In this MasterClass session, Josh and Brian continue the Old School Model Works Minuette build by progressing through the fuselage assembly and introducing the fundamentals of iron-on covering. From bending balsa sheeting to heat-activated fabric coverings, viewers gain practical, repeatable techniques that elevate any model airplane project.
Fuselage Construction & Recap of Core Building Methods
The episode begins with a brief apology for a schedule shift, as Josh had just returned from a Las Vegas trade show. Once underway, he recaps previously covered topics—using wax paper under plans, the wing assembly process, and the “sandwiching” method used to build the Minuette’s horizontal and vertical stabilizers.
Josh then reviews how the fuselage halves were built and joined vertically over the plan. The structure is taking shape, and the next steps focus heavily on sheeting and surface preparation.
To sheet the hatch, Josh softens balsa with Windex, which evaporates more cleanly than water and allows the wood fibers to bend without cracking. After tacking it with CA glue, he reinforces the seams from the inside—ensuring the hatch remains strong and smooth.
Introducing Iron-On Covering: Tools, Materials & Oratex Basics
Josh transitions into the main topic: iron-on covering, specifically using Oratex, a heat-activated, semi-transparent fabric-style film that provides a vintage aircraft appearance. While heavier than typical coverings, Oratex is durable, chemical-resistant, and ideal for showing off internal structure.
Tools Needed for Covering Work
Josh recommends the following essentials:
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Covering iron with temperature control
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Heat gun (not a hair dryer)
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Sharpie for marking hinge slots
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Razor blades & scissors
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Foam contour sanding pads
For clean hinge installation before covering, he uses DU-BRO Small Nylon Pin Hinges, ensuring smooth, secure control-surface movement:
Surface Preparation, Beveling & Pre-Covering Setup
Before covering, Josh levels the surfaces with careful sanding. He rounds edges slightly to prevent wrinkles during application, then bevels control surfaces such as the rudder to provide the needed clearance for movement once the hinges are installed.
For precision surface shaping, he leans on DU-BRO Long Sanding Bars, which deliver the rigidity and accuracy needed for flat, ripple-free framing
Josh also demonstrates marking hinge slots before covering so they’re easily reopened later.
Covering Techniques: Tacking, Wrapping & Heat Shaping
Covering begins with cutting the Oratex oversized, then tacking the middle of the first edge and working outward—allowing mistakes to be corrected by reheating and lifting the material.
Josh compares wrapping edges to “wrapping a Christmas present,” folding one side neatly before securing the other. Corners require small, careful relief cuts before stretching the material into place with heat.
After sealing corners, he irons the edges at about 280°F (tacking temperature). For builders working with standard film coverings, a Heat Gun provides consistent, controllable heat for tightening material across open bays.
A viewer asks about using a covering sock. Josh explains that socks are excellent for glossy films but not ideal for textured Oratex—even recommending baby socks for improvised covers.
Final Sealing, Cutouts, and Drum-Tight Finish
Josh increases the iron temperature to 327°F for final sealing, eliminating waviness and activating the adhesive fully. He cuts openings for hinges, singes seams for a clean finish, and uses a heat gun on high to shrink the covering drum-tight across the frame.
Afterward, he demonstrates cleaning Oratex—showing that it resists acetone, isopropyl alcohol, and permanent marker, making it forgiving to work with.
To secure wiring, tubing, or servo leads inside the fuselage during covering and assembly.
Learning, Community & Final Giveaway
Josh discusses Oratex’s weight penalty and why it's better suited for models over 50–55 inches due to area scaling. He encourages experimentation, celebrates shared learning, and highlights the community aspect of the RC hobby.
The final giveaway question asks: What is the governing body of the model airplane hobby in the U.S.? While many answered AMA, the correct answer was the FAA.
This episode reinforces the value of learning through doing, working with quality materials, and relying on trusted tools like those from DU-BRO to achieve professional-level results—even on your first covering project.
