The suggested guidelines as presented below are for basic information purposes for those individuals who ask for advice. These guidelines are by no means the only methods of installation but do correspond with installation techniques used by our facility for installation of plastic parts.

Even in today's highly technical world, there are variances in airframes. No two airframes have the brackets and holes in exactly the same places. Our parts are built to average dimensions and occasionally you must hand fit the parts. Most parts will require some trimming. If a part appears impossible to fit, CALL US!

Choose a topic:

I. Unpacking

II. Installation of Plastic Interior Parts

III. Cleaning, Care and Painting of Plastic Parts

 

I. UNPACKING

A. Unpackage parts from shipping container taking care to sift through all packing material for small parts.
NOTE: Small parts may be taped or attached to larger parts to prevent losing them.

B. Check purchased parts against packing list contained in packet on exterior of shipping container for completeness of shipment, part numbers, and damage.

C. Visually check purchased parts against the current parts you are going to replace for size & style.

D. Having satisfied yourself on completeness of order, part numbers, correct size, and style, please proceed to Section II Installation of Plastic Interior Parts. If you have any questions on any of the items listed above call us at (580) 327-1565 before painting and/or attempting installation.

NOTE: Parts are packaged for temporary transport and storage only. For different circumstances, repackaging may be required. Proper storage of parts would entail no direct access to sunlight, cigarette smoke, exhaust fumes, fluorescent light, UV light, plus no pressure that would misshapen the parts. High and low temperatures would need to be taken into consideration also. Plane Plastics, Ltd. is not responsible for improper handling and storage of Plane Plastics, Ltd. Plastic Parts.

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II. INSTALLATION OF PLASTIC INTERIOR PARTS

A. Suggested Tools

1. DOTCO Pneumatic Dremel Tool with Pressure Trigger
   a. double cross cut router bit
   b. saw blade
   c. 1/2' drum sander
   d. face shield
2. Metal Files-medium grade, double cross cut
   a. rat tail-tapered 8"
   b. half round-8"
   c. square-tapered 8"
3. Metal Deburring Tool-hand held, swivel
4. Metal Hole Saws (for instrument panels)
   NOTE: For instrument panels, arbor press cut dies work great.
5. Pencil
6. Tape Measure
7. 1/16"-1/4" Drill Bit Set
8. Clothes Pins
9. Phillips Screwdriver

B. Suggested Supplies

1. Masking Tape or Equivalent
2. 300 Grit Sandpaper (metal)

NOTE: Suggested tools and supplies are the responsibility of the owner/installer. In addition, the suggested tools and supplies as listed are not the only means of installation and any substitutions or deviations should be checked for proper usage, efficiency, and aircraft quality.

CAUTION: Tools and supplies should be used only by an experienced mechanic and at the users own risk.

C. Basic Part Trimming

1. Remove one part from the aircraft that you are going to replace with a Plane Plastics, Ltd. part.
2. Trial fit Plane Plastics, Ltd. part into aircraft to get a basic idea of what trimming, if any, is going to be required. By doing this and referencing your original part, you should obtain enough information for installation.
3. Should some areas need trimming, reference your original part dimensionally and transfer marks to Plane Plastics, Ltd. part, using a tape measure and pencil.
4. Using a straight edge or masking tape connect your transfer marks to make a reference line.
   
   NOTE: It may be preferable to trim the Plane Plastics, Ltd. part a little larger than your original to allow for minor variances. Things such as new carpet, upholstery, new windows, and structural repairs can affect part installation. It is also better to trim a little off 2 or 3 times and trial fit than attempt to trim it all at once and make a mistake.
   
   
5. Depending upon size and shape of part and amount to be trimmed you can use your dremel tool with saw blade. For smaller amounts you may touch it up with a file or on the belt sander.
6. ALWAYS TRIM ON WASTE SIDE OF REFERENCE MARKS! Always retain your reference marks; if you trim squarely on your marks and deburr your part, it could possibly become too small.
7. On completion of your trimming, touch up with the appropriate file, deburr edges, and touch sandpaper to edges lightly for finished look.

D. Basic Part Installation

1. Hand hold part in place and view if additional trimming is desired. (Ref. C1-C7)
2. Locate installation holes through any number of methods including but not limited to referencing the old part, measuring hole locations on structural attaching piece and transferring to plastic part.
3. Use drill with small bit (for a pilot hole) to drill installation holes. If drilling plastic part in place, put a drill stop on to prevent any damage.
4. Install new part using existing fasteners from old part or using new appropriate approved fasteners.
   
   NOTE: Use applicable guidelines as set forth in the airframe manufacturers' maintenance manual, FAR's advisory circulars and etc. for plastic installation and fasteners.
   
