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  #1  
Old 02-23-2021, 08:28 AM
greghughespdx's Avatar
greghughespdx greghughespdx is offline
 
Join Date: Nov 2011
Location: Aurora, OR
Posts: 990
Default Quick Build Kits - Review Announcement

Van's staff has been working the past couple of weeks to review a few reports of surface corrosion being seen on quick build kits received by customers in the second half of 2020. We will be communicating this morning with a specific, defined group of customers who received QB kits from us, where the QB kits were received from the assembler by Van's between this past June and January. The purpose of reaching out to those customers is to ask them to complete a set of assessment steps and report their results (photos and info) to us so we can catalog each kit's results and, if and where needed, help take care of any issues.

Please note that the scope of this review is limited to those kits received by Van's from our QB assembly contractor between June 2020 and January 2021.

Below is the text of our announcement. It's important to us at Van's to deliver a quality product and take care of our customers.

---

Van’s Aircraft is investigating a few reports of potential surface corrosion appearing on the interior aluminum surfaces of specific Quick Build wing and fuselage kits. Kits that are in-scope for this review are those that were assembled by our contract company and delivered to Van’s Aircraft between June 2020 and January 2021. Note that not all kits from this time period are necessarily affected, and the scope of our investigation is intentionally broad at to help ensure sufficient and complete information collection.

As we all know, COVID has resulted in significant impacts on the staffing and timeliness of businesses around the world. While we have worked hard to navigate the difficult business environment and maintain our business as close as possible to pre-COVID operations, these impacts have affected Van’s and our various subcontract business partners. In mid-2020 our Quick Build contract team was forced into a 100% closure for several weeks, and then was significantly limited in terms of staffing due to local COVID regulations.

Our investigation and a series of lab analyses indicate that in cases where surface corrosion is present on these QB assemblies, the cause appears to be the incorrect application of primer combined with the introduction of sweat on the parts’ surfaces during assembly at the contractor’s facility. Van’s temporarily halted Quick Build production in January while the primer application issue was identified, verified, and remediated. In addition, Van’s has examined and is in the process of remediating primer issues found on Quick Build kits that have already been delivered to us and are currently stored at our factory warehouse. This will, of course, take some extra time to complete, but we will ensure first and foremost that the QB kits we ship meet our standards.

As we continue our investigation, we are reaching out directly to customers who received Quick Build kits that could potentially be affected, to assess the delivered kits and ensure they are checked. We will ask each of these customers to complete a survey, in which they will follow specific instructions to briefly examine and photograph certain parts/areas of their Quick Build kits, and then submit that information to Van’s Aircraft for review. In the event a customer’s kit is affected, our staff will work directly with each kit owner to resolve his or her individual needs based on our analysis of that kit. As always, Van’s Aircraft stands by its customers and products, and we’ll do what it takes.

Thank you, as always, for your continued support and understanding!

The Van’s Aircraft Team

https://www.vansaircraft.com/2021/02...ck-build-kits/
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Greg Hughes - Van's Aircraft - VP/COO
Van's web site | Instagram | Facebook
Opinions, information and comments are my own unless stated otherwise. They do not necessarily represent the direction/opinions of my employer.

Building RV-8A since Sept 2014
Dual AFS 5600, Avidyne IFD 440, Whirlwind 74RV, Superior XP IO-360
VAF build thread - Flickr photo album - Project Facebook page
Aurora, OR (EAA Chapter 105)


Last edited by greghughespdx : 02-23-2021 at 09:00 AM.
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  #2  
Old 02-23-2021, 09:34 AM
oaklandaviator oaklandaviator is offline
 
Join Date: Dec 2014
Location: Somerville, Tn and Little Rock, Ar
Posts: 138
Default Corrosion

Thank you for looking into this. Looks like sweat drops that were allowed to get going and then not cleaned prior to applying the anti corrosion treatment. At least that's what it looks like to me.
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  #3  
Old 02-25-2021, 04:50 PM
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bk1bennett bk1bennett is offline
 
Join Date: Nov 2015
Location: Sachse, TX
Posts: 79
Default Unforeseen Delays

I have had RV-14A QB Wings and Fuselage on order since May 2020. Original quote was for delivery in Oct/Nov 2020.

