RV-7A QuickBuild Wings: Blue film strips cut with boxcutter?

[grayforge]

Hi folks,

I found an issue with my recently purchased QB Wing Kit:
The right wing's bottom inboard skin has pretty deep scratches along both sides of each rivet line as if the builders used a box cutter instead of a smooth soldering iron to remove the protective film along the rivet lines.

Photos are below. A mix of overall shots and closeups. Below the embedded photos are a couple links to full size photos if you want extreme closeups. After jumping to the photos via one of the 2 links, your browser may give you the option to click on the photo to view it at full size.

I haven't contacted Vans yet, but just wanted to ping the folks here to get a feel for what my options are and what to expect from Vans.

Add'l info for those who don't have time to read every post:
These are not 2nd hand wings. These were purchased new. They came without blue film, but it looks like the film was left on during construction (except for strips along rivet lines) and removed sometime before delivery. Also, I've been in touch with Vans and we're looking at a few options. From buffing the scratches out if this doesn't weaken the wings to replacing the panel.

Thanks!
Russ

















One of the good panels:


http://www.grayforge.com/RV7_Scratches/DSC04386_lg.JPG

http://www.grayforge.com/RV7_Scratches/DSC04388_lg.JPG

[jjconstant]

I am by no means an expert so take this FWIW:

I think the key is how deep the cuts are and it looks like it is mostly in the alclad. I think you're absolutely right to check with Vans but my guess is to take some fine sandpaper, and work the lines such that you can't catch a fingernail on it and then feather it out to a gradual meeting of the rest of the surface, then hit it with some primer to prevent corrosion. It will look ugly but be protected and unless you had your heart set on a polished plane, it will disappear with paint prep and paint.

If there are deeper cuts, I would be more concerned.

[Mel]

But to me, that is totally unacceptable. A "scribe line" like that is just asking for failure.

[krw5927]

UNACCEPTABLE!!! If these truly are scratches and not residue from the solder-iron melt line that wipes off, then this is a definitive example of the absolute poorest workmanship. Every one of these is, by definition, a crack. Who knows what effect these defects have on the fatigue life of your wings. And you can forget aiming for polished skins.

Either the community in general is being more diligent in inspecting their quickbuilds as received and reporting defects, or the quickbuild factory is churning out more sub-standard product. Either way, the rate of reported defects on VAF seems to be climbing. Vans needs to hear the message loud and clear that these sorts of basic workmanship issues will not be tolerated. If the subcontracted quickbuild facility cannot get their rear ends in gear, then Vans should find someone who can.

This may sound harsh, but if these were my wings, I'd give Vans one chance to make it right (total replacement) before I sought legal counsel.

[Sid Lambert]

Wow, those look deep! I would surely talk with Vans but I bet the lines will polish out. Just make sure you do around any rivet holes or edges.

[JonJay]

That is a real shame. Certainly get Van's opinion.
My first step would be to determine how deep the scratches are. If you can get your hands on a surface depth guage that has a needle stylis perhaps you can measure into the scratch.
Regardless, the scratches will need to be smoothed out. A 90 deg. die grinder with 3M rotoloc, fine grit (blue) disks, would do the job relatively quickly and you can control the amount of material removed very well.
I suspect that the box knife only penetrated the Alclad layer. That layer is pure aluminum and does not add significanly to the strength of the sheet. It is primarily a corrosion inhibiting layer.
Most airframe repair manuals I have reviewed allow a certian percentage of material loss before a repair is required. 10% is a common number. The bigger concern to me would be the linear nature of the scratch, that is why fairing it in to the surrounding sheet is important to elliminate any stress risers that could develop into a crack. I could only guess at the amount of material needing removal and what affect it may have on the overall strenght and longevity of the wing.
Just one persons opinion. I am sure you will get many more and be able to best determine your next steps.

[Don Jones]

Did this QB wing kit come to you from Van's or did you buy it from someone else? I would be surprised if the QB factory even cuts the blue plastic from the rivet lines. I bet they just remove it all during assembly.

[krw5927]

Originally Posted by Don Jones

Did this QB wing kit come to you from Van's or did you buy it from someone else? I would be surprised if the QB factory even cuts the blue plastic from the rivet lines. I bet they just remove it all during assembly.

Good point - are the bottom wing skins usually attached by the QB factory? Perhaps I ranted too soon

[Bob Axsom]

I would not use those wings no matter who is at fault or what anyone says. If it came to that I would write them off and cut my losses.

Bob Axsom

[RV7Guy]

Don asked the question i was going to ask about whether you bought from Van's or from someone else.

Maybe Joe Blank will see this and comment, but I believe the skins are completely covered with the protective stuff and sent to the QB manufacturer intact and then they cut the areas for riveting.

There has been a discussion on this in the past with the depth limitations for go/no go decisions.

Even if they say they are acceptable, this is a butt load of work to get things smoothed out. I would be worried about potential fatigue failure as well.

Good luck. Please keep us posted.