What to do about this?

[PMcClure]

I had to replace the roll servo on my KFC225. Nothing unusual about that. But after the repair, I found this damage on the wing above the outboard inspection plate. After discussing the damage with the avionic shop that did the work, they agree that they likely did it and are willing to do whatever is needed to make it right. But, how do you fix it and who to do it? At first the idea of just tapping it out would be OK, but after some consideration the concern of paint damage or worse, aluminum cracking could happen. Then we discussed using dry ice to shrink it, but no one has experience doing this. Any suggestions? I don't want to cause a bigger problem by trying to fix a small problem. But can't really come to terms to just live with it. 

PS  - the picture makes it look worse than it really is, but it is noticeable. 

[Ftlausa]

Equally as troubling, is the fact that you had to bring it to their attention, instead of the other way around.  That would really tick me off. 

[bradp]

I'd I were the owner I would involve an independent MSC that has done that type of repair before (Lasar, Top Gun, DMax, Hen Web) and get an estimate. It may come down to how much "surgery" they recommend.  I'm sure m20Doc and Turbo as well as others will give some details as to what replacing a skin would involve.   Regardless the damage should be covered by the shop or their insurance as they see fit.  

Are you planning on selling or is this forever plane?  Does down time or distance from a capable shop matter to you?

[N601RX]

Your plane being newer makes it a harder call, the 1st hanger rash always hurts the most be it a car or plane.  It looks like that is the 2nd skin from the end which is a larger skin.  There are shops who have the experience to replace it and the work will be as good as the factory and there are shops who will make small errors doing the work and the total end result may not much if any better than the dent you currently have.

It could also be supported from the back and worked down until level or very slightly depressed and the a few coats of high build sealer/primer to bring it back up level.

There is also a guy not for from you in Tennessee who uses electromagnetic pulses to remove dents, It is very popular on more expensive planes.  It seems if he could get his machine to the back side it might still work.

It seems to me a reasonable path might be to allow someone to try to work it down level with the understanding if it wasn't to your satisfaction they the plane would be flown to a shop of your choice and have the panel replaced.

[Guest]

I'm not sure how the application of dry ice would work. In any event the metal has been stretched from the inside outward.  If it can't be shrunk, changing the skin would be an option but a drastic one.

Clarence

[Mooneymite]

I was going to recommend Fluxtronics, but apparently they are either no longer doing aluminum repair, or they are operating under a new name.

http://www.fluxtronic.com/

Anyone know if Rob Olsen is still in business with his amazing machine?

 

[Godfather]

6 hours ago, Ftlausa said:

Equally as troubling, is the fact that you had to bring it to their attention, instead of the other way around.  That would really tick me off. 

The end of my wing was damaged (8 inches of paint scraped off by a rolling toolbox) by one of the shops named above.  They did not bring it to my attention and did not agree to cover any of the damage...THAT ticked me off.

[PMcClure]

Yes it sucks, and even more so because the plane is in excellent shape.

I try to give everyone I work with the chance to do the right thing, even if they didn't do it the first time. Usually I am not disappointed.

Thanks for all the suggestions. I plan on calling a Mooney Service Center and asking them for a quote and advice. The avionics shop is looking into it as well and we will then try to agree on next steps. Any other suggestions are welcome. 

 

8 hours ago, N601RX said:

It seems to me a reasonable path might be to allow someone to try to work it down level with the understanding if it wasn't to your satisfaction they the plane would be flown to a shop of your choice and have the panel replaced.

I think this is good advice.

Do you have the contact in Tennessee?

 

[Bob_Belville]

I'd call Don Maxwell in Longview TX. (KGGG) He does a lot of insurance work. Taking it to him would be an easy flight from anywhere in AL or he would pick it up.

[jetdriven]

A paint shop can fix that. Tap it down with a shrinking hammer and a dolly, and make a shallow dent of it, then fill, and repaint the area to match.  Buff the panel the repair disappears. Please have them scan an inspection panel and computer match it, don't settle for the paint codes in the book from 15 years ago, or worse, picking a white from a book  

Replacing the skin is worse than fixing the dent

Edited May 26, 2016 by jetdriven

[MB65E]

Don't replace the skin! Not worth it. You will do more damage, oversize holes, possible oil canning, etc.  I think tapping it out and filling it in would be the best bet. Then maybe see if you can shoot the entire wing? Probably not with that either.  I recently had some paint cracks repaired on an airplane. The Sherman Williams Matty white that blended really nicely. The paint was 5yo and in good shape. Color was perfect. 

If it was mine, I'd hire the most recomended paintless dent repair guy in the area, then polish the scratches. Have the shop pay the bill. Don't get the insurance involved, they might want to replace the entire skin. 

Might ask the shop for a few years of IFR certs. 

-Matt