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To cut or not to cut?
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jdm(at)wideworld.net
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PostPosted: Thu Mar 02, 2006 2:54 pm    Post subject: To cut or not to cut? Reply with quote

I have an original Firestar TTAF 905 hrs. It's fat 388 lbs. as am I 215 lbs. It is the 5 rib wing sporting a 503 on top. I've had the plane for 40 hours of it's flight time. I don't know about how it was flown in the past except an entry in the logbook that states "did first loop today".

I fly conservatively but as someone mentioned, you never know when you are going to hit turbulence. Last summer I banged my head on the canopy a few times and other times it felt like the bottom had fallen out followed by an abrupt stop. Other times I had been doing something else GPS, radio, etc and when I looked up I was going 80 and once I know I saw 90. So, no matter how gentle we try to fly there are going to be times when the plane gets stressed.

My question is should I strip the covering off the wing and brace the leading edge and perform a full inspection or should I continue to fly and not worry about it?

The condition of the covering and plane is very good. Looks like this plane has been taken care of at least as far as appearances go. But is this an accident waiting to happen? What would you do? Thanks!
John Murr


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JetPilot



Joined: 10 Jan 2006
Posts: 1246

PostPosted: Thu Mar 02, 2006 3:38 pm    Post subject: Re: To cut or not to cut? Reply with quote

That is a LOT of hours on that plane JDM... If you are good at covering and building, and you could easily do the job, I personally would take the time to get in the wing and do it, especially given the history of someone doing loops in that plane. I would reinforce both the leading and trailing edges of the ribs. If they look fatigued, I would even replace them. That would really really worry me, because the "did FIRST loop today" entry implies many more followed Shocked The more I think about the history and the weight you are flying at, the more I dont like it....

If you do not have the ability and shop to do that type of work that makes the choice much harder. Maybe someone here with more experience than I will help you out there.

One thing I definately would recommend is getting a BRS (ballistic chute). That gives you a really good backup and can save your life if the worst does happen.

Best of luck with that one, I really hope someone can give you some better advice than I can on this.

Michael A. Bigelow


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Last edited by JetPilot on Thu Mar 02, 2006 4:14 pm; edited 3 times in total
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Frcole(at)aol.com
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PostPosted: Thu Mar 02, 2006 4:06 pm    Post subject: To cut or not to cut? Reply with quote

5 Ribs vs 7 !. The weight of that Firestar is just about what my Firestar 11
is. The 7 rib vs 5 uses the same primary structure in that the spar will take
the bending moment. The problem is distributing the air load thru the fabric
into the ribs and then into the spar. I think the probable failure would be
pulling the fabric from the rib caps and not folding the wing. Its still a
terminal failure though, best solution would be to rebuild the wing with more ribs.
Dick C


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rsanoa



Joined: 10 Jan 2006
Posts: 71
Location: Bell Buckle,TN

PostPosted: Thu Mar 02, 2006 4:10 pm    Post subject: To cut or not to cut? Reply with quote

I guess I'm just an old fuddy duddy but my first line of defence, and insurance, would be the installation of a BRS. A damaged plane in our catagorys can't do much damage to anything on the ground descending under a chute.
Ray ... UltraStar
Tenn.
do not archive

John Murr <jdm(at)wideworld.net> wrote:


I have an original Firestar TTAF 905 hrs. It's fat 388 lbs. as am I 215 lbs. It is the 5 rib wing sporting a 503 on top. I've had the plane for 40 hours of it's flight time. I don't know about how it was flown in the past except an entry in the logbook that states "did first loop today".

I fly conservatively but as someone mentioned, you never know when you are going to hit turbulence. Last summer I banged my head on the canopy a few times and other times it felt like the bottom had fallen out followed by an abrupt stop. Other times I had been doing something else GPS, radio, etc and when I looked up I was going 80 and once I know I saw 90. So, no matter how gentle we try to fly there are going to be times when the plane gets stressed.

My question is should I strip the covering off the wing and brace the leading edge and perform a full inspection or should I continue to fly and not worry about it?

