On Friday, February 24, 2017 at 8:00:04 PM UTC-5, JS wrote:
On Friday, February 24, 2017 at 4:56:06 PM UTC-8, Bob Kuykendall wrote:
Your first step is probably to quantify the condition yours are in. From your description they sound pretty bad, but you probably ought to do a rigorous survey of the dips and sags to find how deep the worst ones really are. That way you know what you really have.

Your next step may be to contact the factory and see if they have any leftovers, or perhaps damaged ones from a factory repair. Ailerons that have been broken cleanly are probably easier to fix than the ones you describe.

You should probably also call all the Usual Suspects to see what they have in the rafters:

Eds Hollestelle (Solaire Canada)
Eastern Sailplane
JJ Sinclair
Williams Soaring
Robert Mudd in Moriarty
Fidel in Moriarty
Mark Grubb in Tehachapi

If worst comes to worst, I can show you how to make them; that is allowed here in the US under 14CFR§21.9(a)5, and may be allowed under similar Canadian rules. Basically, we'd take your existing ailerons, profile and paint them so they are nice and pretty, then make a set of splash molds off of those. Then you'd make replacements in the molds. Ideally we'd get the factory lamination plan from Schleicher, otherwise you'd have to tear apart your existing parts to figure out what's on the inside.

Thanks, Bob K.

Bob, you left out Uncle Hank...
Jim

..... and the Gehrleins in Waterford, PA. They had a good collection in their barn.
Uli