Well, No use crying over spilled milk or Nitrate dope. My wife was gone today so I started the recover job. After I removed the old (brand new) cover I re-sanded the entire structure. The purpose is to get it as smooth as possable. This sanded off all old dope so it was necessary to paint 2 coats of unthined dope on the areas where the new fabric will be attached. I covered the flaps and ailerons because they are small and I could use the leftovers from the first covering.
The first photo shows the precut fabric dobed to the leading edge of the flap. I cut a slot in the cloth where the control horn comes through the leading edge spar. the cloth is doped over the spar and across the top. Allow the dope to set up. The tecnique I use is to wet the wood, apply the fabric and then wet out the fabric. You can use the brush or your fingers to smooth the fabric out from the center.

The second photo shows the fabric pulled aorund the flap and doped to spar. You can leave the material a little long so as grip it and pull out most of the slack. After the dope begins to set you can trim the excess just below top of the spar. On this plane the fabric must be cut to allow the hinges to protrude thru. I make a slice at the hinge at this point and adjust the fabric while the dope is still wet. All of the seam overlap is on the leading edge spar and will not show.

The last shot shows the finished flap after it has been heat shrunk. It is important that the fabric be allowed to move freely during the shrinking process. For this reason the ribs and bottom sheet are not doped. The fabric is secured at the leading edge and on the end ribs. The trailing edge is NOT doped. I ironed the bottom sheet and all the wrinkles came out of both surfaces. The top was ironed to achieve the drum-head tightness I like. This fabric is a medium heat product and it will crush light structures if too much heat is used. If the part starts to creak, back off.

It took about an hour to cover and shrink the flaps and ailerons. Plus a little wait for the dope to dry between operations. I have not changed my opinion of Koverall, I still think it is the best covering I have used. Keep in mind that I have not used all the brands of material available and would like to try some of the Nelson fabric on an upcoming project.

More later.