Aircraft Paint vs. Automotive Paint: What Pilots Should Know to Avoid Costly Mistakes
- Matt Farrell
- Dec 14
- 8 min read
Why This Matters
Aircraft and automotive paint systems may look similar, but they’re built with very different chemistry, thickness, and durability requirements. Using automotive-grade cleaners on aircraft may seem convenient or cost-effective, until you consider:
Major differences in paint thickness and structure
The absence of a clear coat on most aircraft finishes
Compatibility concerns with sealants, coatings, and composites
FAA and OEM recommendations against harsh chemicals
This post explains the chemistry and design of each paint system and why aviation-grade cleaners matter and lays the foundation for a safe, effective cleaning strategy.
How I Came to Know Aircraft Cleaning and Why This Series Exists
In 2020, when Aero-Mach acquired Wilco Aircraft Parts, I suddenly had access to a wide range of aviation parts and cleaning products. I needed to know and understand them if I were going to represent them well.
Naturally, I grabbed a can of belly cleaner and went to work on the company's Cessna T210.
To be honest, I wasn’t expecting much. Most of what I’d used before just turned oil and grime into a streaky mess. But this cleaner was different, spray on, wipe off, no residue, and no damage. It worked.
That result made me pause. Why was this different? Why did it work better? More importantly, if it worked so well, could it be damaging the paint on our plane?
That moment led me to dig deeper into the chemistry and specifications of aviation coatings and the products designed to protect them.
Over the course of my 30-year aviation career, I’ve received product training across many product lines. From avionics and instruments to detailing products and aircraft lighting, and I’ve always believed that kind of technical knowledge doesn’t mean much if it stays behind the counter. It needs to be shared with the flying public.
This blog series is about bringing hands-on, hangar-tested knowledge out into the open with real-world results you can evaluate for yourself.
Aircraft Paint vs. Automotive Paint: A Structural Overview
Let’s start with how the paint systems differ.
Paint System | Layers | Clear Coat? | Approximate Thickness |
Single/Dual Part Polyurethane Aircraft Paint System | 1–2 stages (primer + topcoat) | Rare or minimal | 2–3 mils |
Multi-Part/Multi-Stage Water Based Automotive Paint System | Primer + basecoat + clearcoat | Always included (1.5–2 mils) | 4–6 mils
|
Modern automotive finishes use a water-based acrylic basecoat with a polyurethane (or acrylic urethane) clearcoat system, whereas most general aviation topcoats are a high-solids, solvent-based, two-part polyurethane enamel (or simply polyurethane) applied as a single-stage system.
Aircraft paint is much thinner and simpler in structure than automotive finishes — and that matters when choosing a cleaner.
Why Aircraft Paint Is More Vulnerable
Aircraft Paint is Thinner by Design
Aircraft finishes are applied with weight and airflow in mind. Thick coatings can affect control balance, increase drag, or even conceal critical inspection points.
FAA AC 43.13-1B specifically warns that excessive paint buildup around seams, rivets, and access points can interfere with corrosion detection and proper sealing. View FAA Advisory Circular AC 43.13-1B (PDF)
No Clear Coat Buffer
Most automotive finishes are applied through a multi-stage process and rely on a clear coat layer to absorb UV rays, road grime, and minor scratches. The clear coat is applied to a thickness about 1.5 to 2 mils. That's the thickness of two sheets of printer paper! That outer shell can be buffed, waxed, or even repaired without damaging the base color.
Aircraft? Not so much.
As Sherwin-Williams Aerospace notes:
“Aircraft coatings typically do not include clear coats, making the color layer more exposed and sensitive to harsh chemicals and abrasion.”— Sherwin-Williams Aerospace Technical Brief
What you see is what you get. If you damage the topcoat, there’s nothing left underneath— you are down to bare metal.
Harsher Operating Conditions
Aircraft are exposed to more than road grime:
High-altitude UV (Did you know that was a thing?)
Rain erosion
Exhaust stains
Fuel, hydraulic fluid, de-icing agents
Constant vibration and material flexing
Why Automotive Clear Coat Doesn't Translate to Aircraft
Modern car finishes are built around clear coat chemistry. These hard, UV-resistant layers are made from high-solids urethane or acrylic systems — tough, polishable, and designed for regular chemical exposure.
That’s why automotive cleaners often contain:
Alkaline detergents
Petroleum-based solvents
Silicone waxes or polymers
Mild abrasives or polishes
These ingredients are designed to work on top of that clear coat — not on a thin, unprotected aviation topcoat. The durability of automotive clear coat allows for more aggressive cleaning and polishing properties.
Aircraft finishes don’t have this luxury. Their polyurethane or epoxy topcoats are the final layer — applied thin, left exposed, and chemically sensitive.
What works for your F-150 may not be safe for your Bonanza.
A Note on Paint Longevity
A high-quality aircraft paint job isn’t just cosmetic, it’s a protective layer that, with proper care, should last the entire life of the aircraft.
Most repainting happens for two reasons: Corrosion from beneath or damage from above.
Corrosion can be unpredictable, but what happens on the surface is in your control. Using the right cleaners, applying sealants, and polishing as needed can help your paint last 30+ years, especially with indoor storage.
Indoor hangar storage drastically reduces UV damage and environmental exposure. But for aircraft stored outside, extra care is essential including more frequent washing and reapplication of protective products.
In short: a good paint job should be a once-in-a-lifetime expense, not a routine maintenance item.
The Financial Reality of Paint Damage
A repaint on a certified single-engine aircraft (properly stripped and re-painted) typically runs $20,000 to $35,000. At these price points, your paint becomes the second most expensive part of the aircraft to replace, behind the engine.