The condition of the covering and plane is very good. Looks like this plane has been taken care of at least as far as appearances go. But is this an accident waiting to happen? What would you do? Thanks!
John Murr



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PostPosted: Thu Mar 02, 2006 5:17 pm    Post subject: To cut or not to cut? Reply with quote

John, I love your candidness. My Firstar is in the same weight category and
I weigh about 15 pounds more than you, as did my predecessor. But hitting
your head on the canopy, may I suggest tightening your seatbelt! Ha, HA! As
far as the feeling of the bottom falling out, I might suggest apiece of 3/8"
thick mild steel plate along the base of the frame. Of course the plane may
have difficulty getting off in less than 500 feet but when you hit the
ground you will make a dent in the earth that they will know you were there!
Ha! "Logbook entry of "first loop today". Now that one really scares me!
John Houck, have you ever done intentional loops? To answer your question, I
really don't know. I do know that it is a considerable amount of work. My
life in it? Yours hours flying it? You would be the best judge of your
values. How old is the plane? It might be time anyway. And I know I would be
a bit more comfortable knowing for sure what's under the rapping paper.

Ohio Ralph

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edchmiel(at)mindspring.co
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PostPosted: Thu Mar 02, 2006 5:32 pm    Post subject: To cut or not to cut? Reply with quote

Guys,

Seems to be too much 'TLAR' (that looks about right) engineering and
conjecture going on here. Homer built a very sturdy bird to start with!
All the chicken littles (with no design experience!) should perhaps refrain
from expounding on alterations. As pointed out in an earlier post, going
from a 5-rib to a 7-rib involves more than just sliding on a couple ribs - a
new spar would be in order. Where's the failure data that was mentioned
earlier, which started all this?

Ed in JXN
MkII/503
Do not archive.
---


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David.Lehman



Joined: 10 Jan 2006
Posts: 265
Location: "Lovely" Fresno CA

PostPosted: Thu Mar 02, 2006 6:15 pm    Post subject: To cut or not to cut? Reply with quote

Ed, I'm with you, where's the data?... This thread has actually got me a
little scared to go fly my new (to me) airplane...

I bought a Kolb for several reasons and one of the most important is the
reputed strength... I'm starting to get a little disenchanted with it and I
haven't even flown it yet...

If there are documented Firestar airframe failures, please, please guide me
to the reports... The life I save may be my own... If it's just hearsay,
please say so and I'll take it as such...

Thanx...

David
On 3/2/06, Ed Chmielewski <edchmiel(at)mindspring.com> wrote:
Quote:


>

Guys,

Seems to be too much 'TLAR' (that looks about right) engineering
and
conjecture going on here. Homer built a very sturdy bird to start with!
All the chicken littles (with no design experience!) should perhaps
refrain
from expounding on alterations. As pointed out in an earlier post, going
from a 5-rib to a 7-rib involves more than just sliding on a couple ribs -
a
new spar would be in order. Where's the failure data that was mentioned
earlier, which started all this?

Ed in JXN
MkII/503
Do not archive.



--
=F4=BF=F4 "I started with nothing... And I still have most of it left!"...


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Frcole(at)aol.com
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PostPosted: Thu Mar 02, 2006 6:15 pm    Post subject: To cut or not to cut? Reply with quote

Just a quick question, why a new spar ? A few extra holes, so long as they
are plugged at the old rib locations would make no difference. Did Homer change
the tube spar thickness?
DickC


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PostPosted: Thu Mar 02, 2006 6:47 pm    Post subject: To cut or not to cut? Reply with quote

John Hauck knows of two. His and a friend of his. Perhaps her could expand
exactly what failed in each case and should we be worried?

Quote:

Ed, I'm with you, where's the data?... This thread has actually got me a
little scared to go fly my new (to me) airplane...

I bought a Kolb for several reasons and one of the most important is the
reputed strength... I'm starting to get a little disenchanted with it and
I
haven't even flown it yet...

If there are documented Firestar airframe failures, please, please guide
me
to the reports... The life I save may be my own... If it's just hearsay,
please say so and I'll take it as such...

Thanx...




