Flap Repair Help

[mfleming]

Back on March 14th I put up a post about dropping my wing in the shop

The aileron has been fixed and I kicked the can down the road on the lower wing skins and end rib.

Talking to Van's tech support, they said re-skinning the flap is doable but take a crack at fixing it first as I have nothing to loose.

I thought I would canvas the best minds in the RV game to see how you would approach this repair.

Here's three photos of the damage.

[cderk]

When I messed up my fuel tank, I bought one of these sets... its a must for doing any kind of metal work. Based on what you’re showing, I’d get one of these sets and then go to a hardware store and buy a piece of bar stock to put on the inside to hammer against.

As an alternative, I’d take them to a local EAA chapter meeting. I imagine that there’d be someone there with metalworking expertise...

https://www.eastwood.com/7-pc-econom...caAuRtEALw_wcB

My $0.02

[mfleming]

Originally Posted by cderk

When I messed up my fuel tank, I bought one of these sets... its a must for doing any kind of metal work. Based on what you?re showing, I?d get one of these sets and then go to a hardware store and buy a piece of bar stock to put on the inside to hammer against.

As an alternative, I?d take them to a local EAA chapter meeting. I imagine that there?d be someone there with metalworking expertise...

https://www.eastwood.com/7-pc-econom...caAuRtEALw_wcB

My $0.02

Good idea on the body/fender tools...a friend has a set i could borrow. Unfortunately the closest EAA chapter with that kind of expertise is 8 hours away

[wirejock]

I think the best success will come if you drill the skin off. That way you have full access to both inside and out. If you don't succeed, just buy a new skin and replace it.

[mfleming]

Originally Posted by wirejock

I think the best success will come if you drill the skin off. That way you have full access to both inside and out. If you don't succeed, just buy a new skin and replace it.

If I have to drill the skin off, I'll fit a new skin. I'm contemplating drilling out some of the top skin to bottom skin rivets for access, then resemble with MK-319-BS pull rivets.

I'm reassembling my old flap stand to make it easier to hold the flap steady when I attempt to knock the dent out.

[David Paule]

You might try taking it to a good, repeat good, auto body shop and asking the manager to put his best sheet metal guy to work fixing it. A good bump artist can work wonders. That's what I did when I was unable to work out a dent I'd put in one of the aft fuselage skins on my project, and when I got it back, there was no sign of a flaw.

They have the tools and the know-how, and are worth whatever they ask. Generally it's modest by airplane standards.

Dave

[mfleming]

Originally Posted by David Paule

You might try taking it to a good, repeat good, auto body shop and asking the manager to put his best sheet metal guy to work fixing it. A good bump artist can work wonders. That's what I did when I was unable to work out a dent I'd put in one of the aft fuselage skins on my project, and when I got it back, there was no sign of a flaw.

They have the tools and the know-how, and are worth whatever they ask. Generally it's modest by airplane standards.

Dave

Interesting thought. Might have to wait for this Covid19 pandemic to get over before enlisting outside help

[Maxrate]

Michael, your second picture shows that the damage can be worked out fairly easy if you drilled out the rivet on the end rib and removed it. Then use some wedge shaped dollies/bucking bars and a flat faced hammer to bring back to its original shape. Then just re-rivet the end rib back in place. Follow it up with a small amount of filler if necessary for a smooth appearance.

[DaveO]

I too have made some damage when I was building. I think you can fix it. Give it a try!
Just as you have embarked on a building project, a little body building experience will make you the better.

[JonJay]

I agree that end rib needs to come out. The impact dented the trailing edge and then pushed the skin askew. The skin loaded on that first rivet and the force creased and buckled the skin. Getting the crease out will be the bigger challenge. You have to relieve the stress at that rivet and get room to back it with a bucking bar of some sort. My only concern about the trailing edge is the potential for cracking. 2024 T3 gives you one or two shots before fatigue. Go slow and don?t over work.
As you look at the repair attempt, think about the sequence of events as the flap hit the floor. Try to repair in the same sequence in reverse. Work the crease and buckled top skin and flatten that part of the skin, then progress to the trailing edge. The skin should then start to lay flat as the trailing edge comes into shape.
Have fun. You have nothing to lose. Working metal is both science and black art. Experience is the only teacher.