Piper Pawnee

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Sills Aviation Services

Piper Pawnee had a hard landing . We recovered the aircraft and trailered it to our facility at KGYB.
Damage to the landing gear hydrosorbs and shock chords, propeller strike, tail wheel spring broke off, engine mount damage.
The wings didn't show any damage from the hard landing but has many years of repairs and other damage. The owners decided to repair and recover the wings , we will start with those pictures first.  
At the moment the pictures are not in order . I will correct this as time permits.  

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False spar brace broken

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Missing some rivets

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Rib damage

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A little corrosion

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Both flaps have trailing edge damage.

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 New trailing edge installed.

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Removed the walk area , replacing some broken , cracked up ribs. Fabricating new sheet metal panels.

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Fit it all back together , drill and cleco . Will come apart again to debur and prime.

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New ribs and nose ribs from Univair Aircraft

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A few new leading edge skins.

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Rib repairs using splice strips from Univair Aircraft

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New, fabricated and or cleaned parts ready for primer.

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Example of new nose rib from Univair Aircraft

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All of the angle brackets on this piece had to be fabricated and replaced .

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Assembly time .

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The fittings were removed , bead blasted clean , inspected and epoxy primed, reinstalled. Trying to keep the corrosion from coming back for a few years.

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 UniVair ribs  and trailing edge. Fabricated wing walk skin.

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All back together and ready for cover.

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 Rib lacing .

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PolyFiber process . Heavy (101 ) fabric.

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The brush coat of PolyBrush applied, reinforcement tape to ribs in prep for stitching.

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Stitching done and now the tapes, inspection ring and other reinforcements

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Spray on coats or PolyBrush applied

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Spray on coats of PolySpray applied

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Flaps getting covered after repairs

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Flaps are ready for silver ( Poly-Spray)  we will also silver several other flight controls that we didn't recover so to prep for top coat of new paint .

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Left wing getting Poly Tone top coat and then the blue trim is Aerothane.

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Pretty slick !

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Fuselage in the booth, prep for a top coat of Poly Tone and Aerothane over the old stuff !

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Aerothane on the gear legs.

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Poly Tone on the fabric.

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N numbers going on and some of the other trim and graphics.

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Fuselage out of the booth. We have some of the panels and struts painted in aerothane. We are having to re-do some parts that didn't get prep'ed well enough and the paint didn't look good enough to us . Nothing like doing it twice ! ! !  

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Right wing repairs are / have been completed , now for some epoxy primer.

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 This one will be in good shape again. Was a whole lot of rib damage to repair.

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Primer is on ! Now the assembly starts..

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Same process as the left wing.

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Let's put the wings on !

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Now , the other 90% to go ..

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Will be back to work soon looking like new :)

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Above pic is what can happen when you spray one system on top of another system and the surface has been breached ( cracks in the paint ) to the fabric. Nothing left to do but razor blade it all off and start from scratch. Just a little setback to deal with and another week before the project is ready for flight.  

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DONE !