.

Layout Do's and Don'ts

• Do not connect the dots directly; guidelines are just that, guidelines.
• Use guidelines for general layout, but prioritize smooth flow and matching the opposite side.
• Minor discrepancies are acceptable if the overall flow is maintained.
• Maintain a steady hand while applying tape.
• Smoothly apply the tape with consistent hand pressure to avoid waving or pressing into the plane unevenly.
• Use a squeegee.
• When leaving tape hanging, prevent warping by pulling extra tape and ensuring it hangs straight down.
• Handle tape with gentle pressure, except on sharper curves.
• Warped or dirty tape should not be used.
• Avoid reusing old tape if it is warped from heat or dirty.

Tape

• Tape has memory and warps with repeated use.
• Limit tape use to three tries before replacing.
• Pull tape in small sections, about 3ft, to prevent connecting the dots.
• Only stop tape at seams or windows, not mid-panel.
• Avoid cutting and continuing tape mid-fuselage to prevent blowouts.
• When adjusting tape, pull it to the nearest breakpoint, such as a window, door, or antenna.

Practical Application Tips

• Double or triple-check work from multiple angles, and seek a second opinion.
• Start with the dominant stripe when pulling crossover lines.
• Relax tape into flutes by removing tension to ensure it adheres to curved surfaces, preventing blowouts and the need for cutting/tacking.
• Prepare to cut and tack anywhere the line is interrupted.
• Raised tape can cause blowouts if not addressed, so slice the tape around obstructions such as rivets, remove the small piece, align the metal tape and squeegee.
• Cut halfway through tape along seams.
• Windows and main cabin doors on M class aircraft do not require special attention due to masked areas.
• When pulling tape over obstacles, like flutes, door handles, or static wicks, know how to pull tape.
• Ensure layout is consistent on both sides for wingtips and tails.
• Prioritize accuracy on the first side and match landmarks as closely as possible on the opposite side.
• Typically, when a color butts up against the bottom base, flip the tape.
• Apply gentle curves, straight lines, swooshes, and points accurately, taking extra care with inside and outside points.
• Follow guidelines for 8x8x8 N-Number layout application and wing location simulation.
• Trim points and cut tape properly using gentle pressure and blade control.

Goals for Beginners

• Check the APO for every plane.
• Locate, verify, and apply mylar to aircraft.
• Mark everything properly.
• Use the correct masking order.
• Pull wingtips and straight line layouts.
• Use proper cut and tack techniques.
• Trim points and cut tape correctly to avoid harming the plane.
• Avoid connecting the dots.
• Squeegee every line, making it completely flat.
• Know what size tape is required for specific layouts.

Goals for Intermediate

• Apply N-Numbers.
• Apply Swooshes.
• Apply Crossover "X" layouts.
• Apply split lines
• Apply Curves
• Apply Designs through louvers
• Achieve proper "mating" of both sides, aligning curves on the bottom and top while making difficult layouts work.

Explore the techniques and goals of aircraft masking. Learn about finding the Aircraft Production Order (APO), masking order, and color scheme. This curriculum covers preparations, including sanding and layout application.