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Repairing damaged UltraStar wing

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undoctor(at)rcn.com
Guest

Posted: Tue Feb 07, 2006 8:22 am Post subject: Repairing damaged UltraStar wing

Hello Kolb builders,



A couple of weeks ago I posted a general question about repairing a damaged wing from a wind storm breaking a tiedown and flipping the plane on its side.  I appreciate the emails I got, but now that I can talk about it without crying, I'd like some response from you pros who have built Kolbs to a specific question.



There are three points of damage, the trailing edge of the aileron between two of the ribs, the device inside the wing where the bolt used to hold the folded wing screws into is bent from the impact and the bolt is about 15 degrees off, and the tube which forms the cross section shape of the inboard end of the wing has a bend.  My specific question is: from your experience and knowledge, which is 100% more than mine, is it feasible to make a cut in the fabric just large enough to make the repair and then glue and shrink a patch?  Or will it be necessary to uncover the entire wing, make the repairs and completely recover it again? 



I sure would appreciate any insight those who have experience with the covering aspect of my US.  I can take some pics and email them to you if ift would help to make a more accurate recommendation.



Thanks in advance for your help.



Dave Kulp

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ElleryWeld(at)aol.com
Guest

Posted: Tue Feb 07, 2006 8:28 am Post subject: Repairing damaged UltraStar wing

Dave what kind of paint is on your plane? Aerothane or Poly Tone it will make 

a difference on how you will go about your repairs and pictures would be of 

some help



                                               Ellery



do not archive

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Richard Pike

Joined: 09 Jan 2006
Posts: 1669
Location: Blountville, Tennessee

Posted: Tue Feb 07, 2006 8:54 am Post subject: Repairing damaged UltraStar wing

If the damage is fairly localized, it is almost always feasible to cut 

off a small amount of fabric and do a localized repair. Depending on 

what sort of finish was used, it can get a bit complicated, but getting 

the new finish to adhere to the old is usually not that big a deal, at 

worst you might not be totally satisfied with the cosmetics. If you know 

what finish was used, that would help. If you don't know, then call Jim 

or Dondi Miller and ask them for advice, I could give you my opinion, 

but why not ask a professional?  The only real question is if it will be 

easy, or a bit of a nuisance.



Several years ago, I had a situation where the fabric shrinking on my 

J-6 caused the lightweight built-up wood ribs to buckle just ahead of 

the trailing edge. Upon the advice of an A&P, I cut off the trailing 

edge fabric within about 6" of the trailing edge, cut a bit of the rib 

stitching loose along the aft part of the rib, and lifted a couple 

inches of  the fabric forward along the ribs, top and bottom. Repaired 

and reinforced the ribs, and then pulled the fabric back down, 

overlapped new fabric over the old, and bonded the finishes together. 

Since I was using Randolph, they bonded very well. Reattached and shrunk 

the repair and with a couple extra coats of silver, and lots of 

sanding,  it was almost un noticeable. That was twenty years ago, and it 

is still holding up.



Richard Pike

MKIII N420P (420ldPoops)



David Kulp wrote:

 	  Quote: 	
		   



 Hello Kolb builders,



 A couple of weeks ago I posted a general question about repairing a damaged wing from a wind storm breaking a tiedown and flipping the plane on its side.  I appreciate the emails I got, but now that I can talk about it without crying, I'd like some response from you pros who have built Kolbs to a specific question.



 There are three points of damage, the trailing edge of the aileron between two of the ribs, the device inside the wing where the bolt used to hold the folded wing screws into is bent from the impact and the bolt is about 15 degrees off, and the tube which forms the cross section shape of the inboard end of the wing has a bend.  My specific question is: from your experience and knowledge, which is 100% more than mine, is it feasible to make a cut in the fabric just large enough to make the repair and then glue and shrink a patch?  Or will it be necessary to uncover the entire wing, make the repairs and completely recover it again? 



 I sure would appreciate any insight those who have experience with the covering aspect of my US.  I can take some pics and email them to you if ift would help to make a more accurate recommendation.



 Thanks in advance for your help.



 Dave Kulp

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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.

slyck(at)frontiernet.net
Guest

Posted: Tue Feb 07, 2006 9:38 am Post subject: Repairing damaged UltraStar wing

Brother Pike has good info.  It all comes down to cosmetics, ambition, 

and $$$$.

If the existing cover is in good shape and you want to fly instead of 

polish...

(that's making shiny, brother Swiderski)  patching is nearly always 

feasible.

If the existing paint is ultra thick then you may want to do some 

stripping in the

overlap area before you cut the fabric.  Otherwise some sandpaper to 

rough up the

glue area will suffice.   Since the ends are not overlapping you will 

need at least

3 inch tape or cut a wider strip from a piece of dacron.



I did my new left wing cover using only 2" tape.  Since there is an 

overlap of the

basic cover the 3" stuff isn't required.  -hey, we are still subsonic!

Happy sniffing, BB

On 7, Feb 2006, at 11:21 AM, David Kulp wrote:



 	  Quote: 	
		   



 Hello Kolb builders,



 Dave Kulp

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