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Sneaky Wind - Kolb Damage Report

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WhiskeyVictor36(at)AOL.CO
Guest

Posted: Fri Apr 07, 2006 9:03 pm Post subject: Sneaky Wind - Kolb Damage Report

Alan Mancus, the owner of the Original Kolb FireStar that was turned  over 

onto it's back by the wind, while parked, has decided to rebuild it.   Today we 

did a complete survey of the damage.

 

WINGS and AILERONS:

Alan was at first reluctant to cut the fabric from the wings, thinking  he 

may be able to do the repair and just patch up any access holes.  But  after 

talking to him about possible internal hidden damage, he finally did get  out his 

knife and remove the fabric.

 

We had already cut a couple of holes to look inside, but it was hard to see  

the damage we then found with all the fabric off.  When the wings hit the  

ground inverted, the force caused the leading edge tube spars to push on  the 

ribs.  There are two diagonals in the front portion of the rib.   The longest 

one, that goes from the top center of the rib to the bottom of the  flange on the 

main spar was bent out of column and the flange was also bent  where the 

diagonal attached.  The rivets held tight.  All but  two ribs, in both wings, were 

damaged identically.  Also, the leading  and trailing spars of the wings and 

ailerons were bent.  On one wing,  the trailing spar and aileron leading spar 

were minimally bent and we were  able to straighten them.  But all of the 

others will be replaced.   Some of the wing tip bow support tubing was also bent 

slightly.  Most will  be replaced.  The bow tube itself was not bent.  The 

right  aileron will have to be rebuilt as both leading and trailing spars were  

bent.  The left aileron will need a new trailing spar only plus a rib or  two.

 

TAIL FEATHERS:

The rudder and one elevator will have to be rebuilt as they were severely  

bent and a couple of ribs broken.

 

BOOM TUBE:

Completely bent and twisted to the point of almost broken in two at the aft  

end of the 'H' section, were the big bolt holds it to the cage.  Will be  

replaced.  The 'H' section is bent.  Possibly can straighten it, but  then would 

have to weld all the rivet holes shut in order to install in new boom  tube.  

Unless someone has an idea on how to match drill the existing  holes.

 

FUSELAGE CAGE:

Saved.  No damage to it except for a few scratches on the Lexan  windshield.  

He had just spent 6 months or more rebuilding the cage with a  new nose cone, 

fabric and Lexan windshield, so was fortunate there.

 

COVERING and PAINTING:

Almost all surfaces will be redone.  This will probably be the most  

expensive part of the rebuild.

 

It will be a lot of work.  Drilling out the old rivets will be the  worst 

problem.  Some come out easily, some with great difficulty,  especially those 

stainless steel ones.  If the rivet spins during drilling,  it can cause the hole 

to become enlarged, but Alan has discovered that if  you just drill the head 

off, then punch the rest of the rivet through into the  tube, or whatever its 

in, it won't enlarge the hole.  If it does, we found  a source for 5/32" 

rivets that will fill the gap.  



Bill  Varnes

Original Kolb FireStar

Audubon NJ

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Eugene Zimmerman

Joined: 10 Jan 2006
Posts: 392

Posted: Sat Apr 08, 2006 4:59 am Post subject: Sneaky Wind - Kolb Damage Report

On Apr 8, 2006, at 1:00 AM, WhiskeyVictor36(at)aol.com wrote:



 	  Quote: 	
		   The 'H' section is bent.  Possibly can straighten it, but  then would

 have to weld all the rivet holes shut in order to install in new  

 boom  tube.

 Unless someone has an idea on how to match drill the existing  holes.


	


Bill,

It is possible to match all the holes. Just drill all the rivets out  

and remove the H section.



Then take a large piece of paper and wrap it around the tube snugly  

and tape it together securely to form a paper tube. Secure  this  

paper tube with tape in place where the rivet holes are then  

carefully drill or punch the holes in the paper.



Carefully remove this paper tube "pattern" from the old fuse tube by  

sliding it off the tube away from the bent and distorted end. Slide  

this pattern on to the new  tube, making sure it is oriented exactly  

the same as on the old one.  Center punch the holes and drill one  

hole each end of the line of holes. Use these holes to realign the H  

section in place in the new tube.  Then drill and rivet the remaining  

holes.



It is helpful to use paper that is large enough to extent 4 to 6  

inches past the line  of rivets to form a  slight " bell end" into  

the paper pattern you want to slide on to the new tube.



Gene

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Richard Pike

Joined: 09 Jan 2006
Posts: 1671
Location: Blountville, Tennessee

Posted: Sat Apr 08, 2006 4:59 am Post subject: Sneaky Wind - Kolb Damage Report

For match drilling the holes, you might try this:

Take just the section of boom where the old holes are at and cut if off 

from the rest of the boom tube. Now cut it in half vertically. Verify 

that all the holes line up with the straightened H section. Lay each 

half on either side of the new tube with an equal gap top and bottom 

between the two pieces. Make sure they lay snug and flush.  Giant hose 

clamps would be good. Drill just the four end holes, slide the H section 

in and see if they line up enough to cleco the tube to the H section. If 

they do, proceed. If they don't, you are only out four holes, which 

would probably still work with a new H section.



Richard Pike

MKIII N420P (420ldPoops)



WhiskeyVictor36(at)aol.com wrote:

 	  Quote: 	
		   



 Alan Mancus, the owner of the Original Kolb FireStar that was turned  over 

 onto it's back by the wind, while parked, has decided to rebuild it.   Today we 

 did a complete survey of the damage.

