Overlapping Panels vs Butt-Joints

There are a lot of ways of doing panel lines, the most common being the "primer and tape" method. However, first you have to determine which type of panels your aircraft used on the fullscale plane. Most common is the standard "Butt-Joint" panels. These are made by applying 1/32" or 1/64" Chartpak graphics tape on all your panel lines, spraying them with quite a few coats of primer, sanding, then removing the tape. This will leave a thin recessed line to simulate the "crack" where the panels butt together. However, the fullscale Duantless used "overlapping" panels, which require a different technique to create.



Actually, the technique is pretty much the same as with butt-joints. But, instead of thin tape for a recessed "line" at panel joints, you use wide tape and paper to mask of entire areas, and produce "one side" of the butt-joint relief... ergo a "stepped, overlapping" panel joint.

So, basically, you measure your panel lines from your 3-Views, mark them on your plane, then begin adding a wide tape along the "low-side" of the overlap for each panel line. Use paper to mask off the rest of the area to avoid overspray problems. The rule of thumb for determining which panel is "on top" is this... you want to "shingle" them from top to bottom and nose to tail. This helped keep the elements from blowing up under the panels in the direction of flight and gravity.

There are exceptions, so check your photo documentation for any such instances. There are a lot of materials you can use to build up the panel, but I use Spot Filler/Primer in a spray can, same as for priming. It takes a lot of coats to build it up, but don't do them too heavy or fast, or it will bleed under the tape. Light coats, with plenty of dry time. It takes some experience to determine how much you need to apply.

Once done and dry, sand it lightly (I use a sanding sponge) until you cut the primer down to the surface of the tape. Then, pull the tape of and you have a nice overlapping relief. The tricky part is planning out which areas to do first when you get into 3 or more panels converging in the same area. This may require going back and doing some panels more than once to gradually build up the "stacking order" of the panels.






"Wingtip Lights and Hardpoint Fairings"