Making Templates
Well fitting blankets depend on accurate measurements or templates. If you buy raw materials or if you have purchased a generic kit, you will need to make blankets that fit well and that often means making templates. Measurements will work in many places but for complex areas, a template is far superior. Templates may be made from kraft paper, or even news paper, however these are prone to tearing and being opaque, details are not seen through the pattern material.
Two other options are superior to plain paper. Clear drafting Mylar is available at many drafting supply stores or you can buy a template making kit from us using yarn reinforced Mylar sailcloth. This material is also transparent but is better than drafting film since it is lighter and less stiff making it easier to use for getting into corners and tight areas for tracing. In addition, our kits have adhesive backed hook and loop to hold the template in place during tracing.
Tools needed:
Sharp utility knife
Scissors
Sharp felt tip pen
Table large enough for template that you can cut into with a knife
ALWAYS BE CAREFUL NOT TO CUT ANY ELECTRICAL, MECHANICAL, HOSES OR OTHER AIRCRAFT PARTS AND STRUCTURES DURING THE TEMPLATE TRACING AND CUTTING!!!
- 1. First, take a little time to plan the overall blanket shape and details such as slits that allow the blanket to be removed. This can save a LOT of time later so THINK IT THROUGH! Make sketches if needed but try and reduce the number of slits to a minimum since they are a weakness that can allow the blanket to tear. Frequently, you may be able to extend one slit to include two or more details thus simplifying the installation and reducing the slits. You may also find that many times a slit is needed over such a long area that it may be best to cut it all the way across and make two blankets. Also, it is a LOT easier to make a slit than a hole in a blanket covered with film. For small cutouts like a 1"-1 ½", pipe or hose, I simply make a slit rather than a round cutout. This may depend a bit on the blanket material but make these cutouts no larger than needed.
illustration #1
marking registers
(as described in step 3)
illustration #2
adding hook and loop
(as described in step 4)
- 2. Begin by measuring and rough cutting the template to a size slightly larger than the finished template dimensions. For a sidewall, this will be the entire length of the aircraft interior using one template. If you have straight areas, you may be able to pre-cut one edge using a straight edge and utility knife. If you are doing a sidewall of an aluminum aircraft with many blankets, you should label each area for a blanket with a unique code such as "L-1" for the first blanket on the left and so on. Mark this label on your template and to the blanket.
- 3. Using a SHARP felt tip pen, make 3-4 "registers" on the aircraft. A register is a mark (a "+" sign works well) that will help align the template as it is removed and re-installed. Make these "+" signs near the edge of the aircraft part being traced but exact placement isn’t required. Marks should be fine lined for a good reproducible fit of the template each time it must be removed and repositioned.
- 4. The hook and loop is now placed on the aircraft that will hold the templates immobile while the tracing is being done. Generally it is best to place 2"-3" hook near the edges of the aircraft template but you can always add or subtract material as needed. You may elect to use this hook position for holding the blanket or not. Mark the permanent hook and loop positions if you will use other placement.
- 5. Place the rough cut template on the aircraft and first mark the placement of the hook in order to place the loop on the back of the template. Also mark orientation of the blanket such as placing an arrow marked "UP" and/or "RIGHT SIDE" or "LEFT SIDE".
- 6. Attach loop to the back of the template as marked to match the hook. Place template back on aircraft. Mark registers from the aircraft on to the template. If you are doing a complex area of the aircraft such as a firewall that has many penetrations, you may have to do small portions cutting slits or cut-outs as you go. ALWAYS BE CAREFUL NOT TO CUT ANY ELECTRICAL, MECHANICAL, HOSES, OR OTHER AIRCRAFT PARTS AND STRUCTURES DURING THE TEMPLATE TRACING AND CUTTING!!!
- 7. Trace the border of the aircraft part on the template and mark any other holes needed to make the part fit. Be careful to make all parts fit snug for maximum performance BUT UNDER NO CIRCUMSTANCES SHOULD ANY BLANKET EVER INTERFERE WITH THE MOVEMENT OF AIRCRAFT CONTROL SURFACES!!!!
- 8. Clean up any rough edges, repairing rough or poorly done edges with tape and re-cutting as needed. The template is now complete. Remove the template and any hook not needed to hold the blanket.