   

<snip>
	


 	  Quote: 	
		    

 BOOM TUBE:

 Completely bent and twisted to the point of almost broken in two at the aft  

 end of the 'H' section, were the big bolt holds it to the cage.  Will be  

 replaced.  The 'H' section is bent.  Possibly can straighten it, but  then would 

 have to weld all the rivet holes shut in order to install in new boom  tube.  

 Unless someone has an idea on how to match drill the existing  holes.

 <snip>

 Bill  Varnes

 Original Kolb FireStar

 Audubon NJ

 Do Not  Archive

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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.

Richard Pike

Joined: 09 Jan 2006
Posts: 1671
Location: Blountville, Tennessee

Posted: Sat Apr 08, 2006 5:17 am Post subject: Sneaky Wind - Kolb Damage Report

Boy, I wish I'd read this before I posted my idea 5 minutes ago. I like 

yours better.

Richard Pike

MKIII N420P (420ldPoops)

Eugene Zimmerman wrote:

 	  Quote: 	

 On Apr 8, 2006, at 1:00 AM, WhiskeyVictor36(at)aol.com wrote:

> The 'H' section is bent.  Possibly can straighten it, but  then would

> have to weld all the rivet holes shut in order to install in new  

> boom  tube.

> Unless someone has an idea on how to match drill the existing  holes.

>     

 Bill,

 It is possible to match all the holes. Just drill all the rivets out  

 and remove the H section.

 Then take a large piece of paper and wrap it around the tube snugly  

 and tape it together securely to form a paper tube. Secure  this  

 paper tube with tape in place where the rivet holes are then  

 carefully drill or punch the holes in the paper.

 Carefully remove this paper tube "pattern" from the old fuse tube by  

 sliding it off the tube away from the bent and distorted end. Slide  

 this pattern on to the new  tube, making sure it is oriented exactly  

 the same as on the old one.  Center punch the holes and drill one  

 hole each end of the line of holes. Use these holes to realign the H  

 section in place in the new tube.  Then drill and rivet the remaining  

 holes.

 It is helpful to use paper that is large enough to extent 4 to 6  

 inches past the line  of rivets to form a  slight " bell end" into  

 the paper pattern you want to slide on to the new tube.

 Gene

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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.

Eugene Zimmerman

Joined: 10 Jan 2006
Posts: 392

Posted: Sat Apr 08, 2006 6:50 am Post subject: Sneaky Wind - Kolb Damage Report

Hello Pastor Pike,



  Have you experienced damage from any of the storms that hit your  

state or ,,,,,,, "is the living God, is thy God, whom thou servest  

continually, able to deliver thee from the lions?"



Gene



On Apr 8, 2006, at 9:16 AM, Richard Pike wrote:



 	  Quote: 	
		   



 Boy, I wish I'd read this before I posted my idea 5 minutes ago. I  

 like

 yours better.



 Richard Pike

 MKIII N420P (420ldPoops)

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Richard Pike

Joined: 09 Jan 2006
Posts: 1671
Location: Blountville, Tennessee

Posted: Sat Apr 08, 2006 11:51 am Post subject: Sneaky Wind - Kolb Damage Report

Since Hebrews 11:32-34 is still true, we did well.

Thanks,

Richard Pike

MKIII N420P (420ldPoops)



Eugene Zimmerman wrote:

 	  Quote: 	
		   



    Hello Pastor Pike,



   Have you experienced damage from any of the storms that hit your  

 state or ,,,,,,, "is the living God, is thy God, whom thou servest  

 continually, able to deliver thee from the lions?"



 Gene

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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.

WhiskeyVictor36(at)aol.co
Guest

Posted: Sat Apr 08, 2006 6:22 pm Post subject: Sneaky Wind - Kolb Damage Report

In a message dated 4/8/2006 9:00:17 A.M. Eastern Standard Time,  

richard(at)bcchapel.org writes:



For  match drilling the holes, you might try this:

Take just the section of boom  where the old holes are at and cut if off 

from the rest of the boom tube.  Now cut it in half vertically. Verify 

that all the holes line up with the  straightened H section. Lay each 

half on either side of the new tube with  an equal gap top and bottom 

between the two  pieces.

 

Richard,

 

Another good idea to try.  Boy, one question got a lot of good  responses.

 

Thanks,  



Bill  Varnes

Original Kolb FireStar

Audubon NJ

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WhiskeyVictor36(at)aol.co
Guest

Posted: Sat Apr 08, 2006 6:22 pm Post subject: Sneaky Wind - Kolb Damage Report

In a message dated 4/8/2006 9:00:14 A.M. Eastern Standard Time,  

etzim62(at)earthlink.net writes:



It is  possible to match all the holes. Just drill all the rivets out  

and  remove the H section.



Then take a large piece of paper and wrap it  around the tube snugly  

and tape it together securely to form a paper  tube. Secure  this  

paper tube with tape in place where the  rivet holes are then  

carefully drill or punch the holes in the  paper.



Gene,

 

Thanks for that idea.  The boom tube is bent somewhat in that area, so  not 

sure if the paper would give an accurate location on the new straight  tube.  

But its an idea to consider and try.

 

Thanks,  



Bill  Varnes

Original Kolb FireStar

Audubon NJ

Do Not  Archive

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