Flap Skin Source

[bagarre]

What's a goo source for the ribbed skin material used on our flaps, ailerons, elevators and rudder?
I want to re-skin the flaps on 95D but would rather not buy predrilled part numbers.

Also, has anyone installed those flap trailing edge forehead protectors?

[Metal Master]

Dave,
I buy my corrugated skins from Karl, in Washington state. He manufactures them as set upper an lower if you order both. The Corrugations match perfectly. They are made from 2024T-3 aluminum. You will not get a FAA PMA. At least talk to him (360) 757-1946. He has an add in Tade-A-Plane.
Jim

[bagarre]

Without the PMA, you work that out as an owner made part?

[DaveF]

McFarlane sells PMA undrilled skins. They just introduced a heavier gauge upper skin, .020 vs. .016. Probably expensive, of course.

[lowNslow]

Dave,
I buy my corrugated skins from Karl, in Washington state. He manufactures them as set upper an lower if you order both. The Corrugations match perfectly. They are made from 2024T-3 aluminum. You will not get a FAA PMA. At least talk to him (360) 757-1946. He has an add in Tade-A-Plane.
Jim

Jim, is that Karl Anderson?? If so does he also do control surface rebuilds?

[Metal Master]

Dave,
I buy my corrugated skins from Karl, in Washington state. He manufactures them as set upper an lower if you order both. The Corrugations match perfectly. They are made from 2024T-3 aluminum. You will not get a FAA PMA. At least talk to him (360) 757-1946. He has an add in Tade-A-Plane.
Jim

Jim, is that Karl Anderson?? If so does he also do control surface rebuilds?

Yes that is Karl Anderson he has rebuilt several sets of wings for me up until I built my own wing jig. He does control surfaces as well at least he used to. Yes they are owner produced parts however I have never made the distinction. To me 2024-T3 aluminum is 2024 -T3 aluminum and the up side for me is I can drive into Mt. Vernon or fly in to Skagit Regional and pick up the skins a get to see Karl.
Jim

[Bruce Fenstermacher]

PMA = Parts Manufacturing Approval.

It means the part was made by someone who has the authority to produce aircraft parts. It does not mean the part is appropriate, or will fit.

What Karl sells is 2024-T3 aluminum sheet. That is a standard part or in this case material. He conveniently cuts the excess for your needs away and folds it evenly in a lovely corrugated pattern to facilitate shipping. You or your mechanic use this material to build the part.

[n3833v]

Check with these people. http://www.royalaircraft.com/index.html I had mine restored by the previous owners as JRA air repair at Hagerstown. Many of the same people still are working there. They made all the skins that we needed.

John

[bagarre]

Dave,
I buy my corrugated skins from Karl, in Washington state. He manufactures them as set upper an lower if you order both. The Corrugations match perfectly. They are made from 2024T-3 aluminum. You will not get a FAA PMA. At least talk to him (360) 757-1946. He has an add in Tade-A-Plane.
Jim

Thanks!

Just got off the phone with Karl and the skins along with the trailing extrusion will go in the mail tomorrow.
Really nice guy and we spoke for a while about how to make the job easier.
He suggested a 30"x2"x1/2" steel bar to do most of the bucking and to make a simple jig to hold things to the work bench.

Mine aren't terrible but the workmanship is crappy. The horizontal surfaces were re-skinned 25 years ago and I think the guy learned how to shoot (and drill out) rivets on the flaps. The other surfaces look much better and wont need any work.

[bagarre]

Skins and trailing edge arrived today. Very nicely packaged.
Karl is a great guy. I'll be sure to take a bunch of photos of the process of putting one of these together.

[lowNslow]

David, I notice McFarland is now carrying skins for the 170 that are STCed http://mcfarlaneaviation.com/Products/D ... D=75542275&
How do they compare price wise with Karl?

[bagarre]

I bought all 4 skins (two flaps, top and bottom) plus the trailing edge bulb (STC included) and shipping for $608.00 but I don't know the break down of that.

The trailing edges came in a 2" PVC tube well protected and the skins were rolled in a 12x12x16 heavy box. All arrived in very good shape.

Next, I need to find a source for steel bar stock around here to make some 30" bucking bars.

[cessna170bdriver]

...

Next, I need to find a source for steel bar stock around here to make some 30" bucking bars.

Be sure and make a video of using that bucking bar. I've seem some photos of some (fairly anal) RV guys using a bucking bar attached to a long rod for closing out ailerons. I have no idea how you could control something like that, but I'm sure it can be done (with PRACTICE).

[bagarre]

If I understand it right, you use a fulcrum.
The flap is secured to the table via the jig (wood screwed to the table)
The bar is on a fulcrum where you can lean on or put weight on one side to buck the rivet on the other.

...yeah, I'll take lots of photos

[c170b53]

I did mine awhile ago and I don't think you need anything, exotic bucking bar wise. The only real difficulty Is bucking rivets in the internal V shaped internal stiffeners as you work aft and out.
I also borrowed a jig from a local pro. The jig, a steel bar held the flap leading edge and had steel slats which lay between the formed V's of the skin, kind of looked like a large hair comb. It allowed the skins to be riveted and kept everything straight.