Bent Longeron At Tail

[pappas]

You simply drill out all the rivets that hold the bent longeron to the fuselage skin. Clamp the new longeron in the bent one's place at several points to be sure it is aligned, then drill through the existing holes in the skin into the new longeron. Cleco as you go. Very simple, don't fear it.

[OtterlyFoolish]

I just finished replacing both upper rear longerons in my legacy kit due to the previous builder completely botching the horizontal stab install...among other things. Kerry was key in pushing my to do it. It was labor-intensive but I'm very satisfied with the end result. I purchased the 1" angle of 6061-T6 locally and saved a ton on shipping cost. Feel free to get in touch with me as I have many photos of the removal and re-install process.

I would love to see your pictures and I may pick your brain if I go that route. At this point I am comfortable moving forward with the build after hearing back from Kerry today. I am going to update this thread once I am done with this message.

[OtterlyFoolish]

You simply drill out all the rivets that hold the bent longeron to the fuselage skin. Clamp the new longeron in the bent one's place at several points to be sure it is aligned, then drill through the existing holes in the skin into the new longeron. Cleco as you go. Very simple, don't fear it.

After looking closer it is not as intimidating as I thought and I could make a simple guide/punch on the lathe that would allow me to accurately locate the new holes. That may not be needed because I heard back From Kerry today and he sees no problem with me moving forward.

[OtterlyFoolish]

UPDATE: I heard back from Kerry at Sonex today and he said that he sees nothing that concerns him and that I should be fine. In addition he told me

"I NEVER recommend parts replaced or repaired because I’m worried about liability. My concern is the safety of each airplane, not whether we may get sued or not."

So I am comfortable with flexing this back and then inspecting it closely once again before making my final decision.

[Bryan Cotton]

Good talk!

[DCASonex]

Not only cost, but shipping long parts can be problematic. Even ACS is not immune to having parts damaged in shipment, and that wastes your time even through ACS is very good about replacement (been there, done that.) 6061-T6 is the most commonly found grade of structural aluminum angle material and there is very likely a source not too far from you unless living in the extreme boonies.

David A.

[Bryan Cotton]

You typically get the best deal if you buy a full length, i.e. 25'. It is nice to have a little extra stock in the shop.

[OtterlyFoolish]

Clamped a large steel block spanning the bend (supported with non marring material) and a 3rd C clamp in the center to gently pull it back. 4 separate tries to get it within about .020” but I did not want to try again and over bend it. This will be perfectly fine once all the other components are riveted in place.