undoctor(at)rcn.com
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 Posted: Tue May 30, 2006 12:40 pm Post subject: Advice on repairing UltraStar Wing |
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Hi All,
Last fall I spent weeks on my UltraStar, replacing the boom tube with a =
thicker Firestar tube and reconfiguring the nose more like a Firestar. =
I also repainted it to make it snazzy, rather than a boring yellow with =
black metal paint job. Then I folded the wings and tail, and tarped it =
and tied it down for the winter.
We had a few days of very high wind and one morning when I awoke and =
looked out the window I saw my beloved project laying on its right side. =
The wind tore a tie down loose and flipped it, causing damage to the =
right wing. Between all my necessary Spring projects and total =
discouragement I didn't untarp it until Saturday to take some pictures =
and get some advice on how to go about repairing it.
When you sight along the leading edge, which is on top on a US folded, =
you can see a bend in the leading edge tube from the front (inside) of =
the wing to about 7' back - it is about 1 1/2" out of alignment at the =
center of the bend.
I made a 2 X 4 rig of two cross-members cut and padded to fit over the =
folded wings and a 2 X 4 "ridge board" extending between the two =
cross-members to create a drainage rake in the tarp to prevent melted =
snow and rain forming an ice block in between the wings. When the plane =
flipped, the rig managed to strike and bend the trailing edge of the =
aileron and the innermost tube that forms the shape of the wing.
Additionally, where the drilled bolt which fits into the folded wing =
"carrier" is screwed into the wing, it is out of alignment and the =
drilled bolt doesn't slip effortlessly into the carrier.
I didn't build this US, so there is a lot of experience I'm lacking, so =
let me run my thoughts by you, and those of you with experience and =
knowledge can say whether it's good, bad, maybe, or DON'T!!!!!!
To minimize cutting the fabric, I have considered making some cuts along =
the leading edge and clamping a 1 X 3 or 4 with no knots to it to =
prevent the tube from kinking. Then carefully bend this unit past =
straight, loosening the clamps, re-clamping and rebending, etc., until =
the leading edge tube is straight again. The aileron repair I thought =
might work is to splice a new tube to replace the bent section, using =
two short pieces of tubing where the i.d. of the short pieces anchoring =
each end is about equal to the o.d. of the replaced section and slipped =
over the stubs of the bent section and the straight new piece, and =
fastening with rivets or epoxy.
The inside wing end I have considered opening the fabric and seeing =
about just replacing the piece that's bent, or the entire thing, if that =
would be simpler.
As for the receiver for the folding wing drilled bolt, I don't know if =
there would be any structural damaged involved, and may re-shape the =
folded wing "carrier" rather than mess with the wing at that point if =
it's not necessary.
Again, I didn't build this plane and I know that many of you will have =
knowledge, suggestions and cautions I never thought about, so let it =
fly!!
Thanks in advance for your help and advice; most of you I've had =
previous contact with seem to be friendly and respectable folks!! I'm =
attaching a few photos so that what I've written can be more easily =
understood and commented upon.
Dave Kulp
Do not archive
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