I think I spent about 8 hours yesterday after dinging the AW Ultimate, and another 12 hours today fixing all the mess I created with my deadstick landing "under" the wheeled irrigation pipes. So here are some pics of today's progress. I final sanded the fin and rudder, located new Robart pin hinges, covered the fin and rudder with spare Oracover, then epoxied the hinges, joining the rudder and fin. I CA'd a couple larger pieces of balsa back into the cockpit backplate, filled cracks and holes with Model Magic, sanded, and painted the backplate flat black. It used to be speckled grey like the cockpit floor. Using blue Oracover, I covered over the area right behind the canopy that had been burnished hard by the pipe. I heat gunned any wrinkles out before laying down the new blue. Let's see, I added some thin fiberglass cloth on the inside and outside BLUE edges of the rear part of the canopy that got shattered by the pipe. I did not do any gluing to the cracks in the clear part of the canopy because I think anything done there will stand out more than the cracks and burnishing. And FINALLY, I removed the aluminum landing gear and bent the right side back into about the same shape as the left one. I used the largest adjustable wrench I have to grasp the wheel end of the LG and bend the nearest angle to attain near vertical alignment of that face and therefore the wheel. For the angle that sits at the corner of the fuselage, and for the strut section between the angles, I just held the LG at the flat part that attaches to the fuselage, put the wheel face of the LG on the carpeted ground, and leaned with all my weight to get that angle back and remove some bow in the strut caused by the hard landing. After reassembly the right stab is only 5mm lower than the left stab, measured to the ground, so that is close enough! Here are more pics.
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I will add the yellow and silver trim to the fin later. |
That was about 20 hours of hard labor to repair the Ultimate to flying condition. Not cherry anymore, but it still should fly good, and I am thankful that the plane did not get totalled by the irrigation pipes. Luck was really with me to allow the wings to make it through before the ensuing bounce and resultant damage to the canopy, cockpit, turtle deck, fin, and rudder. If I did add any weight via the repair, it should be nominal and maybe I will need another ounce of lead up front to counteract, but that is nothing for this plane. I am going to fly it as is and see if it behaves the same or more tail happy. Whew, dodged the bullet on this one!
UPDATE: I added the silver and yellow trim to the top of the fin...NOW the repair looks complete! :)
Update2: I used white Monokote to seal the gap between the fin and rudder. This gap was smaller before the crash, and I had it small during the trial fits, but for some reason I could not get it that small when epoxying the hinges in. You can see in the pic below what the gap looks like at the top of the hinge line, and how the seal looks between all the hinge points.
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