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John Hauck



Joined: 09 Jan 2006
Posts: 4639
Location: Titus, Alabama (hauck's holler)

PostPosted: Thu Mar 02, 2006 7:41 pm    Post subject: To cut or not to cut? Reply with quote

|
|
| John Hauck knows of two. His and a friend of his. Perhaps her
could expand
| exactly what failed in each case and should we be worried?

My accident is well documented in the Kolb List Archives. Do a search
in the Kolb Archives on "leading edge failure". Then scroll down to
around 4 March 2004. There are several posts reference wings there.

john h


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Possum



Joined: 12 Jan 2006
Posts: 112
Location: Georgia

PostPosted: Thu Mar 02, 2006 8:47 pm    Post subject: To cut or not to cut? Reply with quote

At 10:41 PM 3/2/2006, you wrote:
Quote:

| John Hauck knows of two. His and a friend of his. Perhaps her
could expand
| exactly what failed in each case and should we be worried?

My accident is well documented in the Kolb List Archives. Do a search
in the Kolb Archives on "leading edge failure". Then scroll down to
around 4 March 2004. There are several posts reference wings there.

john h
-----------------


>Yes, a gentleman by the name of Aubrey Radford, old Air America pilot
>from VN days installed spades on his original Firestar. Aubrey flew
>hard, very similar to John Hauck, back in those days. Two months
>after I pulled the wings off my original Firestar, Aubrey did the same
>thing with his Firestar. He got a full canopy, but the kevlar bridal
>seperated when it came into contact with the sharp edge of the engine
>mount. Unfortunately, it was his last flight. Those two events
>happened 15 years ago. Mine in March and Aubrey's in May. BTW My
>parachute worked.
He did have the spades on his plane, but later we cut down the ailerons and
archived the same or better results.
That's right about the crash - except Aubrey had a "Second Chance" chute
with a "nylon"
bridal that separated at about 100+ mph on an over loaded KXP going
straight down after doing several aerobic maneuvers - loops and
hammerheads - at an air show.
The front leading edge folded back as far as we could tell - the out of
column sort of thing.
I'm almost sure it was a 500lb max chute system. Aubrey was about 1/2 max
himself.
He hit so hard that the engine block was flattened. Not to be too graphic
.........................you know the rest. We've had two of these
so far - so
be careful out there you guys. Aubrey flew very hard.


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David.Lehman



Joined: 10 Jan 2006
Posts: 265
Location: "Lovely" Fresno CA

PostPosted: Thu Mar 02, 2006 8:56 pm    Post subject: To cut or not to cut? Reply with quote

Damn!...

On 3/2/06, possums <possums(at)mindspring.com> wrote:
Quote:



At 10:41 PM 3/2/2006, you wrote:
>
>| John Hauck knows of two. His and a friend of his. Perhaps her
>could expand
>| exactly what failed in each case and should we be worried?
>
>My accident is well documented in the Kolb List Archives. Do a search
>in the Kolb Archives on "leading edge failure". Then scroll down to
>around 4 March 2004. There are several posts reference wings there.
>
>john h
-----------------

>Yes, a gentleman by the name of Aubrey Radford, old Air America pilot
>from VN days installed spades on his original Firestar. Aubrey flew
>hard, very similar to John Hauck, back in those days. Two months
>after I pulled the wings off my original Firestar, Aubrey did the same
>thing with his Firestar. He got a full canopy, but the kevlar bridal
>seperated when it came into contact with the sharp edge of the engine
>mount. Unfortunately, it was his last flight. Those two events
>happened 15 years ago. Mine in March and Aubrey's in May. BTW My
>parachute worked.
He did have the spades on his plane, but later we cut down the ailerons
and
archived the same or better results.
That's right about the crash - except Aubrey had a "Second Chance" chute
with a "nylon"
bridal that separated at about 100+ mph on an over loaded KXP going
straight down after doing several aerobic maneuvers - loops and
hammerheads - at an air show.
The front leading edge folded back as far as we could tell - the out of
column sort of thing.
I'm almost sure it was a 500lb max chute system. Aubrey was about 1/2 max
himself.
He hit so hard that the engine block was flattened. Not to be too graphic
..........................you know the rest. We've had two of these
so far - so
be careful out there you guys. Aubrey flew very hard.


do not archive


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Denny Rowe



Joined: 10 Jan 2006
Posts: 89
Location: Leechburg, PA

PostPosted: Thu Mar 02, 2006 9:23 pm    Post subject: To cut or not to cut? Reply with quote

---

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PostPosted: Thu Mar 02, 2006 10:13 pm    Post subject: To cut or not to cut? Reply with quote

Well said, Denny!

