Technical data

5.8.6 Roller Application. While not as good as sprayers
for metal surfaces, rollers do provide a smoother and more
professional appearance than brushes. Therefore, rollers may
be used to touch-up large areas. The most effective roller
covers for application of primer are manufactured from
ultra-high density sponge. The most effective roller covers for
topcoat are manufactured from lint-free, extra-density, high-
quality soft-woven fabric, with a maximum nap length of ¼
inch. The core roller center should be resistant to water and
solvent. Choose a handle of the proper length and a roller of
the right width (3 to 9 inches) for the job at hand, and use one
with a splatter shield to prevent the coating from splattering
on personnel and other surfaces not being coated. For large
areas, power or automatic feed rollers are more efficient and
their use eliminates the possibility of spillage from open
containers. To minimize spillage when using manual rollers,
use coating container grids. Move the roller across the grid to
eliminate excess coating material. Polyurethanes and epoxy
coatings require a little more paint on the roller during
application to achieve a smooth surface and a second cross-
coat may be required. The application procedure is as
follows:
a. Scuff-sand and solvent wipe the touch-up area per
Chapter 3.
b. Mix and thin the primer or paint for roller application
per Chapter 6 and the manufacturer’s instructions. Mix
the least amount possible for the job at hand. Insert the
vertical, portable, metal grid into the container; or pour
the liquid into the power/automatic feed roller reservoir.
c. Dip the roller fully into the primer or paint. Withdraw
the roller, and move the roller across the vertical metal
grid to distribute the liquid throughout the roller pile and
eliminate any excess. For power or automatic feed
rollers, depress the feed trigger until the roller is full of
liquid; and move the roller across a vertical, portable
metal grid mounted in an empty container after the
initial filling only to distribute the liquid throughout the
pile evenly.
d. Always start application in a corner of the area being
touched-up. The maximum area of coverage should be
about 9 square feet before moving to an adjacent area.
Place the free end of the roller about 3 feet away from
where the roller stroke will end so that it covers a small
portion of the left or right “feathered” edge of the area
being touched-up completely and with the roller at an
angle to this edge. For horizontal surfaces, always make
the first stroke away from you; and without lifting the
roller from the surface, make alternate strokes toward
and away from you to form a “W” pattern. For vertical
surfaces, always make the first stroke upward; and
without lifting the roller from the surface, make alter-
nate up and down strokes to form an “M” pattern. Fill in
the gaps in the “W” or “M” patterns with crisscrossing
strokes of the roller moving back across the “W” or “M”
pattern and still not lifting the roller from the surface.
Make sure that the entire section is completely covered,
including its “feathered” edges, before moving to an
adjacent section or finishing the touch-up of an area less
than 9 square feet. Always use even pressure on the
roller to prevent bubbles and blotches in the primer or
paint.
e. If the touch-up area is not entirely covered, touch-up a
section adjacent to the first section making sure it over
laps the first section about 2 inches. Application is by the
same techniques as in step (4).
f. If primer was applied; allow the proper cure time, and
then apply the topcoat using the same roller techniques
as in steps (1) through (5).
5.8.6.1 Based on the final report for a Roller Application
of Aerospace Coatings project that is posted on the AFCPCO
web site, the following general vendor information is sup-
plied for rollers tested during the project that were capable of
applying aerospace coatings within the film thickness ranges
listed in this manual. Commercial and NSN info will be
posted on the AFCPCO web site as it becomes available.
5.8.6.2 Primer application rollers can be purchased com-
mercially from any vendor who handles the Whizz-Roller
System, “premium sponge” product line.
5.8.6.3 Topcoat application rollers can be purchased
commercially from any Sherwin-Williams distributor/sup-
plier handling the “contractor series” soft-woven roller ¼
inch nap line of products.
NOTE
Other similar or equivalent rollers are authorized.
5.8.7 Temporary Protection. When polyurethane is not
available, repair of paint systems with MIL-DTL-85054,
Type I or II, CPC sprayed on or brushed on bare metal areas
for protection until polyurethane is available is permissible.
(See TO 1-1-691) Complete painting of aircraft with other
than polyurethane MIL-PRF-85285, Type I, is not authorized.
5.8.8 Powder Coating. New support equipment is be-
ing delivered coated with thermoplastic or themoset powder
coatings. Thermoplastic powder coatings are generally ap-
plied to a surface that has been preheated to a temperature
significantly higher than melting point of the powder,
whereas thermoset powders contain a heat-activated catalyst
and are generally applied to a surface at ambient temperature.
The surface and the powder are then heated and as the
temperature rises past the melt temperature of the powder, it
melts to the surface.
5.8.8.1 Surface Preparation. In situations where com-
plete removal of the thermoplastic/thermoset powder coatings
are required, they shall be stripped with PMB, Type II or Type
V, using procedures listed in Paragraph 2.11. Chemical paint
removal procedures listed in this TO are very ineffective at
removing these coating and, therefore, should not be used.
TO 1-1-8
5-16