Cracked aileron spars

[alwaysoar]

In getting my TCraft ready to annual in March, I found that the aileron spars have nice long cracks along the growth rings. Does anyone have any insight besides the obvious, that is to call AC Spruce for new ones and then recover? AC 43-13 shows how to install plates if the cracks aren't too long, but these are and for the ailerons the spruce wouldn't cost that much (the recovering will).

Ed at BTV,VT

[Robert Lees]

Ed, I had a similar problem...I am making new spars. However, I was dismantling them for restoration anyway. New spruce stock from Aircraft Spruce cost about $70 for both ailerons. I can give you the sizes if needs be.

Rob

[alwaysoar]

Rob, Yes, I would appreciate the sizes. How quickly did they deliver? It does not look like a big job. Am I correct? I am wondering if I can replace the spars without doing a complete recover. Does that seem possible, or is it not feasible?

Ed @BTV VT

[taylorcraft078]

Are you sure that you have cracks? Some of the planes used laminated spars and the glue line can look like a crack. Another source is scratches in the spars from burrs on the ribs when they were slid down the spars. When we pulled the covering off of N36078 there were some dark lines on the spars. A little looking showed that they ended at ribs and were scratches that had been varnished over sometime in the past.

Dave
N36078 '41 BC-12-65
Waiting for it to warm up enough for the compressor lines to thaw

[alwaysoar]

That's a good point, and I'll take a closer look with a magnifying glass. However, I think there is actual separation.

[Wayne]

spars

Here is a completed picture of mine. I don't know if that helps anything. Both of mine were cracked and in very bad shape. I am recovering anyway but that was really the worst thing I found. Aircraft Spruce does deliver quickly. A friend actually did these for me so I don't have demensions but could get them.

[Robert Lees]

Aileron spar dimensions

Ed,
Here are my aileron spar dimensions, Aircraft Spruce part numbers & cost (in 2001) for the aileron spar stock.
The one piece of 3/8" timber is enough to make the reinforcement for both spars.

qty 2 02-12300 Spar stock 1/2" thick x 3" wide x 96" long $32.00each
qty 1 02-38300 Spar stock 3/8" thick x 3" wide x 36" long $10.80

Rob

[taylorcraft078]

Ed,

Let me know if you need any photos or dimensions of the ailerons. Mine are naked and hanging in the garage. It is easy for me to get at them.

They were one of the very few pieces of wing that the IA said had no problems.

Dave
N36078 '41 BC-12-65

[alwaysoar]

Rob, Thanks for the dimensions, part #'s, prices.
Wayne, Thanks for the attachment. It does help.

Ed@BTV VT

[alwaysoar]

I think I'm all set for now, Dave--Thanks

[stormman]

Aileron Spars

Make them out of old main wing spars

[crispy critter]

Aileron Spars

Ed,
I have a couple of ailerons is you need them.One just needs to be cleaned up a little and covered,the other needs a few ribs replaced,they both have perfect spars in them.
I take $250 plus shipping for them both.

[Robert Lees]

Ed,
My aileron spar was broken as per the attached photo, and had de-laminated to that point. It was only the inner hinge holding it together.

Rob

[alwaysoar]

Rob, Judging from your spar I guess these planes were built pretty rugged if they'd fly with a broken spar like that, if not high-tech which brings me to my high-tech IA who works on million dollar helicopters who says my ailerons will have to be balanced after I finish them. Is that necessary? If so, do you all have a procedure?

Ed@BTV VT

[Robert Lees]

Ed,

Your IA is in error...the Taylorcraft control surfaces cannot be balanced (and nor are they required to be).

Look for example at the elevators...how would you balance those? Where would you add the weight?

And for the ailerons, a HUGE amount of weight would be required. They are "balanced" by a cable running behind the headliner.

Go have another chat with him.

Rob