---


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PostPosted: Thu Mar 02, 2006 10:15 pm    Post subject: To cut or not to cut? Reply with quote

Hi Dick,

I suppose it's not required, but I'd always wonder about any holes
in the spar. If my bird had the fabric off and I felt the need to add the
ribs, the spar change would make me sleep better. But I'm no aerodynamic
engineer, either!

Ed in JXN
MkII/503
Do not archive.
---


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rsanoa



Joined: 10 Jan 2006
Posts: 71
Location: Bell Buckle,TN

PostPosted: Fri Mar 03, 2006 6:34 am    Post subject: To cut or not to cut? Reply with quote

My unsolicited advice is ----- if you want to "fly hard" and do acrobatics, buy an aircraft that is designed for it. Killing one's self in a standard category plane, flying outside it's limits, puts a bad undeserved name on the aircraft.
Ray
do not archive

Ed Chmielewski <edchmiel(at)mindspring.com> wrote:


Well said, Denny!

---


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David.Lehman



Joined: 10 Jan 2006
Posts: 265
Location: "Lovely" Fresno CA

PostPosted: Fri Mar 03, 2006 7:18 am    Post subject: To cut or not to cut? Reply with quote

Ray and Denny...

Thanx for the reassuring words of encouragement...

David

do not archive
On 3/3/06, ray anderson <rsanoa(at)yahoo.com> wrote:
[quote]


My unsolicited advice is ----- if you want to "fly hard" and do
acrobatics, buy an aircraft that is designed for it. Killing one's self in a
standard category plane, flying outside it's limits, puts a bad undeserved
name on the aircraft.
Ray
do not archive

Ed Chmielewski <edchmiel(at)mindspring.com> wrote:


Well said, Denny!

---


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PostPosted: Fri Mar 03, 2006 7:24 am    Post subject: To cut or not to cut? Reply with quote

John M & all,
Here's my take and 2 cents on your dilemma. One, the plane has
already 900 plus hours - I don't feel that is a negative, more of a
plus in that it has demonstrated it can handle the normal loads
placed upon it. Next, the two incidences brought up of having wing
failures, it was established both were repeatedly flown hard doing
aerobatics which equates to higher speeds and loads. Being trained
in aerobatics and having owned an aerobatic trainer aircraft, stress
will be induced upon the airframe from increased airspeeds and doing
abrupt maneuvers. Most basic maneuvers like loops, barrel or aileron
rolls if done properly will not place any undo amount of stress upon
the airframe (stay away from tail slides, hammer head stalls which
can turn into tail slides or whip stalls, and snap rolls), however do
them wrong followed by the use of improper recovery techniques can
induce significant loads upon the airframe. Doing airshow type
aerobatics can induce excessive loads beyond the limits of the
airframe which it was never intended to withstand.

You may want to search the archives using search keys of 5 rib and
second key as 7 rib. There is a case similar to yours in which the
party recites his conversation after contacting the factory for there
opinion. Reference message dated 16 Apr 2002 by Ken Korenek.

Now to the real issue, your flying heavy with a 503. The weight and
503, and allowing a back seat passenger were the reason the company
went to the 7 rib wing structure. I am not an engineer but based
upon the comments in that message referenced above I think your fine
as long as you keep the gross weight under 800#. I just wouldn't go
out do any aerobatics, fly it like a Cessna 150.

