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To paint or polish, that was the question...and here was my answer after debating how to finish my a Sonex. Late in the winter, we took a day trip to the Air Force Flight museum in Dayton, Ohio. (wright patt AFB). Upon strolling through one of the exhibits about the Tuskegee Airman, my wife Michelle says you should finish your airplane that way.



It took me another 4-5 months to settle on this scheme. I'm at the stage of the assembly now where it made sense to go ahead and polish and paint what needed to be done with the Tail, so I can move forward with final assembly and control rigging.

A little sneak of the tail polishing.


Then taking the tail apart, and using PreKote to prepare the aluminum for primer.


The PreKote is easy to use, is not nearly as toxic as Chromate...and cleans up with tap water. The directions say to prime within 24 hours, so that's what I did. I used high grade automotive 2K Epoxy primer (SW DP800). Two coats, let it dry thoroughly, then I scuffed up the surface and wiped everything down with wax and grease remover.


Today was the money day! Made a small paint booth in my garage, and had everything staged ready to paint by 7:30 this morning. Had preheated the garage overnight so,it was a comfortable 75 degrees F.

First coat of Single Stage Urethane "Viper Red". You want to spray a light tack coat on the first pass, just enough to cover but not a wet runny coat.


Final (second coat), a little slower on my passes, good overlap and no runs!




There is a little bit of orange peel texture, but the gloss looks good. For an airplane, I'm probably going to let it go and not wet send and polish. It's supposed to look like a WWII war bird, not a show car!

Once it's fully cured I will take some outdoor pictures and post these.

That's going to look great!

Awesome ,

Looks good Scott!

Paint looks great! were you using a spray gun or rattle cans?

Thanks for the positive comments guys!

Vic, I'm using HVLP guns, and a big air compressor. When I did the painting today, since it is catalyzed urethane paint, I was in a full protective tyvek paint suit, goggles, and charcoal filter respirator. I've done a bit of painting like this over the last 4-5 years, so I invested in decent equipment.

From left to right: Sherwin Williams DP800 3-part (2K) Epoxy Primer, my large HVLP paint gun, the detail HVLP paint gun, and the Kirker Ultra-Glo Single Stage (activated) Urethane Enamel Paint in Viper Red


It helps to have a large air compressor:


Remounted the horizontal stabilizer tonight. Trial fitted the fairing, and the vertical stabilizer was doing and impression of Jaws...





While I was painting, I helped my friend Steve with repainting his nose wheel pant and fairing for Waiex#54. He modified his nose gear and needed to make some updates to the wheel pant...and get it painted.

We had some Tuskgee Airmen here at Air Camp in Rockford tonight. They were honored at our final assembly.

A few pictures of the tail going together. Vertical stabilizer is attached now, and the elevator trim tab is mocked up temporarily.

The red looks good with the reflection.