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Kurt Haller RV-9A
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Date:  12-16-2017
Number of Hours:  6.10
Manual Reference:  
Brief Description:  Undoing right tip overtrim; splitting left tip tra

Brought the cured left tip back from home. Sanded the inside edges at the rear of the right tip where I got happy with the trimming, preparing the surface for a scarf joint. I applied packing tape and mold release wax onto two scrap pcs of 0.063 Alclad, then blue taped them to the outside of the tip, overhanging the areas that needed to be untrimmed. Laid up 3x 3" wide strips of heavy glass cloth and topped with peel ply. Also put 3x layers of cloth on the inside where I had drilled holes in the light cutout that aren't needed anymore, and did likewise for the left wingtip. Right tip was put in the truck to bring home to cure.

Carefully installed the left tip with #6 cad-steel screws. The left tip had more distortion than the right. It took quite a bit of carefull screw-driving to get the tip on with no hopelessly cammed-out screws. (Several screws started cam-out along the way, and were tossed. A #6 screw is cheap--removing a stripped or broken screw would be a nightmare!) Only one nutplate was off enough that I couldn't get it started. but after running a tap through, I could get the screw in and it snugged up fine--just need to remember some loctite on that "easy" screw.

With all screws snugged, used the W-930 fixture to put the aileron in the neutral position. The trailing edge of the tip was about an inch lower than the neutral aileron, and the outboard trailing edge even lower than that. So I used the Dremel and vibrating saw to split the TE, and opened the side all the way down to the light cutout. An angle clamped to the aileron and then to the tip will straighten things out, but there's a lot of tension coming from the bottom side. May need to cut out the curve to make the surface floppier? Time to go home and sleep on it before gluing anything!!!
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Untrimming the right wing tip.

Untrimming the right wing tip.

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End view of split and straightened tip

End view of split and straightened tip

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Al angle pushes the low TE up

Al angle pushes the low TE up

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