Having built a Kolb FireFly and a CGS Hawk and comparing their wing
structures, I don't think you have any problem. Unlike the Kolb the
Hawk wing does not use any ribs, instead it uses the forward spar as
its leading edge with shape forming battens that slide into sewn in
pockets between the front and rear (tube) spars to form the curved
shape of the wings upper surface. The bottom surface uses no ribs or
battens relaying on the fabric tension alone between the front and
rear. (The Hawk wing also has the typical wing diagonal
strengthening members.) The Hawk wing is strong and has proven
itself over time. I don't feel the FireStar wing is any weaker.

If you were to rework the wing to the 7 rib configuration based upon
comments from the designer of the Hawk regarding their spar, if you
place a solid aluminum rivet into the vacated rivet holes of the
prior rib locations, that should prevent compression failure of the
spar since the holes are filled. Your other option would be
replacing the spar's. Myself after reviewing the prior post and
comparing the aircraft, I would leave it alone and just fly
it. Don't carry any passenger and don't fly airshow aerobatics. If
your still concerned you might consider buying and installing a BRS,
it would probably be about the same cost you would incur to rebuild
and recover the wings, much less work. It would add another 20-24#.

My conclusion fly it as it is, stay within the gross weight limit of
800# as suggested in the message I referenced above, don't do any
aerobatics, and stay within the never exceed speed, you should be
fine with every day flying, thermals included.
jerb
At 11:21 PM 3/2/2006, you wrote:
[quote]
---


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David.Lehman



Joined: 10 Jan 2006
Posts: 265
Location: "Lovely" Fresno CA

PostPosted: Fri Mar 03, 2006 7:36 am    Post subject: To cut or not to cut? Reply with quote

Thanx Jerb...

Now I don't have to contact Barnstormers to place an ad...

Thanx again...

David

do not archive
On 3/3/06, jerb <ulflyer(at)verizon.net> wrote:
[quote]


John M & all,
Here's my take and 2 cents on your dilemma. One, the plane has
already 900 plus hours - I don't feel that is a negative, more of a
plus in that it has demonstrated it can handle the normal loads
placed upon it. Next, the two incidences brought up of having wing
failures, it was established both were repeatedly flown hard doing
aerobatics which equates to higher speeds and loads. Being trained
in aerobatics and having owned an aerobatic trainer aircraft, stress
will be induced upon the airframe from increased airspeeds and doing
abrupt maneuvers. Most basic maneuvers like loops, barrel or aileron
rolls if done properly will not place any undo amount of stress upon
the airframe (stay away from tail slides, hammer head stalls which
can turn into tail slides or whip stalls, and snap rolls), however do
them wrong followed by the use of improper recovery techniques can
induce significant loads upon the airframe. Doing airshow type
aerobatics can induce excessive loads beyond the limits of the
airframe which it was never intended to withstand.

You may want to search the archives using search keys of 5 rib and
second key as 7 rib. There is a case similar to yours in which the
party recites his conversation after contacting the factory for there
opinion. Reference message dated 16 Apr 2002 by Ken Korenek.

Now to the real issue, your flying heavy with a 503. The weight and
503, and allowing a back seat passenger were the reason the company
went to the 7 rib wing structure. I am not an engineer but based
upon the comments in that message referenced above I think your fine
as long as you keep the gross weight under 800#. I just wouldn't go
out do any aerobatics, fly it like a Cessna 150.

Having built a Kolb FireFly and a CGS Hawk and comparing their wing
structures, I don't think you have any problem. Unlike the Kolb the
Hawk wing does not use any ribs, instead it uses the forward spar as
its leading edge with shape forming battens that slide into sewn in
pockets between the front and rear (tube) spars to form the curved
shape of the wings upper surface. The bottom surface uses no ribs or
battens relaying on the fabric tension alone between the front and
rear. (The Hawk wing also has the typical wing diagonal
strengthening members.) The Hawk wing is strong and has proven
itself over time. I don't feel the FireStar wing is any weaker.

If you were to rework the wing to the 7 rib configuration based upon
comments from the designer of the Hawk regarding their spar, if you
place a solid aluminum rivet into the vacated rivet holes of the
prior rib locations, that should prevent compression failure of the
spar since the holes are filled. Your other option would be
replacing the spar's. Myself after reviewing the prior post and
comparing the aircraft, I would leave it alone and just fly
it. Don't carry any passenger and don't fly airshow aerobatics. If
your still concerned you might consider buying and installing a BRS,
it would probably be about the same cost you would incur to rebuild
and recover the wings, much less work. It would add another 20-24#.

