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Kurt Haller RV-9A
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Date: 12-25-2017
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Number of Hours: 8.00
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Manual Reference:
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Brief Description: Split wing tips rejoined
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I made a second W-930 aileron tool from scrap 063 Alclad, so I could rejoin both wingtip trailing edges at the same time. I sandwiched the split tips between freshly bought HW store 1/8 Al angle clamped to the TE of the fixtured ailerons, then drilled 5 1/8" holes along the tip TE for 1/8 clecoes to provide direct clamping pressure on the tips. See images 1 and 2.
As anticipated, I decided to cut a spanwise slot in the bottom half of the left wingtip, starting at the join line and extending a couple inches inboard, so the stiffness from the curve of the outer edge was relieved. On the right wing tip, slots in the upper and lower halves were required.
I sanded the inisde of the trailing edges with 60 grit, buttered both sides with plenty of flox, and put in clecos that were sprayed with LPS lube so they would release after the flox cured.
I remounted the tips on their respective wings with 6-32 screws and set the Al angle "splints" back in place. The edges will remain open until the TE cures. I looks like the edges can be pinched together, but we'll have to see whether that affects alignment. I'm going to layup several plys on the inside of the split in any case--if the split needs to remain open, I can simply fill it in.
NOTE: The tips were cured as of next afternoon of 12/26. (Temps a little warmer for Xmas). With the splints off and clecos out, the tips remained aligned with the ailerons. I laid out rivet hole locations on the left and right wingtipTE ribs and drilled #40. I located the aft edge of the rib the same distance from the aileron TE's on both the left and right tips. (The rib could be inserted closer to the aileron TE on one side due to the different distortion in the left vs. right tip. I sanded down the gel coat as necessary to locate the aft few holes with a strong back light and drilled the 'glas #40. I'll finish drilling with the tips off the wings, match drilling from the ribs to the wingtips' outsides.
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