Aileron fix/replacement

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Stormswift

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Stormswift
Well crap happened. We are still not sure how or what this is but we are waiting for Mechanic to tell us what we are dealing with . Aileron. Will most likely need to be replaced. I am checking on all used/salvage places to see what we can find for the Cessna 1969/70 Aerobat 150 with extended tanks and Lyco engine.
Based on a pattern I am just not sure what I am seeing here. I see entry and exit. Like a pebble or something else?Kid just flies around to known safe airports. He did get lasered once on Martin State approach. ( That Baltimore) but other than that....I have not had a chance to look myself. He took pics for me but I think this needs to be replaced. Looks like something hot hit at higher velocity? What are your thoughts and any place you think is reputable where I can score the used part?
image000001(4).jpgimage000000(9).jpg
 
You can readily purchase new aileron skins. You'll need to find a shop that has the right jig to do the work, but this isn't a terribly complicated or rare job. Ailerons are also small enough to ship off to a shop for the work. Beegles in Greeley, CO, specializes in stuff like this if you can't find someone in your area. Don't forget to have it balanced after it's painted. You might consider doing an insurance claim for the work.

As to what that is... lightning strike?
 
Stormswift said:
What are your thoughts and any place you think is reputable where I can score the used part?
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Do you have static wicks installed on the aircraft?

Regardless, that is a very simple repair with various option sin how to perform it. No replacement needed.
 
Not an A&P, nor did I sleep in a holiday Inn Express last night, but could that not just be patched or something short of re-skinning?
 
It looks like the aileron hit something. Maybe FOD tossed up from a main? I’d have the mechanic patch it with some thin aluminum and squeezed soft rivets.

You can buy CNC cut skins from Cessna. Perfect fit, including rivet holes. I have some for my right elevator. Been sitting on my shelf for 20 years. My simple patch with squeezed rivets has held up well.
 
Hagerstown Md used to have the jigs for complete wing replacement. May still have them. They patched one elevator, and reskinned another for us, on separate planes. They also did a complete wing.

That looks like a simple patch.

Lightning is a possibility.
 
Jeff Oslick said:
You can readily purchase new aileron skins. You'll need to find a shop that has the right jig to do the work, but this isn't a terribly complicated or rare job. Ailerons are also small enough to ship off to a shop for the work. Beegles in Greeley, CO, specializes in stuff like this if you can't find someone in your area. Don't forget to have it balanced after it's painted. You might consider doing an insurance claim for the work.

As to what that is... lightning strike?
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You know I did not consider a lightning strike? I even thought someone maybe used kiddo 's plane for target practice. He got Lasered recently
 
Maybe lightning. But lightning shouldn't cause the damage in the blue circle. And what's going on in the red circle?

1757373807013.png

And from the top, is the mechanical damage in the red circle associated with the main damage?

1757373969580.png

The brownish paint around the main damage could be heat-damage. Did someone drag the airplane under a hanging extension cord that got cut and shorted by the aileron?


From the Cessna 152 Service manual, structural repair chapter:

1757374595436.png

One can replace a section of skin, but you have to cut that section from a new skin, as existing holes in the skin from an old aileron might not line up. And a small patch doesn't work well, as you'd need to use blind rivets in an area where the skins are too close together to get the rivet all the way in.
 
That has none of the typical characteristics of a small caliber bullet hole. I have seen many such holes.

Hagerstown had the machines to make the proper cross section aluminum for proper patching. The ownership and name has changed, but the staff did not, at least for a few years.

Dan pictured the repair we had done. The colored circles may be damage that will be replaced by repair.
 
Dan Thomas said:
Maybe lightning. But lightning shouldn't cause the damage in the blue circle. And what's going on in the red circle?

View attachment 144908

And from the top, is the mechanical damage in the red circle associated with the main damage?

View attachment 144909

The brownish paint around the main damage could be heat-damage. Did someone drag the airplane under a hanging extension cord that got cut and shorted by the aileron?
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Bell206 said:
Do you have static wicks installed on the aircraft?

Regardless, that is a very simple repair with various option sin how to perform it. No replacement needed.
Click to expand...

Dan Thomas said:
From the Cessna 152 Service manual, structural repair chapter:

View attachment 144911

One can replace a section of skin, but you have to cut that section from a new skin, as existing holes in the skin from an old aileron might not line up. And a small patch doesn't work well, as you'd need to use blind rivets in an area where the skins are too close together to get the rivet all the way in.
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There were some rivets s and minor dings on the plane but nothing like hail damage or anything. She was kept in a hanger before we got her and than we had her outside under full padded body covers from tail to prop ( prop had covers also). Finally got a hanger for her 7 months later. The whole section of the damage is about 1 inch. Its smaller than it looks. I was just questioning that burn like pattern . He did not ding her on anything in the hanger. The flooring is marked where to stop. We have the " princess" sitting on garage tiles. It's a large square so the tyres are not on concrete . She is babied. He is careful about the weather although he did encounter turbulence couple of times. Nothing majorly unpleasant. So this came as a surprise. We don't have light in in the hanger so no cords to catch. We will be putting up the solar battery on the roof but that's about it. He just moved in the spring. We will look into patching

Not sure about Static Wicks. Will ask my son
 
geezer said:
Hagerstown Md used to have the jigs for complete wing replacement. May still have them. They patched one elevator, and reskinned another for us, on separate planes. They also did a complete wing.