My conclusion fly it as it is, stay within the gross weight limit of
800# as suggested in the message I referenced above, don't do any
aerobatics, and stay within the never exceed speed, you should be
fine with every day flying, thermals included.
jerb
At 11:21 PM 3/2/2006, you wrote:
>
>
>
>---


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PostPosted: Fri Mar 03, 2006 8:05 am    Post subject: To cut or not to cut? Reply with quote

-- jerb <ulflyer(at)verizon.net> wrote:


"My conclusion fly it as it is, stay within the gross weight limit of
800# as suggested in the message I referenced above, don't do any
aerobatics, and stay within the never exceed speed, you should be
fine with every day flying, thermals included.
jerb"

Jerb and all,
The Original 5-rib wing Firestar had a gross weight limit of 535 lbs.

Ralph
Original Firestar
19 years flying it

John M & all,
Here's my take and 2 cents on your dilemma. One, the plane has
already 900 plus hours - I don't feel that is a negative, more of a
plus in that it has demonstrated it can handle the normal loads
placed upon it. Next, the two incidences brought up of having wing
failures, it was established both were repeatedly flown hard doing
aerobatics which equates to higher speeds and loads. Being trained
in aerobatics and having owned an aerobatic trainer aircraft, stress
will be induced upon the airframe from increased airspeeds and doing
abrupt maneuvers. Most basic maneuvers like loops, barrel or aileron
rolls if done properly will not place any undo amount of stress upon
the airframe (stay away from tail slides, hammer head stalls which
can turn into tail slides or whip stalls, and snap rolls), however do
them wrong followed by the use of improper recovery techniques can
induce significant loads upon the airframe. Doing airshow type
aerobatics can induce excessive loads beyond the limits of the
airframe which it was never intended to withstand.

You may want to search the archives using search keys of 5 rib and
second key as 7 rib. There is a case similar to yours in which the
party recites his conversation after contacting the factory for there
opinion. Reference message dated 16 Apr 2002 by Ken Korenek.

Now to the real issue, your flying heavy with a 503. The weight and
503, and allowing a back seat passenger were the reason the company
went to the 7 rib wing structure. I am not an engineer but based
upon the comments in that message referenced above I think your fine
as long as you keep the gross weight under 800#. I just wouldn't go
out do any aerobatics, fly it like a Cessna 150.

Having built a Kolb FireFly and a CGS Hawk and comparing their wing
structures, I don't think you have any problem. Unlike the Kolb the
Hawk wing does not use any ribs, instead it uses the forward spar as
its leading edge with shape forming battens that slide into sewn in
pockets between the front and rear (tube) spars to form the curved
shape of the wings upper surface. The bottom surface uses no ribs or
battens relaying on the fabric tension alone between the front and
rear. (The Hawk wing also has the typical wing diagonal
strengthening members.) The Hawk wing is strong and has proven
itself over time. I don't feel the FireStar wing is any weaker.

If you were to rework the wing to the 7 rib configuration based upon
comments from the designer of the Hawk regarding their spar, if you
place a solid aluminum rivet into the vacated rivet holes of the
prior rib locations, that should prevent compression failure of the
spar since the holes are filled. Your other option would be
replacing the spar's. Myself after reviewing the prior post and
comparing the aircraft, I would leave it alone and just fly
it. Don't carry any passenger and don't fly airshow aerobatics. If
your still concerned you might consider buying and installing a BRS,
it would probably be about the same cost you would incur to rebuild
and recover the wings, much less work. It would add another 20-24#.

My conclusion fly it as it is, stay within the gross weight limit of
800# as suggested in the message I referenced above, don't do any
aerobatics, and stay within the never exceed speed, you should be
fine with every day flying, thermals included.
jerb
At 11:21 PM 3/2/2006, you wrote:
[quote]
---


- The Matronics Kolb-List Email Forum -
 

Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:

http://www.matronics.com/Navigator?Kolb-List
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