Top rudder rib cracked
 

While installing my VG kit I found the RH rudder top rib cracked, p/n 1431002-13, rudder cap was loose. At least my parts airplane had a good one, cleaning, painting, and new nut plates will be installed. I think I will also use the fiberglass cap off the donor aircraft also, my plastic one not too good, amazing how the balance weight is loosely installed, and tightened in with the cap screws.

Any particular idea of the cause? If one didn’t have a donor plane, ideas on best repair?

If I had to guess, over time the plastic cap loosens up on the screws, and the whole balance weight assembly vibrates and cracks out the rib. The best way without a donor part is to make an oak form and make one. I have not measured the thickness yet, however, I believe it is .016 or less on the thickness. Not hard to make, just time consuming. 4 Cherry max rivets will be used to re-attach to the inside tabs because they cannot be reached without de-skinning the rudder.

Dan

Using advanced epoxies for minor low-risk repairs?
 

Just an idea toss here...

Maybe useful in this instance.

Anyone have opinions on the use of today's advanced epoxies for low-risk repairs?

From basic JB Bond to even more exotic materials, stronger than aluminum.
I have used them to repair boat, car, and other odds and ends.
They are amazing.

Yes yes, FAA says this and that, and said nothing on this or that.
There are lots of things FAA hasn't 'discovered' yet.
How long before FAA recognized GPS for use as primary nav, even for GA enroute?
Or even the strategy of lean of peak operations, even though common during WW2

Everything written down reflects only that day's attempt to document knowledge.
Doesn't mean there isn't anything new over the horizon.

Rib back in, looks like there is a little interference with the leading edge skin that may have induced a stress crack, gonna provide clearance with the dremel wheel.

Nice job Dan!

Looks great, I'd have my sheet metal guy reinforce the rib with a doubler utilizing flush rivets. There are a lot of different ways to skin this cat. lol
Joe S