Bent elevator spar

[jcarne]

Good day gents, in my infinite dumb-assery I managed to accidentally bent my elevator spar flange a bit. I have an email into Van's on this one but I was wondering what you guys thought on whether I should replace the spar or just bend it back into place. It looks to me that the top flange is bent but I don't believe the main web of the spar is bent, the bottom flange also looks as though it didn't really get bent either. Thanks!

[Scremm]

A good opportunity to "counter-flute"! Counter-fluting may not be the best method but that looks like a quick and simple fix.

[David Paule]

I'd try to bend it back into place, but unless you can get rid of any, and I mean any out-of-planeness, the spar probably should be replaced. Or it can perhaps be doubled there by adding a doubler.

Either way, this is a critical structural issue and you should contact Van's support.

The aspect that makes it important is that when the spar cap is loaded in bending, the flange is in compression and any deviation from straightness is a potential location for local buckling. Local buckling of a spar cap is a failure mode.

Dave
RV-3B, now on the fuselage

[Pmerems]

From the photo it looks like it could be bent back into position without issue. However as others have mentioned, get feedback from Vans.

[wirejock]

Originally Posted by David Paule

I'd try to bend it back into place, but unless you can get rid of any, and I mean any out-of-planeness, the spar probably should be replaced. Or it can perhaps be doubled there by adding a doubler.

Either way, this is a critical structural issue and you should contact Van's support.

The aspect that makes it important is that when th spar cap is loaded in bending, the flange is in compression and any deviation from straightness is a potential location for local buckling. Local buckling of a spar cap is a failure mode.

Dave
RV-3B, now on the fuselage

I wouldn't even consider it. Replace it. It's not installed yet so a swap is easy.

[jcarne]

Thanks for the replies guys, I'm pretty keen on replacing it myself even though I'm torqued about it. I don't mind paying the $20 bucks to Van's it's the $31 dollars to UPS that I'm not happy about. This will be the third time I will have to ship a spar and it's getting old, I wish my mistakes were on tiny doublers! haha I'm also curious if Van's will say to add a doubler as one of you mentioned, I have seen them do that before when I thought they wouldn't. I'll keep you posted.

[TS Flightlines]

Jereme--
Take a deep breath. Relax. I assure you that it wont be the first pieces you'll have to replace. Everyone does it at least once, some of us more than that

Tom

[wirejock]

Originally Posted by jcarne

...
I don't mind paying the $20 bucks to Van's it's the $31 dollars to UPS that I'm not happy about...

Order snail mail. There's always something to do while you wait.

[Lemmingman]

Originally Posted by TS Flightlines

Jereme--
Take a deep breath. Relax. I assure you that it wont be the first pieces you'll have to replace. Everyone does it at least once, some of us more than that

Tom

I stopped looking at my pile of mistakes with shame and started looking at them as lab experiments that led to the proper outcome. I will be ordering angle today that I need more of. I am sure that the last thing I ever do on this build, before flying, will be waiting for USPS to deliver a replacement for something I goofed up on.

[JonJay]

Try bending it back with hand seamers, avoiding the edges of the dimpled hole. If you can get it close, take your squeezers and redimple the hole. The dimple die will reform the area around the hole. As an experienced sheet metal guy, I would have that fixed in about two minutes. If you mess it up further trying to fix it, you will have learned a bit more and then you can order a new part.
This really isn't that bad and is easily fixable in my opinion.