Never had an aircraft painted before? You’re not alone. It’s easy to assume it’s like a car—pick your color, hand it off, done. But aircraft paint is more like a performance: choreographed, detailed, and full of behind-the-scenes magic.
We sat down with our own Mark Glogouski, Paint Manager, and David Bahns, Paint Supervisor at Stevens Aerospace, along with Julie A Voisin, Market Segment Manager at Sherwin-Williams Aerospace Coatings, our trusted paint provider, to walk through what first-time customers should expect before entering the paint hangar. From paint prep and design choices to the latest advancements and downtime realities, here’s what matters most—direct from the experts.
“One of the biggest things customers often don’t realize?” says Mark, “The FAA doesn’t regulate the kind of paint that goes on your aircraft. Some shops may cut corners with lower-quality materials that don’t protect the airframe long-term.”
Mark explains, “Paint might seem cosmetic, but it’s critical to protecting the aircraft’s surface. There’s a big difference between premium aircraft-specific paint and cheaper substitutes — and you might not see the consequences until years down the line.”
That’s exactly why we partner with trusted names like Sherwin-Williams Aerospace Coatings. Julie A Voisin, Market Segment Manager at Sherwin-Williams, emphasizes that their aviation-grade systems are engineered for long-term performance, offering superior resistance to UV exposure, staining, and thermal cycling—elements that generic or low-cost coatings simply can’t withstand. She points out that using the wrong type of paint can lead to early degradation and corrosion, driving up future repair costs.
This isn’t a DIY touch-up—it’s your aircraft’s armor. Don’t let it roll out of the hangar dressed in discount paint.
Preparation: The Unsung Hero of a Great Paint Job
Proper prep includes stripping old paint, corrosion treatment, sanding, and priming. Skipping or rushing this step might not show right away—but give it a few months, and the consequences can get expensive. Think of it like building a house: if the foundation isn’t solid, the rest doesn’t stand a chance.
Julie points out that advancements in adhesion promoters have helped streamline this stage of the process, reducing manual sanding and improving bond strength—saving time while giving your paint a serious grip. Less elbow grease, more staying power.
Planning Your Project: Know What to Expect
David’s advice to first-time customers? “Have your color scheme and aircraft package fully planned out. Expect the unexpected and be ready for an outstanding finished project.”
Questions to consider include:
How will the paint look in high-soot areas near the engine exhaust?
How long does the paint need to cure before applying protective coatings like Xilon or ceramic?
Are there hidden damages beneath the existing paint?
“At Stevens,” David adds, “we have a wonderful design team that sits down with customers to explore multiple schemes and color variations for interior and exterior refurbishment. This helps ensure your vision becomes reality.”
Our experts guide you every step of the way, so you don’t have to sweat the nitty-gritty—unless you really want to nerd out with us (we’re into it). Either way, we’re here to make sure your jet turns heads for years to come.
Design Drives the Schedule
David agrees, adding, “Incorporating metallic or pearl accents, especially on stripes, is a fantastic way to give the aircraft that extra pop and personality.”
Julie notes that while metallics and pearls create an eye-catching effect, they do come with added considerations. These “effect finishes” often require multi-layer application processes, can be more difficult to match during repairs, and may show imperfections more easily. Solid colors, on the other hand, are more resilient, easier to maintain, and generally lower in cost, making them a smart option for frequent flyers or charter aircraft.
Together, their insights show that at Stevens Aerospace, creativity doesn’t just take off—it soars. Whether you’re dreaming of a bold, head-turning scheme or a subtle, refined finish, we have the tools, talent, and tech to bring your vision to life. If you can imagine it, we can probably paint it (and if you can’t imagine it, our design team loves a challenge).
Of course, the more elaborate the design, the more time and precision it takes. But with the right downtime built into your schedule, you’ll get a finish that’s not just stunning—it’s durable, expertly applied, and uniquely yours. Because a paint job this good should last just as long as the impression it leaves on the runway.
Big Impact, Smart Choices for Durability
David shares some expert tips to increase durability and aesthetics:
Choose darker colors for the wings inboard and outboard of the nacelles to help hide soot from engine exhaust.
Apply gloss CAAP coating to wing leading edges for added protection and a polished look.
Mark recommends “focusing on touch-up-friendly designs and low-maintenance finishes to keep inspections and upkeep manageable.”
Julie emphasizes that their ultra-thin, high-performance coatings don’t just look good—they’re engineered to protect the aircraft’s surface while minimizing weight, helping maintain overall performance and fuel efficiency. That means better looks and better longevity.
Good looks may not be everything—but when your jet turns heads and resists grime, UV, and corrosion? That’s a win-win.
Environmental Factors and Quality Control
Mark reminds us, “Climate conditions, airborne particles, and human error all impact the paint finish. That’s why we meticulously control our painting environment—from humidity and temperature to air filtration—to create the ideal conditions for every project. This level of control ensures that every coat of paint adheres perfectly and cures correctly, giving you a flawless finish that lasts.”
David concurs, “Beyond environmental controls, our experienced paint team conducts thorough inspections and tests at every stage—from surface prep to final coat. We check for imperfections, verify adhesion, and confirm that every layer meets our high standards for durability and appearance. This rigorous attention to detail means your aircraft leaves our hangar with a finish that’s as tough as it is beautiful.”
Together, this commitment to precision and quality gives you confidence that your aircraft’s paint job will stand up to the challenges of flight, weather, and time—looking great for years to come.
Final Thoughts for First-Time Customers
A professional aircraft paint job isn’t just a fresh coat—it’s a complex, multi-step process that calls for expert knowledge, patience, and a whole lot of teamwork. When you understand the importance of prep, plan your design thoughtfully, and partner with a trusted crew like Stevens Aerospace, you don’t just get a pretty paint job—you get a finish that turns heads and holds up.
Because let’s be honest: there’s nothing quite like that first walk-around of your freshly painted jet, gleaming under the hangar lights. It’s a moment. (And yes, you’re allowed to take a victory lap.)
Ready to start your paint project? Contact our paint experts at Stevens Aerospace today—let’s bring your vision to life, one glossy panel at a time.