Wing repair- crashed Boxfly 20

[Frank v B]

This plane lost signal on the base leg and went in from about 50'.  No control at all.
The landing gear bent back and caused the major break.  Clumps of soil broke the other leading edge portion and forward wing spar.

Steps:
1) Open up the damaged areas: I cut through the covering of the obviously damaged area- Essentially 3 rib bays.
2) Figure out the best way to do a strong repair.  Decided to open up all the bays between the two damaged areas.
3) Secure the existing covering. All areas cut open left about 1/4" of extra covering.  This was heated and secured against the ribs, leading edge or spar.
4) Make two false ribs and glue them against the good ribs on either end of the open area.
5) Add the replacement spar and leading edge.  One was re-glued, one will be new.

Photos:
15- at the start.  The wheel bent back and crunched the leading edge and sheeting.
17- opening up the obvious damage.
19- decided to fix the bays in between.  Fewer joints.
20- false ribs at the left and right end before gluing them in place.
21- false ribs and new spar in place.
22- the false rib gets trimmed after the glue dries.  One quick swipe with an X-Acto blade.

Next- add:
- the missing leading edge,
- trim the false ribs
- add covering

Total repair time so far about an hour.

Frank

[Frank v B]

Patching the wing:

-82- balsa patch on the top of the wing.
-83- balsa patch on the bottom of the wing
-84- one leading edge on a rib was crushed.  Drew the outline of the rib with a pencil on a piece of balsa.
-85- the outline on the new leading edge.
-88- new leading edge clamped onto the crushed rib.

Next step- covering.

Frank