For this example I will be doing a wing tip "transplant" but the repair would be identical for a complete fracture ... except for any jagged edges that may occur during a full break.
The wingtip on the wing below has been damaged and repaired at least once before and now it's damaged again. It is easier to replace the whole wing tip than try re-rebuild these old repairs... So I am going to cut it completely off and install a transplant tip... I'm going to MAKE this a complete fracture!
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This wing is actually a great wing... except for these three bays that have been previously damaged, and now damaged again.
It's always a good idea to keep your broken wing parts as spares! I'll make these two bad wings a perfect wing!
The first step in a transplant or fixing a fracture is to cut away the Monokote far enough so you can work on the damaged area. Be sure the Monokote on the last good rib bay is well tacked down, I try to cut the coating right along a rib bay line without scoring the ply surface of the wing. In this case of graphting the two together, figure out where you will cut both sides to make the perfect union.
Next, on the leading edge, you will need to slot
both the upper and lower areas below the plywood surface.
On the trailing edge just remove all the blue foam.
On the leading edge sides prep the blue foam for gluing by dimpling the surface.
Next trial fit the material you are going to use to splice with. I prefer flat carbon plate that can still be flexed just a bit. You can also use modeling plywood just like the wings are made of. You want to be able to slide both halves together easily, yes snugly.
Once you are assured of a good fit, apply epoxy (I use the thin "20 minute" type - not the 5 minute) into the slots, insert the splice material and press it together.
Carefully clamp everything together. I use some thin Coroplast plastic to clamp right over the joint. It allows for a little flex and epoxy does not stick to it. You could also use wa paper and thin plywood. I also gently pull the wing together with a couple clamps on the rib bays - BE CAREFUL not to break a rib! Sight down the wing and make sure it's naturally curved like it's supposed to be.
Once the epoxy cures fill any remaining gaps with epoxy and micro balloons. Trim all the excess splice material... I use a dremel tool for the carbon.
Once you are done with the trimming and everything is cured, finish sand the top and bottom of the wing. You are now ready to cover!
This is a wing repaired with this method - not bad eh?
Now you should be able to keep that hawk flying for many years... and many crashes to come!
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