Repair of rudder damage
I knocked the rudder of the bench, and it landed mostly on the horn, transferring some of the stress to the rear trailing edge. The horn was caved in, a slight kink was formed in the trailing edge, and a couple of small depressions made in this skin. The rudder was partly deriveted and the damage assessed.
Caved in horn
Another view
Restored horn skin after carefull hammering around circular former
Restored Rib 5 after small section removed owing to cracking. This removed section plays no role in the mechanical integrity of the horn, or the support of the balancing mass
Another view
Specially made anvil from steel bar for reaching into the trailing edge and providing a rigid surface for knocking the kink out of the trailing edge
Hammers used for bringing sufficient forming forces for dealing with the trailing edge kink
This kink was 90% removed, with the rudder skin being fully straightened. Septone gelcoat filler was used to restore the surface finish
Other side. The curve of the trailing edge was fully restored
Reprimed rib 5
Mass reattached, with Duralac yellow
Reprimed horn
Some space-filling sealant was injected into the trailing edge fold, at the location of the kink to provide additional support
Even though there was no cracking whatsoever - just a precaution
Reattachment of rib 5
Reattachment of horn skin
Author
This post is from Adam Dickson