However, Van's has subsequently experienced a COVID-19 outbreak in the QB contract facility in the Philippines, two more outbreaks in the Oregon factory impacting kitting and crating, an ice storm that closed the plant, and now a corrosion problem. Since late January I have not had a projected delivery date. Right now it is looking like a minimum 10-month lead time to get QB RV-14 assemblies for my case.

While all the delays are frustrating and mounting, I am glad that Van's is focused on safety and quality. My hope is that the QB assemblies show up safe and with excellent quality.
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  #4  
Old 03-22-2021, 03:00 PM
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greghughespdx greghughespdx is offline
 
Join Date: Nov 2011
Location: Aurora, OR
Posts: 990
Default Updated informtion

We've posted an update concerning our QB kit primer investigation and the resulting actions we are taking. That update can be found here. The posted information is rather long and detailed, as we wanted to be sure to communicate as fully as we are able.

A quick update on what we reported here the last time: We discovered that Quick Build kits assembled by our contractor between Spring of last year and January of this year may have insufficient primer applied, so we are communicating with customers whose kits were already delivered, as well as customers whose kits remain in our warehouse. When we started investigating this situation, we paused the shipping of QB kits from our warehouse so we could determine what necessary next steps to take.

For customers who already received what were are referring to as "affected" kits, we have provided a set of options for each customer to choose from. We are also offering essentially the same options to those customers for whom we have a kit(s) in our factory warehouse right now. We will be reaching out to each of those customers to determine what they would like to do. Those options are:
  • Take delivery of the affected QB kit, which has primer that is incomplete in coverage and may have some surface corrosion on the aluminum parts, and remediate it themselves (meaning clean any surface corrosion, prime, and treat as appropriate). In this case, Van's will provide the kit owner a $2,000 stipend for each QB kit to cover remediation needs.
  • Decide not to take delivery the affected QB kit, and instead opt to wait for a QB kit that does not have the affected primer (delivery dates TBD).
  • Decide not to take delivery of the QB kit, and instead opt to change the order to a Standard Build kit (Van's refunds the difference in price), and take delivery when a standard kit is available (delivery dates TBD).
Note that our team is working hard to determine timeframes and to forecast when we will be able to have new kits available based on the realities of the situation today, which we cover in the above-linked post. A complex and layered set of circumstances make the process of determining this information rather complicated. While we are not yet able to provide specific timeframes, we will communicate more as soon as we're able to do so.

Our primary intent is to deliver great kits to customers that meet needs and expectations and to communicate accurately and openly with you - including when the information we need to communicate might not be as happy as we'd like it to be. We've always operated our business as thoughtfully and transparently as we can, with the RV kit builder in mind, and so that's what we are working hard to do now.

We truly appreciate the support and continued understanding of the RV community. We have been blessed and encouraged by the recent kind words of support from many out there as we have navigated COVID, wildfires, extreme weather, and a variety of resulting challenges.

Thank you.

greg
__________________
Greg Hughes - Van's Aircraft - VP/COO
Van's web site | Instagram | Facebook
Opinions, information and comments are my own unless stated otherwise. They do not necessarily represent the direction/opinions of my employer.

