Repair Leading Edge Wing Perforation?

[Kojo]

While closing the last bay of of the bottom skin of the wing while in its cradle the bucking bar fell (fatigue) through the holes in the spar and perforated the leading edge as seen in the pictures.

Defect was "drilled out" finally with a unit to 3/4 inch diameter. After exploring repair options I have come up with the doubler shown however I battling with a filler.

No response from vans support despite two attempts. Friend has subsisted "Bondo" I thought some fiberglass resin. Does anyone have a reliable suggestion or resource that addresses this specific problem. A 3/4" diameter aluminum 2024-T3 filler will buckle if attempting to rivet to this doubler. Any suggestions would be appreciated.

[Kyle Boatright]

I'd drill out the hole (looks like you already have), mount the doubler, and proseal the filler plug in place. Then do whatever sand/fill exercise you need to make the repair disappear from a cosmetic perspective.

[cvairwerks]

Roll a section the same size as your backing plate to fit the contour then cut the section out to use as a filler. Bond with some appropriate adhesive with the backing plate cleco'd in place. Don't forget to lube the area a little to act as a release agent. Pop the patch out, clean everything up and then use a pattern of AN507 screws with AN365 nuts to reinfoce the adhesion. Use 4-40 screws. Probably too hard to find a small quantity of locknuts for 2-56 screws.

[rockwoodrv9]

One thing I learned when installing access panels on the foreskin of my 9 is you can not use the flange going under the skin to mark the holes you drill on the top. They will be slightly off. Im sure you know that but I didnt think the thin aluminum would make that much of a difference but I was wrong.

As for patching the hole after the plate is mounted, I would try jb weld original or Marine. It is harder than bondo. You could mix some epoxy to mostly fill it and top off with bondo or other filler.

This assumes you will install the patch on the inside of the wing.

Good luck on the fix.

[rmarshall234]

Looks like a great place for a pitot tube, or AOA, or stall horn vane, or….

[erich weaver]

I can’t quite follow post #3 but I think my suggestion is similar:

Form two smaller pieces that can be slipped into your hole to form a backing plate so that you can then fill the remaining indent with a filler to make it flush. Your hole may be small enough that proseal alone may be enough to attach the two halves of the backing plate, but best to check with Vans on that. They may want rivets to minimize the chance of subsequent tearing of the skin depending on the size of the hole

[wcalvert]

Any chance this doubler could be attached to the back of the leading edge, inside the wing and a filler piece installed in the existing 3/4" hole? .. bonded in like an inlay?

That patch is going to be pretty unsightly. Maybe step back and think thru it all before you press on with armor plating!

You might also refer to AC43 for specifications on doubler riveting callouts.

Good luck

[Carr]

Would a Duckworks landing light kit fit in where the hole is?

Carr

[gasman]

Your doubler (backup) is way too big. The rivet spacing is too wide, and the shape is wrong for a round patch....

Please reference AC 43.13-1B for round repairs when stress direction is unknown or neutral.....

This is really a question for Van's, for proper repair.

[bruceh]

Yes, refer to AC43-13 for sheet metal repairs. However, in this case, I would seriously consider a new skin since you are under construction.