5. Remove aluminum barrier tape and materials. Re-mask windows with two layers of paper and masking tape. Re-mask static ports, openings and all other areas not to be painted. Remove wing tips, cowlings and any other removable items as needed.

6. An A&P / I.A. will perform an inspection of the stripped aircraft. Check for any hidden damage or stripper-related damage.

Check for any corrosion that was not visible prior to stripping. Photograph any defects found and forward to the owner with repair estimates, if needed (8-hours of corrosion removal and body work are free. Additional work is billed on a time and materials basis).

The chemical stripping process will remove all old body-filler and high-build primer from the bare aluminum surfaces. There is no way to tell where, or how much filler the aircraft contains prior to stripping. If the post-stripping inspection reveals that additional bodywork will be required to repair previously hidden damaged areas, then the owner will be notified and provided with an estimate for this additional work.

NOTE: Bodywork cannot be performed on control surfaces. If the post-stripping inspection reveals damage to control surfaces that was not visible during the incoming inspection, or damaged areas that were hidden by filler, then Cape Air will be notified and our maintenance department will provide an estimate for repair or exchange of these items. If Cape Air elects to supply exchange items from their inventory, Royal Aircraft Services will NOT impose any additional charge for “owner-supplied” items.

7. Re-mask aircraft for prep and primer. Cover engines, wheels, etc with new plastic.

8. Hand-sand painted areas that were protected from stripper by the aluminum barrier material and tape.

9. Hand-sand gear-wells and painted portions of landing gear mechanisms.

10. Hand-sand all plastic / fiberglass / composite items that are to be painted.

11. Sand entire aircraft with 240 or finer grit sandpaper and maroon scotch-brites, paying special attention to avoiding rivets, static ports, antenna bases or anything else that could be damaged by sanding.

12. Perform any bodywork required using Duraglass, which is waterproof and protects the aluminum surface unlike Bondo, which absorbs moisture and promotes corrosion.

13. Apply high-build primer to all areas where bodywork was performed and hand-sand.

14. Seal all the aircraft’s seams with AC730B-2 or equivalent seam sealant.
When this is dry, spray high-build primer over the sealed areas and hand-sand smooth.

15. Rinse all dust and sanding debris off aircraft, then etch aircraft’s aluminum surfaces by hand-scrubbing 13204S etching aluminum cleaner using maroon scotch-brites or medium gray scotch-brites in heavily corroded areas.

16. After checking for a clean water-break, apply 13206S aluminum chemical conversion coating to all exposed aluminum surfaces.

17. Dry aircraft and aluminum surfaces and tack, then apply two coats of 483-928 HS chromate corrosion-inhibiting aerospace primer.

18. Paint the base-coat on the aircraft and control surfaces using Sherwin Williams Jet Glo Express white polyurethane aerospace paint.

19. Prime, then paint the base-coat on any removed fiberglass / plastic / composite components.

20. Hand-scuff and paint the removed rudder and trim tab.

21. Install the rudder and wing tips and layout the stripe and logo designs. Hand-scuff in areas where the design and colors are to go on the aircraft, then paint the stripes and design scheme using Acry Glo polyurethane aerospace paint. Hand-scuff and paint the design scheme colors on removed fiberglass, plastic and composite components.

22. Maintenance personnel will balance-check the painted ailerons and elevators in accordance with the aircraft manufacturer's maintenance manual. Maintenance personnel will remove the rudder after painting and install all removed tips, weights, lights and components and then balance-check in accordance with the maintenance manual. All maintenance activities are performed under the continuous supervision of an I.A.

23. Maintenance personnel will reinstall all control surfaces and other removed components (new hardware will be used if existing hardware is corroded or unserviceable), and replacing standard non-structural screws and CAMLOC fasteners with stainless components as requested. Again, all maintenance activities are performed under the continuous supervision of an I.A.

24. Apply new AC251 B1/2 or equivalent window sealant around all windows, and then perform final detailing.

25. Our maintenance department will inspect bearings and races for any water or stripper residue, ops-check the control surfaces, flaps, landing lights, etc. and perform gear-retraction tests on the aircraft prior to performing the final inspection of the aircraft and preparing any 337’s required and logbook entries for return-to-service.

Call or email now to book your aircraft refurbishment project!
Phone: 301-791-3642 • Toll Free: 866-791-3642 • FAX: 301-791-7368 • Email: quotes@royalaircraft.com

Painting Basics


Royal will perform the following process on each aircraft delivered for a full strip-and-paint:

1. An A&P / I.A. will conduct an initial incoming inspection of each aircraft for defects, dents, signs of corrosion, mechanical issues, leaks, etc. Particular attention will be given to the windows, flight controls, skin surfaces and de-ice boots. Brakes and landing gear mechanisms will be inspected for leaks. Engine cowlings will be inspected for evidence of oil leaks and wings will be inspected for evidence of fuel leaks. If discrepancies are found, the owner will be notified and provided with repair estimates if requested.

NOTE: Active fuel, oil and hydraulic fluid leaks will compromise primer and paint adhesion, and will create paint imperfections in the leak area and surrounding areas like pinhole cavities, solvent pop, peeling, blistering, fish-eyes, pitting, cupping and lifting. If Cape Air declines to correct leaks prior to painting then adhesion and paint quality in these areas will not be covered under Royal Aircraft Services’ limited warranty.

2. Maintenance personnel will record travel limits, then remove ailerons, elevators and rudder.

3. Mask all fiberglass / plastic / composite wing tips, landing light lenses and other removable components that need to be protected from stripper with thick aluminum barrier material. Mask all windows with two layers of paper, followed by one layer of thick, aluminum barrier material. Mask antennas with aluminum barrier material and tape. Mask fuselage around windows and mask seams, static-ports and moving parts / hinges / exposed hydraulic lines and hoses with aluminum barrier tape. Mask wheels and gear-wells with 4 mil plastic. Mask cowl openings and cover engines with plastic.

4. Chemically strip aircraft using an environmentally safe aerospace stripper. Mask and strip control surfaces separately. Mechanically remove all stripper residue where possible, then power-wash remainder of residue off aircraft with hot water and alkali soap. Perform final power wash with clean, hot water.