Aircraft paint isn't meant to be sanded, buffed, or "touched up" like car paint. I speak from experience that once the damage is done, the only fix is often a complete respray of that section or repainting the entire airframe.
What Happens When You Use the Wrong Cleaner?
Even if a generic cleaner gets the bugs or belly grime off, you could be doing long-term damage. Here’s what can go wrong:
High pH cleaners can soften paint and attack seam sealants (Ever wonder why your sealants get soft and messy?)
Solvents may damage vinyl, composites, or adhesives
Abrasives wear at the thin layers of paint, removing expensive material
Incompatible chemistries interfere with future coatings or leave streaked residues
"Avoid cleaners with high alkaline or acidic content. They may damage sealants, adhesives, and painted surfaces."— FAA AC 43.13-1B,
Automotive products simply aren’t built for aircraft paint chemistry or structural sensitivities.
Why Gentle on Wildlife Doesn't Always Mean Gentle on Aircraft
You’ve probably seen commercials showing popular consumer dish soaps being used to clean wildlife affected by oil spills. It’s a powerful image and a testament to how mild and safe these detergents can be for living creatures. However, aircraft surfaces are a different story.
While these detergents are gentle enough for feathers and fur, they often have a slightly alkaline pH, which can be harsh on aircraft paint over time. Remember, cleaning a duck is a one-time emergency measure, but cleaning your aircraft is a regular maintenance routine. Even a mild alkaline cleaner can, with repeated use, lead to gradual dulling or degradation of your aircraft’s finish.
That’s why it’s important to choose a cleaner specifically designed for aviation use. These products are formulated to be pH-neutral and safe for repeated application, protecting your paint and sealants for the long haul.
Another popular household cleaner I’ve heard being used is spray on furniture cleaners. At first glance they seem safe for your aircraft. It has a neutral PH and it gets its shine from Silicone polymers similar to other aviation specific products. The probem lies with what is known as its emulsifiers, or specifically, Secondary Alcohol Ethoxylate. Emulsifiers reduce the surface tension between the oil and water, preventing them from separating and ensuring the product performs as intended on surfaces like wood, granite, and vinyl. When used on an aircraft, this allows the product to act a carrier of water into the crevices of your aircraft and hold it in suspension for long periods of time. This can lead to deep corrosion issues down the line.
So What Makes an Aviation Cleaner Different?
A purpose-built aviation cleaner will:
✅ Be pH-neutral
✅ Contain no abrasives
✅ Non-Corrosive
✅ Be tested for use on aluminum, composites, vinyl, and rubber
✅ Be compatible with thin-film polyurethane and epoxy topcoats
✅ Comply with FAA and OEM material guidelines
It's not just about what it removes — it's about what it leaves alone.
Wrapping It Up: Cleaning with Confidence
There’s no shortage of DIY tips, hangar tricks, and automotive products being pushed as “just fine” for aircraft. But given the cost of painting an aircraft, the dollars you are saving in cleaning products leads to spending thousands on a new paint job.
Using the right chemistry shouldn’t come down to the cost — it’s about respecting the materials, protecting your investment, and staying ahead of unnecessary wear or repaint costs.
Throughout this series I am going to share what works, why it works, and how you can clean your aircraft safely without guessing and without shortcuts.
So next time you reach for a cleaner, ask yourself: "Would I use this on a $20,000 paint job with no clear coat?"
If the answer is no, then maybe it’s time to look into something that was actually designed for the job.
More to come.
—TFS
Frequently Asked Questions: Aviation vs. Automotive Cleaners
Why don’t most aircraft have a clear coat like cars?
Weight and simplicity. Clear coats add extra layers that increase weight and maintenance complexity. Aircraft rely on high-performance polyurethane finishes that are thinner and applied directly as the final coat, without a clear coat buffer.
What happens if I use a car cleaner on my aircraft once or twice?
You might not notice damage immediately, but over time, aggressive chemicals can soften seam sealants, fade topcoat pigments, or interfere with future repainting. It’s not worth the risk to save a few dollars.
Is there any cleaner that works for both cars and aircraft?
Not reliably. Automotive cleaners are designed for clear-coated surfaces and may include solvents, waxes, or high pH formulas. Aviation-grade products are tested for compatibility with aluminum, composites, vinyl, and rivets.
How do I know if a cleaner is safe for aircraft?
Look for:
pH-neutral formula
No abrasives or silicones
Residue-free
Specifically labeled for aircraft use
Compatibility with aircraft materials. When in doubt, check for FAA AC 43.13-1B compliance or manufacturer approval.
How much does it cost to repaint an aircraft?
For a certified single-engine piston aircraft, expect to pay $20,000 to $35,000 for a full, professional repaint — including stripping, prep, and materials. That’s why using the right cleaner is an investment, not an expense.
Where can I find FAA guidance on cleaning aircraft?
The go-to reference is FAA AC 43.13-1B, which outlines best practices and cautions for cleaning aircraft surfaces. Paint manufacturers also provide guidance for the use and care of their products on their websites.
Is washing an aircraft considered "maintenance"?
The FAA has stated that the physical act of washing an aircraft, by itself, is usually neither maintenance nor preventive maintenance. However, a manufacturer’s recommendations and a complete corrosion prevention and control program usually include sequential steps that are considered maintenance or preventive maintenance. These steps may be required either before, after, or as a result of other maintenance or inspection program tasks, including the act of washing the aircraft. Source: FAA InFO 16005
Examples of such tasks could be:
• Aircraft wash preparation, such as covering static ports
• Post-wash inspections
• Lubrication
• Preservation
References & Citations