Painting an airplane is tougher than it looks

Question: When I look at pictures of planes being built at the Boeing factory, the tail of the plane is the only part painted. Why is the tail painted before the rest of the plane?

— Bruce, Carlsbad, Calif.

Answer: It is easier to paint and balance the vertical fin and rudder when they are initially assembled than waiting to do the entire airplane. Airplane manufacturers spend millions of dollars studying the most efficient time and way to execute common processes.

Q: What is the reason that airlines do not paint the wings on their airplanes?

— Steve Donnelly, Auburn, N.Y.

A: Paint adds weight. The aluminum alloys or composite material used for the wings are designed to withstand being exposed to the elements, and the large surface area would require many gallons of paint, adding substantially to the weight of the airplane.

Q: Do metal-colored aircraft, such as older American Airlines models, weigh less than painted aircraft? Do they use some kind of metal preservative instead of colored paint?

— Aaron Heskel, Antwerp, Belgium A: Yes, there is a weight benefit of up to several hundred pounds by not having paint on the fuselage. Unpainted surfaces do require extra buffing and maintenance, offsetting some of the cost savings of flying with lower weight.

Q: I often read about airlines repainting an aircraft to commemorate a city, a sports team, etc. In an industry so focused on the bottom line that they charge for pillows, this seems extravagant. About how much does it cost to repaint a Boeing 757 or Airbus A320?

— Jim P, Rochester, N.Y.

A: The city, team or organization may share the cost of commemorative paint on an airplane with the airline. The cost varies significantly depending on the individual design and the contract with the painting organization. Some airlines, such as JetBlue, have many airplanes in commemorative paint while others have none. It appears some have determined it is a good means to advertise, while others choose other marketing methods.

Have a question about flying? Send it to travel@usatoday.com.

John Cox is a retired airline captain with US Airways and runs his own aviation safety consulting company, Safety Operating Systems.