Sonex Nuvite Polishing Installation Instructions

Polishing Sonex Non-Clad Aluminum Sheet Metal

Thanks for using Nuvite! The following method using Nuvite NuShine II Metal
Polishes will polish non-clad aluminum sheet stock, -as used on Sonex aircraft,
giving you an outstanding finish and a show-quality shine. Sonex aluminum as
supplied in the kit is 6061 non-clad aluminum sheet stock. However, with this
kind of metal sheet, almost by definition, it is “mill finish”, and to get a good final
finish, it requires some special, -but not hard work vs. the process used for “clad”
aluminum sheet (100% aluminum “clad” over the surface of the alloy). This is
because, when you polish the actual alloy, you are working with a much harder
surface than would be the case if you were polishing clad material, which is soft.
The good news is that once polished, the non-clad stock will resist dulling from
atmospheric oxidation much longer than does clad material! Our experience with
non-clad material polished as follows has been excellent.

Nuvite NuShine II metal polishes are manufactured in various grades to match
the needs of the original metal condition in the compounding phase of polishing.
This system makes it ideal to deal with non-clad, mill-finish aluminum sheet
stock. Following the use of a compounding grade of NuShine II polish, the final
finish is always done with NuShine II Grade S that gives you that really bright,
fine and deep image, with no machine swirl marks.

The mill finish usually means that there are fine surface lines over the whole
surface from the rollers that formed the sheet. Because Nuvite NuShine II is a
"burnishing" type of polish (does not grind away the rough spots as other kinds of
polishes do), the compounding phase is meant to merely roll the microscopic
high spots and low spots together into a smoother and more reflective surface.
We call it "healing the surface". Once this compounding phase is complete, the
lines, or “grain” will be minimized or smoothed altogether, and the surface is
ready to take a high and deeply transparent shine with an excellent, mirror-like
image reflectivity.

Polishing Procedure

Compounding Phase:

- Assure that the surface to be buffed is clean, dry and free from oils &
water.

- Using Nuvite NuShine II Grade F9, put wet “fingerprints” of polish every 3”
over a 2’ X 1 _’ area to be compounded. Compound buff using 2000-2500
rpm rotary buffer and 100 % wool “compounding” pad. (Nuvite EQ-140 or
3M #05711). “Compounding” pads can be identified by the tufted pad face
that is “twilled” into tufts, similar to a cut-pile carpet. Do not use standard
“loose wool” pads.

- Move the buffer back and forth over the area with sweeping passes.
About 2 to 3 seconds per foot seems to work well as a starting suggestion.

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Some weight can be placed on the buffing, but keep the buffer moving to
prevent overheating the surface. Do not slowly “grind” across the surface.
Moving slowly, especially when the surface is still relatively rough, can
cause overheating both the metal and the polish. The surface will get hot
as you buff, but will cool quickly as you move over other areas of the
buffed areas.

- In 30 to 45 seconds, the black polish residue should come off the surface,
leaving a clean, clear surface. If the black, wet residue remains on the
surface longer than 30- 45 seconds, too much polish is being used, and
the desired surface burnishing action is reduced.

- Repeat the above over the same area. The more passes, the more the
blending action will ease the mill roller “grain” and the smooth the metal
surface. We recommend two passes as a minimum. Four passes will
give a smoother surface, although even more passes will not harm the
metal or its’ properties. As a suggestion, areas that will be out of sight
–top of wings on a high wing plane (bottom on low wing) and the belly, will
look great after two passes, while “high-visibility” areas, such as underside
of the wing (high wing – top surface of a low wing) and the fuselage
turtledeck, cowl & sides get four passes to get that extra, up-close, smooth
finish.

- Move on to the next area, and so on.

- When through with buffing for the day, thoroughly clean the surface of any

F9 polish residue around fasteners/seams/joints, etc. Microfiber cloth is
very effective when polish is still fresh, and seems to have an affinity for
the accumulated polish.

- Follow the above with a second phase of compound buffing, two passes
only, using identical procedures, with Nuvite NuShine II Grade C. This
pass will brighten the surface color to a high, bright shine, but polishing
marks on the surface will be visible. These are taken out with the final
finish pass. Use fresh buffing pads (not impregnated with F9 polish). It is
always wise to mark pads to keep the process organized so that a
stronger grade polish is not introduced during compounding with a finer
grade (i.e., later in the process).

- When polishing a kit type aircraft, we recommend that at least the
compounding polishing should be done before assembly – on a padded
bench or similar such as an assembly jig, so that overhead and “lying
down” polishing effort is avoided. Completing the compounding phase
while unassembled and doing the final finish after assembly will minimize
the muscle strains.

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