Major NACA vent screw up....ideas?

[Phil]

I'd add a doubler on the inside of the skin that returns the opening to the proper shape. Then I'd build up the recessed area with microballoons until you get it flush with skin.

[Pat Stewart]

The proper repair is a nickle/dime patch. I think thats what Patrick (flion) was trying to describe. To keep the explanation simple its basically an internal doubler that is larger than your current opening after you square it up. The next step is a piece of skin cut to match the opening and the same thickness as the damaged skin riveted to the internal doubler. After riveting both skins you can cut your duct opening again. The seam can later be filled with micro balloon and sanded for paint.

Piece of cake.

Pat

[Seansull]

Thanks everyone for the great ideas and instruction. I will post a few photos of the finished product very soon.

I really appreciate this group and the wealth of knowledge that is here!

[curtis]

Instead of resin and micro I would recommend using tank sealer to fill any gaps. I work for a large aircraft plant in Wichita, KS and we use ProSeal to seal gaps on panels and fairings on the aircraft after installation. It remains flexible and it is paintable.

[aerhed]

Perfect opportunity to make an access hole. Just tell everyone its for ELT access. Oops, too late you already posted.

[johngoodman]

NACA vents come in different sizes - how about getting a large one? Here is a place to start:

http://secure.chassisshop.com/partlist/6015/

John

[Seansull]

Thanks again for all of the great ideas! You guys are awesome.

I basically took a little bit of everyones advise along with a few of my own and came up with a fix that I think will look just fine. I still need to sand my micro balloons then prime and sand a few times. After that, I am pretty confident that I will be the only that knows this is a fix. Thanks again!

[Bill.Peyton]

Great Job!

[Ironflight]

I've said this many times - the real art of building is knowing how to turn your own mistakes around into a success. Anyone can buy a new part when they mess one up - a true builder can fix most mistakes to established standards. Good job!

Paul