Building RV-8A since Sept 2014
Dual AFS 5600, Avidyne IFD 440, Whirlwind 74RV, Superior XP IO-360
VAF build thread - Flickr photo album - Project Facebook page
Aurora, OR (EAA Chapter 105)


Last edited by greghughespdx : 03-22-2021 at 03:20 PM.
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  #5  
Old 03-22-2021, 05:51 PM
sellis sellis is offline
 
Join Date: Apr 2020
Location: Shalimar, Fl
Posts: 14
Default

Thanks to everyone at Vans for the detailed communication and hard work to fix this issue. As I am somewhere in the line for delivery of a QB kit, it's good to hear everything that is being done. Could you also let us know the specifics of the new primer that is being used? I was literally about to order SW P60 G2 for empennage parts for consistency with primer on the QB. I'd like to consider using whatever the new stuff is on the QB parts. Thanks!
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  #6  
Old 03-23-2021, 05:50 AM
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bjdecker bjdecker is offline
 
Join Date: Jun 2005
Location: Georgetown, TX
Posts: 797
Default Need more information...

Greg,

Do you think it would be possible to share some photographs of the corrosion and recommended steps for remediation?

Thank you!

B
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Retired Firmware Guy and Airplane Builder

2020 RV-14 QB -- Under construction - Tailcone & Empennage Complete.
2018 RV-7 QB -- Built, Flying
2007 RV-7 QB -- Built, Drowned, Resurrected and flying
1998 RV-8 QB -- Started, Sold
1986 Mooney 205SE
1980 Mooney 231

Aided and abetted building a number of other RV's.
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  #7  
Old 03-23-2021, 06:07 AM
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marchudson marchudson is offline
 
Join Date: Feb 2006
Location: East Texas
Posts: 196
Default corrosion

I commend Vans for their honesty and transparency in dealing with this situation. The quality of all the kits I have ordered in the past have been top notch. My quick build fuselage has been on order for a while but has not yet shipped so it looks like I will have to choose one of the three options listed. It is a bit difficult to make a decision without seeing the extent of the damage caused by the corrosion. There is a big difference between surface corrosion found on the inside of un-supported skin and corrosion between mating surfaces of say the longeron and the skins. One I can easily scuff and re-apply a protective coat, the other...well I would rather not.

If it's only sweat drops, that would be very easy to deal with. Looking forward to hear what others have seen.
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  #8  
Old 03-23-2021, 07:01 AM
KatanaPilot KatanaPilot is offline
 
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Location: Locust Grove, GA
Posts: 700
Default

Is it possible to share how many kits are affected and what the normal production rate is in the Philippines? That would provide a clearer picture as to the extent of the issues and the lead time for new customers going forward.
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Krea Ellis

Locust Grove, GA
DA20-A1 "Princess Amelia" - gone home to Amelia Island
RV-7A Phase 2 (Honored to be Van's "Miss July" 2021)
RV-10 under construction at Synergy Air South
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  #9  
Old 03-23-2021, 12:00 PM
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jrock836 jrock836 is offline
 
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Location: Burleson, Texas
Posts: 298
Default

Quote:
Originally Posted by KatanaPilot View Post
Is it possible to share how many kits are affected and what the normal production rate is in the Philippines? That would provide a clearer picture as to the extent of the issues and the lead time for new customers going forward.
Posted on the Van's website..

"We have adjusted our Quick Build kit lead times for all new QB orders to “one-year-plus,” meaning we cannot yet provide a more specific estimated delivery date, and that our current estimate is more than 12 months."

https://www.vansaircraft.com/2021/03...iation-update/
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Van's RV-12 #120566 - ELSA - N49DD
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If you can walk away from a landing, its a good landing. If you can use the aircraft the next day, its an outstanding landing. Chuck Yeager

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Last edited by jrock836 : 03-23-2021 at 12:04 PM.
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  #10  
Old 03-23-2021, 01:10 PM
KatanaPilot KatanaPilot is offline
 
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Location: Locust Grove, GA
Posts: 700
Default

Yes, I read the announcement on the website, which is why I asked the additional questions.

I know Van's is not Boeing and has no obligation to disclose the extent of the corrosion issue, but having some "numbers" of affected kits and production rates would provide a lot more clarity.
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Locust Grove, GA
DA20-A1 "Princess Amelia" - gone home to Amelia Island
RV-7A Phase 2 (Honored to be Van's "Miss July" 2021)
RV-10 under construction at Synergy Air South
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