That looks like a simple patch.

Lightning is a possibility.
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I am looking at Hagerstown . Do you by chance recall the name of the place that does these repairs? There is one called Plane Care LLC. Do you think that's the one?
 
They are a recent company, but claim a staff that has been there for years, so that sounds like the transition that took place when we were using them.

I have been out of the active club activities for years now. The club has not had major skin work done for a while.

Send them the pictures and see what they say. The previous company never was cheap, but were the best bargain when quality was considered.
 
Beachy said:
Thoughts? Baltimore - bullet?
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Bullets go through .020 Al like butter.

Lightening is a better guess.

Without a good light and 10x 'glass its hard to tell from these photos. Corrosion generally doesn't turn black unless there is movement / fretting (aka smoking rivet)

I just looked up some used 150 ailerons and they are over a grand. Hope you can find a skin patch for less.
 
Pl
geezer said:
They are a recent company, but claim a staff that has been there for years, so that sounds like the transition that took place when we were using them.

I have been out of the active club activities for years now. The club has not had major skin work done for a while.

Send them the pictures and see what they say. The previous company never was cheap, but were the best bargain when quality was considered.
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Plane Care rebuilt a damaged tip tank for me. Excellent work.
 
Salty said:
Sure looks like a stop hole was drilled. Not new damage. Jmo
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I had the same thought.
The darkening can simply be atmospheric grit accumulated over time due to altered airflow.

How long have you owned the plane?
 
Maybe not lightening strike. I'd think the guy flying it would have mentioned flying in a thunderstorm, seeing a blinding flash, etc.

Given the previously mentioned stop hole, the dirt, the other oddities you circled in post 11, my guess would be that this is an old repair. The bondo/over paint covering it up finally came off and you're now noticing it.

And yeah, Admin should be along soon to move this to the maintenance section.
 
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Stormswift said:
I am looking at Hagerstown . Do you by chance recall the name of the place that does these repairs? There is one called Plane Care LLC. Do you think that's the one?
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A couple annuals ago, I got a peek at Plane Care's sheet metal shop; looked good to me. I'll probably take my plane there or to Lancaster Aero at Smoketown to have it rerigged this fall. I've had good experiences with both.
 
WDD said:
Maybe not lightening strike. I'd think the guy flying it would have mentioned flying in a thunderstorm, seeing a blinding flash, etc.

Given the previously mentioned stop hole, the dirt, the other oddities you circled in post 11, my guess would be that this is an old repair. The bondo/over paint covering it up finally came off and you're now noticing it.

And yeah, Admin should be along soon to move this to the maintenance section.
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We located some old pics from last year that my son took of the plane when we were ordering covers for her. It did not look like visible damage there. The ridges looked even but it's possible all was perfectly patched and not visible if it was repaired . In any case ... We checked with one of the repair places . Quote is over 2K. Waiting to see what local mechanics can do . Regardless, she'll need to be mechanic patched before going anywhere and I'll see if we can find Aileron replacement or skin replacement...will be looking at all options
 
The Cessna Service Manual has a Structural Repair chapter.
It provides guidance whether damage is negligible, repairable or non-repairable. Also various types of repairs. It’s a good place to start.
 
Don’t bite me but is that really that bad or critical for flight? Flatten with pliers and keep flying? Definitely somebody stop drilled it.
 
bonefishpete said:
Don’t bite me but is that really that bad or critical for flight? Flatten with pliers and keep flying? Definitely somebody stop drilled it.
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Its damage, so technically it needs to be permanently repaired as it doesn't meet the requirements to be considered negligible. The difference in paint color gives the impression something was installed there and torn from the skin. Regardless, the skins on an aileron are </= .020" which given the location of the damage could easily cause the damage/crack to expand during normal use. Its a simple repair now so usually best to fix it now than later.
 
Methinks that may have been from a “Static Wick”.

Trim Tab would likely have rivet holes spanwise.

FYI- A Tab on a strutted Cessna is screaming “ Bent Wing” or “ Ignorant Tech”!
 
Has to be one…….
Hammer it flat and 100 mph tape. ;)
Disclaimer:
This advice is not to be taken seriously.
 
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