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<DIV>Anthony, I'll throw my 2 cents in also, FWIW.</DIV>
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<DIV>I would first try folding back the plastic covering to bare balsa, to about 2 inches past the end of the phenolic. Then I'd find the center of the phenolic socket and scribe a line on the sheeting. Carefully, I would cut a slot just large enough to fit 1/8" balsa sub-spars, spanwise. </DIV>
<DIV> </DIV>
<DIV>The slot would go from the sheeting to the tube depthwise, and extend 2" beyond the end of the socket. Same process top and bottom of panel, to sandwich the phelolic socket.</DIV>
<DIV> </DIV>
<DIV>Then a good spritzing of water in the slot, poly-u expanding glue in the slot touching the socket and foam, med-light glue application of the balsa spars and then insertion into slot. Let it cure for 24 hours, sand well and fill if needed and re-set the plastic film. </DIV>
<DIV> </DIV>
<DIV>You will pick up about 10-15 grams per panel, but beats building a new one. Unless of course, you want to or the old one was crap to begin with. </DIV>
<DIV> </DIV>
<DIV>BTW, when building new panels, this technique works exceptionally well except the work is done on the foam prior to sheeting. I set the phenolic socket and spars in the foam first, sand smooth and then sheet. </DIV>
<DIV> </DIV>
<DIV>MattK</DIV>
<DIV> </DIV>
<DIV>In a message dated 8/11/2006 11:28:15 PM Eastern Standard Time, natpenton@centurytel.net writes:</DIV>
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<DIV><FONT face=Arial size=2>Anthony</FONT></DIV>
<DIV><FONT face=Arial size=2>How far does the socket go into the wing ? I quit using a false rib years ago but my socket , 1", goes in 18 ins. The tube goes in about 16". The simpliest way to stabilize the socket is with spray insulation foam, one injection hole 3/8 ?and one vent hole 1/8 ?. The kind I have used does not attack styrofoam. It is a fast repair and you have not lost anything if it fails for some reason.</FONT></DIV>
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<DIV style="FONT: 10pt arial">----- Original Message ----- </DIV>
<DIV style="BACKGROUND: #e4e4e4; FONT: 10pt arial; font-color: black"><B>From:</B> <A title=mailto:aabdu@sbcglobal.net href="mailto:aabdu@sbcglobal.net">Anthony Abdullah</A> </DIV>
<DIV style="FONT: 10pt arial"><B>To:</B> <A title=mailto:nsrca-discussion@lists.nsrca.org href="mailto:nsrca-discussion@lists.nsrca.org">NSRCA Mailing List</A> </DIV>
<DIV style="FONT: 10pt arial"><B>Sent:</B> Friday, August 11, 2006 3:36 PM</DIV>
<DIV style="FONT: 10pt arial"><B>Subject:</B> Re: [NSRCA-discussion] Wing tube phenolic repair "help"</DIV>
<DIV><BR></DIV>
<DIV>Dean,</DIV>
<DIV>I hadn't thought of that, but wasn't that repair kind of heavy? I think it is hilarious that you covered them in yellow!<BR></DIV>
<DIV>I am fairly certain that I will use the false rib from the bottom technique to fix it. I will take great care to cut a uniform slot where the rib fits in snug, particularly around the phenolic. That should provide lots of surface area to transfer the load to the entire foam core wing panel. </DIV>
<DIV> </DIV>
<DIV>Next question:</DIV>
<DIV>What should I make the rib out of? Would a balsa rib laminated in carbon fiber be strong enough or should I just go with light ply? Of course weight is an issue. </DIV>
<DIV> </DIV>
<DIV>Should I still use Poly glue or would foam safe CA or 30 Minute epoxy be better?</DIV>
<DIV> </DIV>
<DIV>Thanks again for all of your great suggestions.</DIV>
<DIV>Anthony<BR><B><I>Dean Pappas <d.pappas@kodeos.com></I></B> wrote:</DIV>
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<DIV><SPAN class=803282315-11082006><FONT face=Arial color=#0000ff size=2>Hi Verne, Hi Anthony,</FONT></SPAN></DIV>
<DIV><SPAN class=803282315-11082006><FONT face=Arial color=#0000ff size=2>I had to do such a fix maybe 14 years back on a Desire 120.</FONT></SPAN></DIV>
<DIV><SPAN class=803282315-11082006><FONT face=Arial color=#0000ff size=2>The foam started to tear away from the tube, just as you describe.</FONT></SPAN></DIV>
<DIV><SPAN class=803282315-11082006><FONT face=Arial color=#0000ff size=2>I poked a 3/4" diameter hole in both sides of the wing just inboard of the end of the tube.</FONT></SPAN></DIV>
<DIV><SPAN class=803282315-11082006><FONT face=Arial color=#0000ff size=2>Then I took a piece of broomstick, sanded a concave to mate to the tube, and carved and sanded the other end to be flush to the top of the sheeting.</FONT></SPAN></DIV>
