First time repairs...X-21

[bundyglida]

Hi, I had an unfortunate incident a few weeks back at the State titles.
I'll set the scene....
After a line break, I grabbed some line from another competitor to respool my winch.
On launch, I asked Jeff Irvine (doing a excellent thread of a europhia 2 build), to give it plenty of tension...'"I want that winch stalled!" I called, "before you let go"....he did as I asked......
What i didn't account for was the line I borrowed was speedline not my usual 1.3 soft pink.
So as pretty X-21 left Jeffs hands, it flicked straight into the ground at full tension :eek: , left wing tip, followed by the nose and then the right wing tip.
:censored: I picked up the bits and thought the worst for this sailplane that has been very good to me.
I was encoraged to rebuild it by everyone around.....We've seen worse....they said.
Now i have stopped sooking about it and now I'm going to attempt to repair it


[IMG]

[bundyglida]

Ok I'll start with the wings.
Firstly I cleared out all the dirt and grass from inside....where did it all come from?
I opened the wings at the back by separating the lower skin from the rear spar. and cut small pieces of pine to chock the area open.
I then used CA and kicker with screww divers and blades to ease all the broken bit together and spot welding them with the glue.

[bundyglida]

After all the cracks were joined, it was apparent that the tips had no structural strenght.
I drew a rough plan of the wing shape and used this to cut 1mm balsa sheets to laminate to the inside of the skins, so that there was something to provide support to the shattered tips.
I sheeted both the top and bottom skins, and packed the gap with foam to ensure good contact.

[bundyglida]

once the balsa was glued in I removed the foam and inspected the bond...I had to fix a couple of places but overall fine.

Next i mixed up some lightweight filler and epoxy resin and worked this into the cracks on the outer skins, and allowed it to dry.

Once dry I started to sand it back....not great with only 800grit paper...so a quick trip to the hardware to buy a detail sander, and the job was done in no time.

3/4 ounce glass cloth was then used to cover the external of the skin, and then allowed to set.

[Jurgen]

Like they always say, it will fly better afterwards, if not for the plane performance, the pilot will compensate by flying more relaxed :D
J.

[bundyglida]

Once the glass had set, I rubbed back the wing tips until they were smooth, I then sprayed them with a sandable filler, and then sanded this back to the desired finish.
The rear sparand skins were then bonded back together
I managed to find a blue tamiya paint very close to the one on the wing, which I dusted on lightly, until no under coat could be seen.
WINGS DONE!!!! THEY LOOK GREAT!!!, and to think I was going to throw it out????

[bundyglida]

On to the fuze.
I used the same method using CA and kicker to reattach the pieces together.
for the middle break, I used a dremel and cutoff wheel, to cut open a 'hatch' so that Icould access the inside.
I used carbon cloth inside and out, ensuring good contact was made with the fuze.
Once this had set I used a detail sander to sand the outside back.
Noy looking pretty at the moment, but we'll see....

[bundyglida]

Mmm....look what just turned up on my door step.....
a shiney new f3b Europhia 2, thanks to Bob from SoaringUSA, now I have 2 :D
My 'Evolution' from Jiri Tuma will be here next month, along with my hopefully repaired X21, and my quiver will be complete.

[bundyglida]

Now that all the resins have had time to set, I have sanded back the excess carbon and resin.
The fuse is now looking like the shape it used to be in.
I tacked on some carbon cloth to the hatch that I had cut out earlier, wet it out, and replaced it in it's original position. A piece of sponge on a stick was then used to clean any excess inside.
The V-tail saddle was then rebonded using CA,Kicker, and then carbon on the inside to strengthen the mend.
A trial fit of everything, all is good and straight....

[bundyglida]

T he fuse was then sanded back and a filler undercoat was used to remove any further scratches....this is very heavy stuff and must be used lightly.
This was then rubbed down with 1200 paper.
I went to see my local paint shop, asking for solutions on matching paint. He matched an exact yellow to one of the wings, and supplied me with an attachable spray pack.....and well, what more could I ask for.

[bundyglida]

Hi, I have come to the final part of my repairs, I have had the aileron hinges split about 20cm. I thought it was going to be an easy fix with some CA hinges, but it won't set/adhere to the surface.
I need some suggestions on what I could use.....silicon? what type and how.
any help would be appreciated

[jirvin_4505]

Hi bundyglider
Just found this thread - wow man! what a great job you have done on the rebuild.

I remember you saying that you lacked skills - I'm humbled.

Let me know if you want me to send up some wacker Silcone for the hinge repair.

cheers jeff

[bananaman]

Good one Dale,
See I told you it would come out alright, what else could I say, it was my line that killed it :eek:

Really though, good job.

[Wing-span]

Great job on the repair! Wow!

[lamk]

Thanks for this thread I will be less hesitant to fly my first moldie which I just ordered.

[bundyglida]

Don't be scared of em'. I you take the time to build it right, strong and seviceable!, then just hook up the winch give it tension and watch it almost do exactly what you want ;)
Thanks for this thread I will be less hesitant to fly my first moldie which I just ordered.