Pat Brookins of Lexington, KY. has decided to refurbish his 1979 Cessna 152. We'll use this page to keep all our friends updated on the progress. Here's a quick look at what we have to start with. We'll then go through the disassembly and cleaning process and then design a whole new look for it. We'll also be doing some glass replacement too, so that'll top the job off.
Everything is pretty much factory original paint which has worn really thin. Time for a repaint.
Most of the interior, seats, and all are original Cessna. Take a good look at these seats, because they won't be there long. The tnwings seats are ready to install. You can see the seat backs are missing the pockets, but the tnwings seats will have solid upholstered backs with deep pleated pockets sew in.
The tnwings carpet is already fabricated and ready to install. We'll remove all this original stuff prior to paint and then install the new tnwings carpet after the paint job.
Everything's coming along really well. The door jambs are not normally part of a repaint, but since we're putting in new seats and carpet, I couldn't resist the temptation to top it off with a door jamb repaint. Here, you can see the jambs cleaned down really well. Since the windows are being replaced anyway, we haven't worried about them so far. We are now ready to install the new windows before we press on to the primer stage.
We'll start with the rear window. First, we drill the window frame off and remove the center strip. Next, we clean the channel that the window sits in and we put the new gasket on the new rear window and slide it in place. Its a tight fit and the window has to bow out slightly to fit in there. Lastly, we rivet the lower window frame back in place and drill the center strip holes in the window and install the center strip.
O.k., so I'm going overboard. This is my one chance to make a difference. I went ahead and beed blasted the seat frames. This will give us a super clean job on the seats. I know its a small detail you can't hardly see, but none the less, it'll make it look good and get rid of a lot of rust. This cleaning method is about the only way to get down into the tiny parts to get them clean for paint. The next photo shows the flight controls in the booth. After some extensive detailing around the edges, I've got everything cleaned with metal conditioner. The flight controls and small parts take the longest, but the entire aircraft is done now and ready for primer.
While the basic airplane is now getting ready for the final paint, the bits & pieces are being finished out. This includes the flaps, rudder, elevators, ailerons, etc. We want to be sure they are ready by the time the airplane is ready to accept the part.
Now that's a tricked-out set of frames .
Before the new windshield is installed, the top of the panel is painted with low-gloss black. Here you see the windshield riveted in place just prior to painting. The windshield strap will receive on last primer coat before the final coat of paint goes on the airplane. All the glass, including the door glass is now installed.
New chrome door handles and new plastic door latch covers will add an extra finishing touch to our project.
While cleaning the inside of the engine cowl, it was found that the center baffle rib needed to be replaced. I replaced the rib with a serviceable unit I had and finished cleaning the inside of the cowl. I'll prep and paint this part just as the exterior gets completed.
As the finish work starts, all the time working each individual piece begins to show. For example, I replaced the vertical fin tip with a new part. Prior to installation, I primed and painted the part, then cleaned the inside ribs to the fin, the barrel of the flashing beacon socket, and anything else I could find that needed a cleanup. Lots of stuff in just a little tip. The tip also houses the VOR "cat whiskers" antenna. Had to repair a broken wire in here as well. Stainless screws round out the completion of the tip.
Got the new strut cuffs put on and even replaced the loose rivnuts in the inspection panels with flush riveted nutplates. Installed new flap rollers, bushings, and new attachment bolts and nuts.
These have been done for a while, but I thought I'd throw in a picture for good measure just to get one before its installed. Also did a custom embroidered fuel placard.
Repaired the eyebrow by recovering with leather.
Found the rudder front spar cracked in 4 places. Removed and replaced with a new part from Cessna. Notice how the new part doesn't have the lightning hole where the old part cracked ! Installed the new part, painted the rudder and reinstalled. While I was at it, I removed all the bushings in the rudder and cleaned & polished. The tolerances were very good, so I greased the bearings and reinstalled with new bolts and nuts.
Cleaned, primed, and painted the nose gear assembly. Installed new collar shims. Removed, painted, and serviced damper. Replaced the clevis bolt here as well. Installed new bearings and races in the nose wheel. Installed a new nose tire. Powder coated the axle bolt head and nut.
Cleaned, primed, and painted all the wheel halves. Cleaned and repacked the wheel bearings and installed new brake discs.
Cleaned the rusty alternator brackett and powder coated with mirror chrome.
Repainted the inside of the engine cowl with Gamma Grey.
Repaired both the gear leg fairings by replacing the flex supports on the inside. Primed and painted, but before installing I wanted to get rid of the rust that was on the main gear legs. The tubes weren't too bad, but now's the time to clean them up and stop the rust where it's at. Cleaned them down and primed with epoxy primer and painted with silver metallic. Installed the newly repaired and painted fairings with new stainless steel screws. Powder coated the foot pegs and reinstalled.
Beed blasted and powder coated the trim tab actuator rod. I used Anodized Silver Metallic Poly for this so it looks like new metal while giving us maximum rust protection since the better part of the rod is exposed to the elements.
Added custom burlwood yoke emblems
Refinishing the wing tips and all the little reinforcement strips, nav light holders and all separately makes a more "assembled" factory look as opposed to the paint job "sprayed over" look on the screws and strips. Powder coated the landing light retainer ring with reflective chrome and reinstalled after I painted the lower cowl.
Finished out the upper cowl by installing new baffle gaskets on the top and sides. Also installed new stainless steel camlock fasteners.
I checked the new baffle seal from inside the cowl to be sure we got a good tight air seal without excessive gasket. As you can see, the side seals around the baffle fit perfectly and the rear baffle gaskets fit very well against the back engine baffles.
............and here it is :
The Before/After recap :
Before After Before After Before After
