On May 4, 3:47*pm, Bob Kuykendall wrote:
On May 4, 3:34*pm, Reed von Gal wrote:

Trust me, it's not repairable. Even if it was, you would end up
spending years and 30k dollars plus fixing the thing.

I've seen some pretty clever repairs on about this magnitude, so I
respectfully disagree. For example, there was the Genesis where JJ
basically created about six feet of wing from scratch. It took him a
winter of on-and-off work, and turned out so nice you could not tell
the wing had been repaired.

Thanks, Bob K.http://www.hpaircraft.com

Hi Bob,
AIG salvage will (should) tell you who got the DG-500, but they won't
tell you how much the bid was. My Genesis had the last 6 foot of the
left wing severed by a steel fence post. I contacted Marskey (one of
the designers) with my repair scheme and got his OK to proceed. I made
top and bottom templates at root, tip and inboard end of aileron from
the good wing, then set the bottom templates on my level table
arranged to accept the left wing. Laid in the two pieces and checked
for straight L/E & T/E + straight top and bottom. Then I removed the
carbon rods from the top spar cap on what would be a 150:1 scarf ratio
by grinding out each rod, one at a time using a skill-saw with a 8"
abrasive disc. This moved the repair inboard some 6', just before the
location of wet-wing ballast tank. When all rods had been removed, I
prepared the replacement rods by laying in each new rod every 3" which
= 150:1. Things got a little complicated because the original spar
achieved a taper by dropping a rod every few inches. Had to make sure
all the new rods went as far as possible ( root spar cap starts with
100+ 1/8" carbon rods and the tip has 18 rods. The rods are wrapped in
one layer of thin cloth (92110), so we laid a strip of that in before
gooping each rod with epoxy an flox before laying it in its new hope.
Working fast, Pat and I had them all in place in 45 minutes, wrapped
the 92110 over the top, laid in a strip of peal-ply followed by a 2X4
with lead weights on top of it to achieve a compact unit. Next, I
repaired/replaced the spar web and drag spar + as much of the lowes
shin that were accessible which gave the newely re-joined wing pieces
some regidity. When all that could be done from the top was
accomplished, we carefully hoisted the wing up and rotated it upside
down and laid it into the top templates. Then.....................did
all the above again on the lower spar cap! I estimated I had 25K in
the repair (at my normal shop rate $65/hr. When all was finished and
post-cured we proof-loaded both wings to 5.3 G-s.................they
took it without a groan and didn't hardly bend!
A fun and challenging project. I planned on selling it, but got to
liking it too much and with a new wing fairing and a few other tid-
bits, she will climb with most ships..............won't out-climb
anybody, but as delivered the ship wouldn't climb an inch in a 1 to 2
knot thermal. Believe me, I have tried...................she always
did run well, the faster you go, the better she runs!
Cheers,
JJ
PS, Just finished installing a ballistic parachute from BRS. The
Genesis was designed for this system, so the hard points and hatch
were all there.