by Brent Stockwell
If you're buying your first or your fourth balloon, there are some considerations that might make a difference in cost of maintenance and repairs that you might be unaware of. Most balloons are bought emotionally, but there are practical considerations that will make your balloon more satisfactory.
Many balloon manufacturers offer an option of Nomex fabric at the mouth of the envelope and for the skirt or scoop. Nomex was not made for prolonged exposure to heat and discolors easily (usually to tan or red, regardless of the original color), becomes brittle, and either tears easily or just falls apart. Nomex is very expensive and replacement panels or patches never match. The threads may also disintegrate, leaving a bunch of panels flapping. The use of Nomex in balloons is a misapplication. Some balloon manufacturers offer Nomex or Kynol lining at the mouth and of the skirt; when the flame comes too close to the Nomex or Kynol, the fabric on the other side melts, resulting in a very expensive repair because the Kynol/Nomex and Dacron/Nylon must be separated to allow replacement of the melted nylon. This makes the repair far more expensive than a repair to a single-layered panel.
Our school balloons have nylon mouths and skirts. The instructor makes the first inflation and the student makes all subsequent inflations. Our balloons don't get burned, the fabric doesn't get melted. It's hard to understand why pilots with hundreds or thousands of hours burn their balloons when students with 2 hours don't. We think it may be an attitude which assumes that "everybody burns balloons, so it's OK", or that pilots mistakenly think Nomex/Kynol is impervious to damage, therefore they aren't careful.
If you insist on burning your skirt, we think it makes more sense to have 2 nylon skirts. Two (or three) nylon or dacron skirts cost about the same as one Nomex or Kynol lined skirt.
It has been our experience that dark colors have a longer life than light colors and we advise our customers to design envelopes with dark colors at the top. The more colors you have (particularly at the top) the more fabric testing is required at each annual inspection. So, a dark, one-color top will save you money each annual and will probably last longer.
The more complex the envelope design or artwork is, the more costly the repairs will probably be.
At the time the balloon is ordered, order at least 10 yards of each color fabric in the balloon so you have your own stock for repairs. Even if your repair station stocks a lot of fabric, manufacturers change fabric and colors change, and sometimes it is impossible to match the fabric in your balloon unless you have your own supply.
If you work with a repair station you like, find out what kind of relationship they have with the manufacturer of the balloon you plan to buy. If your preferred repair station and the manufacturer of your balloon don't get along, you're probably going to get poor service in cases where factory cooperation is required or if the repair station needs quick shipment of parts. If your favorite repair station doesn't like the manufacturer of your balloon, change manufacturers, or change repair stations.
If you are considering several different brands of balloon, find out what kind of reputation they have in your area for customer support. Do they deliver replacement parts and components in a timely manner? Are they helpful with advice on making repairs, or do they want everything sent to them (at your expense) for expensive factory repairs?
There aren't great differences between different brands of nylon. (Nylon is a trademark of DuPont and all nylon filament is made by DuPont or under their patent. Different milling companies offer different weaves, styles, densities, etc.) There are some differences in coating which may result in longer life. When deciding what fabric to order, an important characteristic to know about balloon fabric (nylon or polyester) is that, in general, the heavier it is, the longer it lasts.
Steel or kevlar cables? Which is better? We don't know. Even in a powerline contact, you don't know which material is safer. Kevlar cables will abrade more easily, severing the basket from the envelope. Steel cables may transmit electricity to the basket; they may also form part of a system that allows electricity to circumscribe the basket, consequently bypassing its occupants. The aviation/aerostation industry has used steel cable for a long time and testing criteria are well-established. One balloon manufacturer is satisfied that Kevlar is holding its strength over time, however, to date, no one has supplied repair stations with testing criteria for Kevlar's integrity. Since we operate a repair station with a mandate from the FAA to declare a balloon either airworthy or not airworthy after periodic inspections, we're much more comfortable with steel cables, and that's what we have on our own balloons. Don't hit powerlines.
Some baskets are constructed with the rattan sides lashed to a wood bottom with a fabric or steel cable. If the balloon gets wet, or is stored wet, the cable may eventually corrode or rot and break, allowing the bottom of the basket to separate from the sides. It's always important to store your basket dry and in a dry place, however, if your basket has a cable lashing the bottom to the sides, you should not only dry and store the balloon correctly, but also check the condition of the cable on a regular basis. Replacing the cable is time consuming (therefore costly) as it is usually covered with leather or rawhide, which also must be removed and replaced.
If you're buying a used balloon, you won't be able to choose individual options, however the presence or lack of options that are important to you should be a consideration when determining how much you are willing to pay.