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Dec 01, 2020, 08:01 PM
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Build Log

Main Wing Spar Repair (Balsa and Plywood) - Complete-A-Pac A1H Skyraider

After an unfortunate Aileron control failure, my A1 Skyraider landed in the rough outfield and snapped its wing near the root.

On assessment of the damage, I have decided to repair it rather than build a new wing as it will be quicker and reasonably cost effective.

This Blog Thread will document the repair.

Complete-A-Pac A1H Skyraider - Broken Wing 1 (0 min 12 sec)

Complete-A-Pac A1H Skyraider - Broken Wing 2 (0 min 15 sec)
Last edited by Vortrog; Dec 01, 2020 at 08:11 PM.
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Dec 01, 2020, 08:36 PM
Son's Ground Crew
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Planned Repair Strategy

Below is my planned repair strategy.

The Red line indicates the structural break line.

Green lines indicate my proposed Plywood Splices to run accross the break lines to tie the wing back together.

I will need to balsa shear plates between R5 & R4 plus the top and bottom splines at each location.

So, in summary:
0. Cut back all damaged balsa to nearest spar/rib
1. Initial glue of wing parts back to true shape
2. Cut and insert new Front Wing Brace splice (clamped and glued)
3. Cut and insert new Rear Wing Brace Splice (clamped and Glued)
4. Insert Balsa gusset at Leading edge/R3 junction
5. Repair Top and Bottom Splines to Front and Read wing brace
6. Replace Wing Sheeting
7. Fibreglass repair
8. Paint
Last edited by Vortrog; Dec 01, 2020 at 09:16 PM.
Jan 11, 2021, 06:04 AM
Son's Ground Crew
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All repairs completed. Flies as good as new.
My paintjob was not as good as original (I removed some masking tape an hour after painting and some paint stripped) but all else was good

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