   
5. It is best to remove and install one part at a time using existing original parts to assist in locating the new part.
   
   NOTE: Final fit, trim, cutouts, and installation of fasteners is the responsibility of the owner/installer. All placarding, their placement and correctness is the responsibility of the owner/installer. Please reference airframe & engine manufacturer maintenance manuals, service bulletins, the FAR's, AD's, Advisory Circulars, and original parts and other applicable FAA Approved data for placards and their placement.
   
   NOTE: To glue two pieces together, put scrap plastic in a metal can with a metal lid. Pour MEK (methyl ethyl ketone) into can to cover plastic. Close the lid and allow the MEK to melt the plastic to a runny paste. Apply this "glue" with a syringe or pop sickle stick.

E. Basic Plastic Window Trim Installation

1. Hand hold part in place and view to see if additional trimming is desired (ref.C1-C7). Part may need to be shifted around to locate best placement in relationship to the window and corresponding plastic pieces. Make pencil reference marks to know how to locate your part back in plane.
2. Locate and drill installation holes (ref. D2 and 3).
3. After all trimming is completed you may wish to attach your rubber beading by either taping it in place on the backside or by gluing. Use appropriate approved glue and clothespins for holding rubber in place until bonded.

F. Two or more parts that have to be installed together.

1. Hand hold or tape in place parts and view if additional trimming is desired. (ref. C1-C7)
2. Position parts in relationship to each other to achieve best coverage of area, cosmetic appearance, and function.
3. Follow steps D2 through D5 as applicable for installation.
   
   NOTE: In certain aircraft (i.e. Cessna 177, 182, 210) there are areas in which to get the best overall appearance maybe 2, 3, or 4 parts have to be fitted and installed simultaneously to provide the best fit.

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III. Cleaning, Care, and Painting of Plastic Parts

A. Cleaning

1. For slight scuff marks & black marks use a pink eraser and/or 409, or equivalent cleaner that won't mar finished surface.
2. For multipurpose cleaning you can use 409, Windex, Brillanize, or equivalent cleaners that won't mar finished surface.

CAUTION: Tools and supplies should be used only by an experienced mechanic and at the users own risk.

As always, when doing steps 1-2 above, allow adequate ventilation and follow health precautions as outlined by chemicals manufacturer. Owner/Installer should choose what chemical he feels comfortable with that does the best to preserves the plastic.

B. Care

1. Protect your plastic from nicotine
   a. Don't smoke in your aircraft or let anyone else smoke.
   b. If you must smoke, paint your parts to protect them.
2. Protect your plastic from Ultraviolet Light
   a. Put a cover over your windshield if your plane is constantly in direct sunlight and/or close-up out on the ramp, etc.
   b. For best protection, paint your plastic parts.

C. Painting

1. You may purchase Water-Reducible Polyurethane Dispersion JetFlex™ paint in a variety of colors online from the Plane Plastics, Ltd. website at www.planeplastics.com or call a sales representative at (580) 327-1565. Following are benefits of purchasing JetFlex™ Paints:
   
   • Contains no free isocyanates, therefor no free isocyanate health hazard.
   • No flash point or fire hazard
   • Performance similar to solvent based polyurethanes
   • One package - no catalyst
   • Excellent hardness
   • Easy to use
   • Free of lead and chrome hazard
   • Good solvent and chemical resistance
   • Meets FAA FAR 25.853 regulation for burn, smoke and heat release
2. Application of JetFlex™ Paint:
   a. Plastic should be free of mold release, grease and other contaminants.
   b. Wash surface with Isopropyl Alcohol.
   c. Paint can be applied directly to most plastic surfaces.
   
3. Painting seals your plastic parts and extends the life of them. Covering your windows to avoid harmful light and cracking a window open to allow fresh air to circulate when you are not flying also extends the life of your parts.
   
   NOTE: When using chemicals, do so only if you feel comfortable and competent about what you are doing. Be alert to the possibility of softening, marring, and deformation of plastic.
   
   CAUTION: Tools and supplies should be used only by an experienced mechanic and at the users own risk.
   
   As always, allow for adequate ventilation and follow health precautions as outlined by chemical manufacturer. Owner/Installer should choose appropriate chemicals for the job and best preserves the plastic.

The above information is intended to be used and interpreted as suggested guidelines for installation of plastic interior pieces for a purchaser's new Plane Plastics, Ltd. parts and is no way intended to be complete or precise information. Airframes and aircraft, even with the same make and model designation will differ and, therefore, installation of interior pieces may vary. Plane Plastics, Ltd. assumes no responsibility or liability for any installation of plastic interior pieces in which the above suggested guidelines have been used, relied upon, referenced or consulted and furthermore, specifically disclaims and separates from such suggested guidelines from being any type of maintenance instruction, handbook, manual, or authority as any such document is defined or referenced by Federal Aviation Regulations. Please consult your own FAA approved mechanic to determine the most appropriate method for installation of plastic interior pieces in your aircraft.

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