Richard Pike
Joined: 09 Jan 2006
Posts: 1671
Location: Blountville, Tennessee
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 Posted: Sun Jun 18, 2006 7:43 pm Post subject: Looking for advice repairing bent Ultrastar wing. |
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You are going to have to remove some fabric so that you can see just
where and to what extent the aluminum is damaged. It could be that you
have some bent ribs that are pulling the leading edge out of column, but
you won't know until you open up some fabric.
I would slit the fabric around the edge of the root rib and remove it,
because that rib will need repair. Once that fabric is out of the way,
you will be able to see inside the wing and see if any other ribs are
damaged, or if the leading edge is damaged. Then you will know which
fabric needs removing, and how far back to remove it. What you find will
determine what happens next.
On the aileron, I would slit the fabric along the underside of the
aileron, next to the trailing edge, in the vicinity of the ding,
probably out about half way to the two good ribs. Very possibly you will
be able to carefully cut out just the damaged section of tube, sleeve in
a good length, and then reglue your fabric back so you don't have to do
a major fabric repair. Here's how you do it: get a length of fabric
about 6" wide and about as long as the slit section, and polybrush it
(not polytak) onto the fabric along the top side just ahead of the
trailing edge. You want it to overlap your present fabric about two
inches, the 4" that hangs loose off the back is to give you a handle to
pull the fabric back in place with. Let it get good and dry and then
spread a coat of polytak along the trailing edge, and then pulling with
the doped-on fabric, pull the original fabric tight onto the tube and
around the corner toward the bottom. Weight it or clamp it or something
so it will stay tight and let the polytak dry. Now peel off the doped on
6" wide "pull handle" section without pulling your top fabric loose from
the trailing edge.
Now dope (polybrush) a fresh 6" wide section of fabric onto the rear
edge of the loose fabric along the bottom, with about a 3" overlap, and
let it dry. After it is dry, pull it tight around the tube and dope it
onto the top fabric, with about 3" overlap on each side. Let it dry,
cover it with some wide tape, polybrush it, shrink it, and a couple more
coats of silver/color and you ought to be good to go.
Depending on what sort of repairs you have to do to the wing, and where
or how you have to slit that fabric, you might be able to do a similar
thing with that fabric. For instance, if you have to replace a leading
edge, but the ribs are unharmed, doing a similar thing to the fabric
along the leading edge allows you to keep 95% of the wing fabric intact.
It won't look quite as tidy as an original job, but if you are careful,
and the paint matches, it will only be noticeable at close inspection,
and will save you the time and cost of a complete recover of the wing.
On the other hand, if you have serious structural damage to the wing,
don't scrimp on fixing the structural damage just to save on paint and
fabric.
Richard Pike
MKIII N420P (420ldPoops)
David Kulp wrote:
| Quote: |
Hi Kolbers,
A short time ago I posted a request for advice and cautions on repairing the right wing on my Ultrastar, which broke free from its tiedowns in a wind storm and flippen onto its right side. The photos I attached failed to make it with the post, so I got no response. Now I've got the photos, so what I'm mainly concerned with is whether and/or how to straighten the leading edge of the wing, which is bent about 1 1/2 inches in the first 8 feet or so. The other two damages I believe will be more straightforward, but I'd still appreciate advice with them, too.
Thanks in advance!!
Dave Kulp
Bethlehem, PA
bent Ultrastar
Do not archive.
http://www.matronics.com/photoshare/undoctor(at)rcn.com.06.01.2006/index.html
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_________________
Richard Pike
Kolb MKIII N420P (420ldPoops)
Kingsport, TN 3TN0
Forgiving is tough, being forgiven is wonderful, and God's grace really is amazing. |
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