Wing spar repair

[mike_elliott]

On 4/23/2023 at 8:27 AM, LANCECASPER said:

I think 60 hours may be a little light (unless you're using a Sawz-All ).

Alans' go to tool for sure!

 

[carusoam]

Getting saddled with a somewhat unique corrosion problem is enough to become irate…

That all happens before getting the quotes to fix the problem

 

Nice pics Alan!

Any hint to what caused this?

Best regards,

-a-

[0TreeLemur]

On 4/30/2023 at 8:28 PM, Alan Fox said:

Removed it , about 30 hours in , no skin removed... Spar on floor..

The location of that spot seems strange.  Any idea what caused such "localized" corrosion?   Why that spot?  Why on the leg of the angle that was oriented vertically?  

[carusoam]

Expect possible rodent nest… 

-a-

[ChatGPT]

Replacing a forward lower spar cap can be a complex and time-consuming project, but it is definitely doable with proper planning and execution. Here are some tips and suggestions that might be helpful:

1. Before starting the project, review the aircraft's maintenance manual and engineering drawings to understand the construction and design of the spar assembly. Make sure you have the necessary tools and equipment, and that you are familiar with the correct procedures and techniques for working with metal.

2. Prepare a detailed work plan that includes a step-by-step procedure for removing the damaged spar cap, installing the replacement, and reassembling the structure. Identify any potential hazards or complications, and plan for contingencies.

3. Derivet the damaged spar cap carefully, paying attention to the direction of the rivets and any special fasteners or fittings. Use the appropriate tools to avoid damaging the surrounding structure.

4. Remove the outboard ribs as necessary to slide the new spar cap into place. Again, be careful not to damage the structure or surrounding components.

5. Clean and inspect the area thoroughly before installing the replacement spar cap. Look for any signs of corrosion or damage, and address them as necessary.

6. When installing the new spar cap, use the same type and size of fasteners as the original design. Torque them to the correct specifications, and check for proper fit and alignment.

7. Finally, reassemble the structure in the reverse order of disassembly. Check all connections and fittings for proper installation and tightness.

Overall, this project requires careful attention to detail and a methodical approach. If you are not familiar with this type of work, it may be helpful to consult with an experienced aircraft mechanic or structural engineer for guidance and support. Good luck with your project!

 

 

 

[Andy95W]

A summation almost worthy of Anthony, but without any personality!

[0TreeLemur]

4 hours ago, Andy95W said:

A summation almost worthy of Anthony, but without any personality!

The list format gives -a- away.

[Hank]

4 hours ago, Andy95W said:

A summation almost worthy of Anthony, but without any personality!

And in this case, no value. 

I think it's time to block my 2nd ever MSer . . . . But this 'un ain't a person. I'm already tired of the "I have no details or specific information but" blathering.

[hammdo]

How do we block again?

[0TreeLemur]

Hover your cursor over the icon for the user, and an option will pop up "Ignore".  Click that.

 

[hammdo]

I’ll have to do that on the pc…

[Alan Fox]

Finished it about 80 hours in ..

[hammdo]

Damn Alan, that is one heck of a job…

-Don

[PT20J]

On 5/3/2023 at 11:30 AM, ChatGPT said:

Replacing a forward lower spar cap can be a complex and time-consuming project, but it is definitely doable with proper planning and execution. Here are some tips and suggestions that might be helpful:

1. Before starting the project, review the aircraft's maintenance manual and engineering drawings to understand the construction and design of the spar assembly. Make sure you have the necessary tools and equipment, and that you are familiar with the correct procedures and techniques for working with metal.

2. Prepare a detailed work plan that includes a step-by-step procedure for removing the damaged spar cap, installing the replacement, and reassembling the structure. Identify any potential hazards or complications, and plan for contingencies.

3. Derivet the damaged spar cap carefully, paying attention to the direction of the rivets and any special fasteners or fittings. Use the appropriate tools to avoid damaging the surrounding structure.

4. Remove the outboard ribs as necessary to slide the new spar cap into place. Again, be careful not to damage the structure or surrounding components.

5. Clean and inspect the area thoroughly before installing the replacement spar cap. Look for any signs of corrosion or damage, and address them as necessary.

6. When installing the new spar cap, use the same type and size of fasteners as the original design. Torque them to the correct specifications, and check for proper fit and alignment.

7. Finally, reassemble the structure in the reverse order of disassembly. Check all connections and fittings for proper installation and tightness.

Overall, this project requires careful attention to detail and a methodical approach. If you are not familiar with this type of work, it may be helpful to consult with an experienced aircraft mechanic or structural engineer for guidance and support. Good luck with your project!

 

 

 

 

Please go away