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RV6 Wing - Outboard Leading Edge Repair

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Endeavour

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Need to repair the outboard leading edge. There is a possibility of a proper patch but overall it would be best cosmetically to replace the complete panel. Has anyone done same? Not sure when Van's changed over to pre punched panels (this is an older aircraft), so having the holes match might be an issue. The shaping of the 2024T3 .025 around the leading edge, would anyone have suggestions starting with 4' x 5' sheet? Thank you...
 
I helped someone do this on an aircraft that was before prepunched. You will need to add one or more access panels on the bottom of the wing aft of the spar. Vans has instructions for this. If you have prepunched it might be easier. Certainly doable.
 
You didn't describe the damage on the wing so I don't know if my input will be useful or not. I hit a duck with my RV-6 and had to repair a football-size cave-in in the leading edge. Here is the thread:

https://vansairforce.net/threads/joined-the-bird-strike-club-today.194892/

Page two of that thread has photos of the wood duck, er, buck I made to push out the damage. Hopefully there is something here you can use. Replacing the leading edge is a major job because the new skin has to be drilled to match the existing nutplates on the spar. There are ways to do this but it is tedious and requires great care to make everything line up. Instead of a flat sheet of skin stock you will be far ahead purchasing a pre-bent leading edge skin from Vans along with all the ribs.

Hope you can achieve a good repair!
 
It might depend on where the damage was and how extensive. A picture would help. I’ve damaged the outboard leading edge of a wing out at the tip on two of my four RV builds when I drooped the wing while moving it. I was able to make a small patch, which included doubling the outboard leading edge rib. My planes have always been painted, and after proper body work, the repair was invisible, and still is years later. (My current RV doesn’t have this camouflaged repair)
 
I have seen at least 2 RV's that had repairs made by obtaining a factory Tank skin (cut to required length) and replacing a 1 or 2 rib bay section, joining them the same way the tank is mated to the wing L/E skin. Forming the skin yourself can be done, but its not easy to get the perfect match.
 
fixnflyguy said:
I have seen at least 2 RV's that had repairs made by obtaining a factory Tank skin (cut to required length) and replacing a 1 or 2 rib bay section, joining them the same way the tank is mated to the wing L/E skin. Forming the skin yourself can be done, but its not easy to get the perfect match.
Click to expand...
That is the method I had decided on if replacing skin, would only need one bay for my repair. This would considerably simplify fitting the new skin. Add flanges to the existing ribs and use platenuts on the spar flange.
 
We recently did this repair on a 6a. We removed the wing. With the fuel tank and wing tip removed we drilled out all rivets, replaced 1 damaged rib and purchased a blank skin. Using a vacuum and poly we were able to vacuum form the leading edge with a pipe taped inside to ensure the bend happened in the correct location. We then cut the trailing edge correct, laid IMG_0908.jpegIMG_0682.jpegIMG_0675.jpegIMG_0685.jpegthe old skin on top where not damaged and match drilled the holes. We were able to reach all required rivets with different bucking bars from either end of the skin. See attached pictures.
 
Hi Greg,

That's the exact repair we'd like to accomplish instead of a patch. Those 4 pictures just spelled it out. I'm impressed how the skin was worried around the leading edges of the ribs.

That was very helpful. Thank you all for your suggestions!

Best Regards.
 
Endeavour said:
Need to repair the outboard leading edge. There is a possibility of a proper patch but overall it would be best cosmetically to replace the complete panel. Has anyone done same? Not sure when Van's changed over to pre punched panels (this is an older aircraft), so having the holes match might be an issue. The shaping of the 2024T3 .025 around the leading edge, would anyone have suggestions starting with 4' x 5' sheet? Thank you...
Click to expand...
 
Endeavour said:
Hi Greg,

That's the exact repair we'd like to accomplish instead of a patch. Those 4 pictures just spelled it out. I'm impressed how the skin was worried around the leading edges of the ribs.

That was very helpful. Thank you all for your suggestions!

Best Regards.
Click to expand...
Glad to help. We just flew this one again yesterday. It had been sitting for 8 years since the damage happened to the last owner. Now you just have to find someone with long arms to reach all the rivets!
 
Have you confirmed that the wings were not built with pre-punched skins?
If they were, this is a very simple repair.
 
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