RV-9 rear wing spar damage - how to fix?
 

While bucking the rear wing spar and top skin, the bucking bar struck the rear spar at an angle. The impact created a "V" shaped notch which nearly cut through the rear spar :(.

Can this be fixed using a doubler plate?

http://www.flickr.com/photos/25289870@N04/2383939026
http://www.flickr.com/photos/25289870@N04/2383938010
http://www.flickr.com/photos/25289870@N04/2383936862

Pictures
 

You can view the pictures if you right click on the X and then hit properties. copy and paste the URL that appears in the properties box into your browser. You can then select a slide show from flicker to see all 3 pictures.

don't worry - I did something much more stupid and had much worse damage :eek:

I talked to Vans, make a cool doubler angle (not a plate), and now it is fixed, stronger than original, and impossible to detect!

Good Luck!

Looks like it's in the flange not the web. I'd just build on but include a peek at it in the annual inspection.

Best to check w Vans
 

Thinair - -

Although the advice you get here is excellent, this is a situation best remedied with an e-mail to Vans.

A while back, I managed to put a teensy split in a VS spar flange dimple hole. I was worried that I might have to order a do-over HS spar (which already had a few dozen rivets in place). I sent an e-mail to Van's and their solution was pretty simple... I put in a doubler using tank sealant and a blind rivet.

Don't go by what they told me, your situation is different, and there is no such thing as an unimportant spar.

Good luck resolving the spar cracks.

Integrity of the spar....
 

The flange and the web together make up the equivalent of a sort of "I" beam.

The flange is just as important, if not more important, structurally as the web. The center of the web has little load on it, and is often cut away with lightening holes.

The flange is seriously compromised and not fulfilling it's design... definitely call Vans on this one. A doubler angle will probably be the correct solution.

When structural elements are compromised, "build on" is not the correct answer....:rolleyes:

gil A

How close to the wing tip is this damage? The loads on the spar flange are highest near the wing root, and they decrease towards the wing tip.

The advice to talk to Van's is spot on. Their engineers know what strength is required, and can do the analysis to design an adequate repair. Everyone here is just guessing.

I agree I would call vans for a fix everyone here is just guessing

Spar damage
 

Thank you to all that have replied. I have contacted Vans and am waiting for an answer.

The damage is about 5 feet from the inboard end of the spar.

Let us know what Van's says, I am interested to know.