<DIV><SPAN class=803282315-11082006><FONT face=Arial color=#0000ff size=2>They went in with epoxy.</FONT></SPAN></DIV>
<DIV><SPAN class=803282315-11082006><FONT face=Arial color=#0000ff size=2>Then a pair of 6" long, by 1-1/2" wide 1/32" plywood scabs were glued to the outside of the sheeting like ribs.</FONT></SPAN></DIV>
<DIV><SPAN class=803282315-11082006><FONT face=Arial color=#0000ff size=2>That way, the tube was supported by a 6" wide swath of sheeting, top and bottom, with the load transferred by the broomstick columns.</FONT></SPAN></DIV>
<DIV><SPAN class=803282315-11082006><FONT face=Arial color=#0000ff size=2>I covered the scabs before gluing, and because I wasn't bashful, I covered them bright yellow which was not present anywhere else on the plane.</FONT></SPAN></DIV>
<DIV><SPAN class=803282315-11082006><FONT face=Arial color=#0000ff size=2>I think it was '92.</FONT></SPAN></DIV>
<DIV><SPAN class=803282315-11082006><FONT face=Arial color=#0000ff size=2>Dean</FONT></SPAN></DIV>
<DIV><SPAN class=803282315-11082006><FONT face=Arial color=#0000ff size=2></FONT></SPAN> </DIV>
<DIV> </DIV>
<DIV><FONT face="Times New Roman">Dean Pappas</FONT> <BR><FONT face="Times New Roman">Sr. Design Engineer</FONT> <BR><FONT face="Times New Roman">Kodeos Communications</FONT> <BR><FONT face="Times New Roman">111 Corporate Blvd.</FONT> <BR><FONT face="Times New Roman">South Plainfield, N.J. 07080</FONT> <BR><FONT face="Times New Roman">(908) 222-7817 phone</FONT> <BR><FONT face="Times New Roman">(908) 222-2392 fax</FONT> <BR><FONT face="Times New Roman">d.pappas@kodeos.com</FONT> </DIV>
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<DIV class=OutlookMessageHeader dir=ltr align=left><FONT face=Tahoma size=2>-----Original Message-----<BR><B>From:</B> nsrca-discussion-bounces@lists.nsrca.org [mailto:nsrca-discussion-bounces@lists.nsrca.org]<B>On Behalf Of </B>Verne Koester<BR><B>Sent:</B> Friday, August 11, 2006 10:33 AM<BR><B>To:</B> NSRCA Mailing List<BR><B>Subject:</B> Re: [NSRCA-discussion] Wing tube phenolic repair "help"<BR><BR></FONT></DIV>
<DIV><FONT face=Arial>Anthony,</FONT></DIV>
<DIV><FONT face=Arial>There should be a false rib near the end of the socket, usually made out of 1/8 lite ply. If there's not one there, you need a new set of wings unless you can figure out a way to put one in there after the fact.</FONT></DIV>
<DIV><FONT face=Arial></FONT> </DIV>
<DIV><FONT face=Arial>Verne</FONT></DIV>
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<DIV style="FONT: 10pt arial">----- Original Message ----- </DIV>
<DIV style="BACKGROUND: #e4e4e4; FONT: 10pt arial; font-color: black"><B>From:</B> <A title=mailto:aabdu@sbcglobal.net href="mailto:aabdu@sbcglobal.net">Anthony Abdullah</A> </DIV>
<DIV style="FONT: 10pt arial"><B>To:</B> <A title=mailto:nsrca-discussion@lists.nsrca.org href="mailto:nsrca-discussion@lists.nsrca.org">NSRCA Mailing List</A> </DIV>
<DIV style="FONT: 10pt arial"><B>Sent:</B> Thursday, August 10, 2006 10:42 PM</DIV>
<DIV style="FONT: 10pt arial"><B>Subject:</B> [NSRCA-discussion] Wing tube phenolic repair "help"</DIV>
<DIV><BR></DIV>
<DIV>I was just about finished setting up my Odyssey when I noticed that the wing seemed a little loose. If I hold the fuselage the right wing panel can wiggle up and down a noticable amount. I thought that maybe the tube mount at the fuse was loose but that was not the case. As it turns out, the phenolic in my completed wing is loose about 3/4 of the way down and is wiggling around. It almost feels like the foam in the sheeted foam core wing has been somehow dislodged and the phenolic is in just a hollow cavern instead of solidly glued to the wing. It is still glued solid at the root so it won't slide out, but it obviously can not be flown in that condition.</DIV>
<DIV> </DIV>
<DIV>Question:</DIV>
<DIV>How do I go about repairing the foam that the phenolic mounts to? The wing is sheeted, covered, and trimmed (complete) and I would like to keep from having to start all over again. Getting out the old one will also be an issue as it is still partially glued in. </DIV>
<DIV> </DIV>
<DIV>I am open to any and all suggestions.</DIV>
<DIV> </DIV>
<DIV>Thanks in advance</DIV>
<DIV>Anthony </DIV></BLOCKQUOTE></BLOCKQUOTE></BLOCKQUOTE></BLOCKQUOTE></BLOCKQUOTE></DIV>
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