Do’s and don’ts of polishing an aircraft

Maintaining an aircraft’s appearance is about more than achieving the perfect shine; it is a crucial aspect of an aircraft’s overall maintenance. Aircraft polishing plays a vital role in preserving the integrity and performance of an aircraft. Polishing an aircraft offers protection of its surfaces, contributing to the longevity of its structural components as well as rejuvenating the aircraft’s paintwork.

A primary benefit of regular polishing is the protection it provides against environmental factors. Aircraft are exposed to harsh conditions, including UV radiation, extreme temperatures, and dust, dirt, oil (skydrol) and pollutants. These factors can degrade the paintwork and lead to fading, causing long-term damage if left unchecked. Following an aircraft exterior cleaning and polishing routine creates a protective barrier, shielding the surface.

From a performance perspective, polishing can directly provide fuel savings. A smooth, polished surface reduces drag, improving the aircraft’s efficiency. While it’s difficult to predict accurately this reduction in drag translates to better fuel economy, lower operational costs, and improved flight performance.

In this blog, we’ll explore the essential do’s and don’ts of aircraft exterior polishing, helping you achieve a flawless and long-lasting shine while avoiding common pitfalls.

Related: How to polish aircraft brightwork

Do’s of aircraft polishing

Aircraft polishing requires precision, a prepared approach, and quality products to ensure a flawless finish while protecting the surface. For best results it’s important to follow best practices and avoid cutting corners.

Here are the key do’s to keep in mind when polishing your aircraft:

Use the right polishing products for the task

Choosing the correct exterior polishing products is crucial for achieving a long-lasting shine without damaging the aircraft’s fuselage. Using the wrong type of polish—such as automotive or household products— will lead to poor results and potential surface degradation and aircraft damage.

Preparation is key: Prepare the Surface

Before polishing, it’s essential to pre-clean the aircraft. Exterior cleaning removes dirt, oil stains, and any other contaminants that could scratch or damage the surface during polishing. Use an aviation-approved aircraft cleaner, such as our Aerowash Aircraft Cleaner, to safely cut-through the toughest dirt, oil and hydrocarbons without harming the paint or metal.

Browse our range of Exterior aircraft cleaners and Degreasers.

Follow a Consistent Maintenance Schedule

Regular polishing is key to maintaining the aircraft’s condition. Establishing a consistent maintenance schedule helps prevent oxidation, keeps the paintwork protected, and maximises maintaining a smooth surface for improved fuel efficiency. Depending on your aircraft’s exposure to the elements and frequency of use, fuselage polishing should typically be carried out every 3 to 6 months.

Consistent upkeep not only extends the lifespan of the exterior but also saves time and costs in the long run.

Use Proper Techniques and Tools

Achieving a professional finish requires using the right polishing tools and techniques. Apply even pressure and work in sections to avoid streaks and patchy results. Consider using tools such as dual-action polishers like the Cyclo Model 5 and high-quality microfibre cloths to achieve a shine without damage.

Incorrect techniques or improper tools can result in uneven polishing, surface damage, and additional maintenance costs.

Inspect for Damage

Before polishing, conduct a thorough inspection of the aircraft to identify any scratches, corrosion spots, or paint deterioration. Address these issues before moving on to the polishing to make sure your aircraft is well looked after. This also ensures that the polishing enhances the surface rather than accentuating imperfections. If you notice any significant damage, consider consulting a maintenance professional before proceeding.

Ignoring damage can lead to further surface degradation and costly repairs down the line.

Don’ts of Aircraft Polishing

Common mistakes can lead to surface damage, uneven finishes, and increased maintenance costs. Avoiding these common pitfalls is just as important as following best practices. Here is the key don’ts to ensure a safe and effective polishing process.

Don’t Skip Pre-Cleaning

One of the most critical steps before polishing is thoroughly cleaning the aircraft surface. Do not miss this step. Skipping this step can lead to dirt, dust, and debris being trapped under the polish, resulting in scratches and swirl marks. This can lead to a costly mistake if the paintwork is severely damaged. Use an aviation-approved cleaner (see our full range of exterior aircraft cleaning products) to ensure the surface is free of contaminants.

Failing to pre-clean can result in permanent surface damage and compromise the final finish.

Avoid Excessive Pressure

Applying too much pressure while polishing can cause abrasions in the paint surface and uneven wear, particularly on sensitive areas, composite panels, and leading edges. Instead, aim to apply gentle, consistent pressure and let the polish and polishing tools do the work. For best results, use quality polishing pads or applicators designed specifically for aircraft surfaces.

Excessive force can lead to costly repairs and reduce the lifespan of the aircraft’s exterior.

Don’t Use Household Polishes

Using household or automotive-grade polishes may seem convenient, but they lack the necessary formulations to protect aircraft exterior surfaces. Aircraft surfaces require more protection due to their exposure to harsh conditions and therefore it’s important to use specialised products like NuGlaze which are formulated to protect against oxidation, UV exposure, and environmental wear to the level that an aircraft requires.

Non-approved polishes may contain abrasive chemicals that can damage the aircraft’s paint, leading to costly refinishing work.

Avoid Polishing in Direct Sunlight

Polishing an aircraft under direct sunlight can cause the polish to dry too quickly, this can lead to streaking, uneven coverage, and difficulty in buffing. Ideally, polishing should be done in a shaded or controlled environment, such as an aircraft hangar, this helps to maintain consistent conditions which can make it easier to achieve a smooth, consistent shine.

Direct sunlight can accelerate polish curing, making it challenging to achieve a flawless finish.

Don’t Rush the Polishing Process

Aircraft polishing is a lengthy process that requires patience and attention to detail. Rushing the process can result in an inconsistent finish, missed spots, and swirl marks. Take your time to work in small sections, ensuring each area is polished thoroughly before moving on to the next. Using a structured approach will result in professional, long-lasting results.

Rushing can lead to a poor finish that will require rework and additional effort later on.

Achieve a Flawless, Long-Lasting Shine

Polishing your aircraft is more than an aesthetic task, it’s a vital maintenance process that shouldn’t be ignored. It not only enhances the appearance but protects the aircraft’s surface and improves fuel efficiency. By following the above tips — and using aviation-grade polishing products like NuGlaze, preparing the surface before polishing, and using the right techniques—you can achieve a long-lasting shine while avoiding the common mistakes.

Browse our range of polishing products to help you achieve the best results. Whether you need high-performance polishes, exterior cleaning products, protective coatings or interior cleaning products shop our large aircraft approved range now!