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  #1  
Old 07-21-2021, 02:39 PM
kaa kaa is offline
 
Join Date: Dec 2013
Location: Boulder, CO
Posts: 137
Default Crack in a flap rib

Hi All,

I was doing a condition inspection on my RV-7 and found that the second-most inboard rib has a crack in it (see photos). There was a corresponding crack in the skin that was previously repaired (I think somebody had stepped on the flap), but I guess they didn't notice the rib crack. Would you have any suggestions on repairing this? I can't really get to it without removing the flap cap, other than maybe to stop-drill it. Any suggestions on what to do? I asked Vans support, but if anyone has suggestions in the meantime, I'd appreciate them.

Thanks,
Konstantin
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  #2  
Old 07-22-2021, 07:08 AM
664781 664781 is offline
 
Join Date: Jan 2005
Location: Powder Springs, Ga
Posts: 333
Default Repair

Looks like you have 3 options.
Stop drill and come up with an inspection program ie: every 10 hours then 20 then 50 etc., if no further cracking.
Stop drill and install an angle doubler.
Replace rib.
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  #3  
Old 07-22-2021, 08:41 AM
kaa kaa is offline
 
Join Date: Dec 2013
Location: Boulder, CO
Posts: 137
Default

Yeah. I'm trying to decide between 1 and 3. Unfortunately I have to remove the flap spar to get access to that area, and at that point it'd be easier to just replace the rib.
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  #4  
Old 07-22-2021, 11:26 AM
Desert Rat Desert Rat is offline
 
Join Date: Aug 2018
Location: Wichita KS
Posts: 668
Default

A buddy of mine mangled a flap on his RV6 and Vans sold him a new assembled flap. I want to say it was around $400 but it's been a while so I might be wrong on the exact amount, I remember it was very reasonable.
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  #5  
Old 07-22-2021, 05:16 PM
PilotjohnS PilotjohnS is offline
 
Join Date: Jan 2016
Location: Southwest
Posts: 1,723
Default Rivets

Those rivets arenít the greatest either. Just saying. But I feel like I am throwing stones in a glass house because I probably have a few too.
I mention this now because it may be a data point in making your decision.
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WARNING! Information presented in this post is my opinion. All users of info have sole responsibility for determining accuracy or suitability for their use.

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  #6  
Old 07-22-2021, 10:06 PM
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nzrv8 nzrv8 is offline
 
Join Date: Jun 2009
Location: Australia and NZ
Posts: 209
Default

You could build a new flap in a couple of days for not much $$, or Vanís does sell assembled flaps as previously mentioned.
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  #7  
Old 07-22-2021, 10:18 PM
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PaulvS PaulvS is offline
 
Join Date: Aug 2019
Location: Western Australia
Posts: 713
Default New flap suggestion

The original repair with the pop rivet going through the cracked area of the flap skin doesn't look too great in the photo. Also some of the rivets along the leading edge appear to be loosened and/or moving.
Any repair to the rib will mean opening up the flap and repainting it afterwards, so depending on the standard of the rest of the aircraft, it may make most sense to replace the entire flap, as others have suggested.
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  #8  
Old 07-23-2021, 12:34 AM
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Janekom Janekom is offline
 
Join Date: Jan 2006
Location: South Africa
Posts: 877
Default

I would build a new flap. I think we under estimate the loading on flaps when you deploy them. Rather safe than sorry
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  #9  
Old 07-23-2021, 06:37 AM
Southern Pete Southern Pete is offline
 
Join Date: Jul 2015
Location: England
Posts: 122
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Yeah - build a new flap might be the easiest option.
Monitor every 10 hours until flap is ready?
Pete

Last edited by Southern Pete : 07-23-2021 at 06:52 AM.
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  #10  
Old 07-23-2021, 09:12 AM
kaa kaa is offline
 
Join Date: Dec 2013
Location: Boulder, CO
Posts: 137
Default

Thanks everyone, appreciate the suggestions!

I got a response from the factory and they said stop drilling and monitoring it is fine. I'll probably do that and assemble a new flap some time later.

I'm pretty sure this crack has been there for years (it looks like someone stepped on the flap maybe), but I do want to get rid of the pop rivet repair.
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