solarguy54 Posted October 19, 2017 Report Share Posted October 19, 2017 Repairing two wingtips shattered during landing short of runway. Link to comment Share on other sites More sharing options...
Anticept Posted October 20, 2017 Report Share Posted October 20, 2017 What's the rest of the plane look like? I would be incredibly impressed if you only ended up with broken wingtips... Link to comment Share on other sites More sharing options...
Runtoeat Posted October 20, 2017 Report Share Posted October 20, 2017 Solarguy, super interesting pictures showing the inner wing structure and the repair. Wish I was nearby so I might be able to take a look at how the repair of carbon fiber is done. If possible, please post pictures as you work thru the rebuild of the wing structure and do the surface finishing. Link to comment Share on other sites More sharing options...
Roger Lee Posted October 20, 2017 Report Share Posted October 20, 2017 CTLSi will be up to see you guys Saturday. Link to comment Share on other sites More sharing options...
solarguy54 Posted October 20, 2017 Author Report Share Posted October 20, 2017 Great Roger! Call me when you land so I can open the electric gate for you. 928-301-6497 Link to comment Share on other sites More sharing options...
Roger Lee Posted October 21, 2017 Report Share Posted October 21, 2017 It will be Randy the owner. I got the plane ready this morning. You'll be shocked. I'll give him the phone number. Link to comment Share on other sites More sharing options...
solarguy54 Posted October 22, 2017 Author Report Share Posted October 22, 2017 Yep. Appalled. Thanks for the loan of the parts. Will ship on Monday. Link to comment Share on other sites More sharing options...
Roger Lee Posted October 22, 2017 Report Share Posted October 22, 2017 I just need the coolant bottle and exhaust pipe. There is a rivet in the bottom of the exhaust pipe that needs to be drilled. I would highly suggest that a new stainless rivet be put back in its place otherwise there is nothing here to keep history from repeating itself. Link to comment Share on other sites More sharing options...
Anticept Posted October 22, 2017 Report Share Posted October 22, 2017 Alright you two. Share with the class. Link to comment Share on other sites More sharing options...
solarguy54 Posted October 23, 2017 Author Report Share Posted October 23, 2017 On 10/19/2017 at 5:50 PM, Anticept said: What's the rest of the plane look like? I would be incredibly impressed if you only ended up with broken wingtips... Check under "Incidents" forum for a photo of the aircraft and a description of the damage. Link to comment Share on other sites More sharing options...
solarguy54 Posted October 23, 2017 Author Report Share Posted October 23, 2017 On 10/22/2017 at 11:21 AM, Anticept said: Alright you two. Share with the class. Exhaust pipe aft of muffler fell off in flight causing hot exhaust to damage cowling, melt coolant reservoir and damage firewall. Shows the value of good firewall coating. Will be repairing firewall and recoating with fire protectant paint. Link to comment Share on other sites More sharing options...
solarguy54 Posted October 23, 2017 Author Report Share Posted October 23, 2017 So Frank Borrmann came over from Germany to do this repair. He is arguably one of the world's most experiencee and knowledgable CT composite repair guys as his company not only has extensive experience with repairing CTs, but also taught CT composite repair classed for FD corporate. He also has done prototype development for FD. I'm thinking about asking him to come over twice a year (March/October) for a couple weeks each time to do CT composite repair if there is enough demand for his services. Sid Lloyd LSRM Kestrel Aviation Services Link to comment Share on other sites More sharing options...
Tom Baker Posted October 23, 2017 Report Share Posted October 23, 2017 Frank taught the FD composite class I attended in Sebring. In conjunction with the class he was also doing a repair while he was there. He is an interesting guy for sure, and very talented with composites. Link to comment Share on other sites More sharing options...
WmInce Posted October 23, 2017 Report Share Posted October 23, 2017 It would be very beneficial if he were a participant on this forum. Link to comment Share on other sites More sharing options...
Roger Lee Posted October 24, 2017 Report Share Posted October 24, 2017 Link to comment Share on other sites More sharing options...
WmInce Posted October 24, 2017 Report Share Posted October 24, 2017 I'd say that had to be rather noisy. Carbon fiber held up pretty good, all things considered. What does carbon fiber smell like when it's burning? Link to comment Share on other sites More sharing options...
Anticept Posted October 24, 2017 Report Share Posted October 24, 2017 It doesn't, the epoxy does, and it just smells like sour burning wood. It is VERY recognizable. Link to comment Share on other sites More sharing options...
Roger Lee Posted October 24, 2017 Report Share Posted October 24, 2017 Because it was at the end of the muffler almost no difference in sound. If a pipe had broken up by a head then that would be different. It definitely burnt the cowl and all the hot gases were directed inside. If this had gone on much longer it may have had a different outcome. Link to comment Share on other sites More sharing options...
FlyingMonkey Posted October 24, 2017 Report Share Posted October 24, 2017 16 hours ago, WmInce said: I'd say that had to be rather noisy. Carbon fiber held up pretty good, all things considered. What does carbon fiber smell like when it's burning? It smells exactly the same as burning money. When my exhaust broke just aft of the cylinder, I didn’t notice until I pulled the cowl, likely a couple of flight hours later. Others said later they thought my airplane sounded a bit different from the other CTs, but not crazy. I didn’t notice any change, maybe because of my noose canceling headset. I did hear a change in some of the GoPro video I reviewed after the repair. Link to comment Share on other sites More sharing options...
WmInce Posted October 24, 2017 Report Share Posted October 24, 2017 53 minutes ago, FlyingMonkey said: It smells exactly the same as burning money. Good one! Link to comment Share on other sites More sharing options...
Mike Koerner Posted October 25, 2017 Report Share Posted October 25, 2017 Andy, Did you have your pipes wrapped at the time of failure? Mike Koerner Link to comment Share on other sites More sharing options...
FlyingMonkey Posted October 25, 2017 Report Share Posted October 25, 2017 2 minutes ago, Mike Koerner said: Andy, Did you have your pipes wrapped at the time of failure? Mike Koerner Negative. Link to comment Share on other sites More sharing options...
Roger Lee Posted October 26, 2017 Report Share Posted October 26, 2017 Header wrap doesn't cause stainless steel Rotax exhaust pipes to break. There is too much chrome and nickel in them vs steel. If you have old school steel pipes on another type of aircraft then the steel pipes are affected. Link to comment Share on other sites More sharing options...
Runtoeat Posted October 26, 2017 Report Share Posted October 26, 2017 Sid, with all of the composite aircraft in the U.S., such as Cirrus and the new GA composite aircraft, most of the sailplanes and a large percentage of Light Sport aircraft, I would think someone who has been trained in the art of composite repair would be able to set up to do a full schedule traveling around the U.S. to do repairs? To my knowledge, there is no one currently doing this. If I were a young guy who was thinking of a good business to go into, I would consider specializing in composite air frame construction/repair and set up with some facilities thru the U.S. so I would be within a few hour flight from those needing repairs. Link to comment Share on other sites More sharing options...
Tom Baker Posted October 26, 2017 Report Share Posted October 26, 2017 The design and materials used in the Flight Design lend it to field repair. Many other aircraft require a more sophisticated facility for repairs. Link to comment Share on other sites More sharing options...
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