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From: "Clifford Scheel" <candp_scheel@msn.com>
X-Original-To: <lml@lancaironline.net>
Subject: Lancair ES-P cracks
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After nearing completion of the repairs to my ES-P, I thought it prudent =
to pass on my experience.  A neighbor was visiting recently and noticed =
a fresh six foot long crack in the paint, down the right side of my =
plane, at the junction of the top and bottom of the fuselage.  The plane =
is two years old and has about 175 hours.  It is almost always flown =
above 16,000 feet, up to and including FL 280.

Upon inspection it was obvious that there was a week point where the top =
and bottom of the fuselage overlap, where there is no core for =
stiffening.  To my knowledge, Lancair has never supplied a construction =
manual for the ES-Ps, but rather given out the ES manual with =
supplements from the 4P book, but nothing for this joint.  After joining =
the top and bottom, and reading the requirement for one bid, two inches =
wide, over this joint, I concluded that was not sufficient for a =
pressurized plane, and applied two bids three inches wide over both the =
inside and outside.  Obviously still not enough.  Another neighbor (it's =
nice living in an airpark) dug out a page from a 4P manual and it showed =
a requirement for three bid, two inches wide.  After all of the paint =
and filler was removed, it was determined that the joint was sound, with =
no delamination's or structural failures yet, just to much flex.  =
Eventually this flex would have caused the joint to fail, and if at full =
pressurization, could have been catastrophic.

I  talked to a professional builder, and he said they always use carbon =
fiber for this part of the construction, which makes a lot of sense =
since the fuselage is made of carbon fiber.  I have put in three bid, =
six inch wide, carbon fiber over both inside and outside, for strength =
and stiffness.  This is in addition to the two bid, e-glass that was =
already there.  Since I have had to tear up the plane, I decided to do =
both sides to be sure I don't have to do this repair again.

The point I am trying to make is, if you own an ES-P, you need to keep a =
close eye on this joint to see if yours is strong enough.  My plane has =
at least 1/8 inch of micro fairing over the outside, and that may have =
contributed to the paint cracking since micro doesn't flex very well.

Just a friendly warning!!!

Cliff Scheel
N272CS
Dry Creek Airpark

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<DIV>After nearing completion&nbsp;of the repairs to my ES-P, I thought =
it=20
prudent to pass on my experience.&nbsp; A neighbor was visiting recently =
and=20
noticed a fresh six foot long crack in the paint, down the right side =
of&nbsp;my=20
plane, at the junction of the top and bottom of the fuselage.&nbsp; The =
plane is=20
two years old and has about 175 hours.&nbsp; It is almost always flown =
above=20
16,000 feet, up to and including FL 280.</DIV>
<DIV>&nbsp;</DIV>
<DIV>Upon inspection it was obvious that there&nbsp;was a week point =
where the=20
top and bottom of the fuselage overlap, where there is no core for=20
stiffening.&nbsp; To my knowledge, Lancair has never supplied a =
construction=20
manual for the ES-Ps, but rather given out the ES manual with =
supplements from=20
the 4P book, but nothing for this joint.&nbsp; After joining the top and =
bottom,=20
and reading the requirement for one bid, two inches wide, over this =
joint, I=20
concluded that was not sufficient for a pressurized plane, and applied =
two bids=20
three inches wide over both the inside and outside.&nbsp; Obviously=20
still&nbsp;not enough.&nbsp;&nbsp;Another neighbor (it's nice living in =
an=20
airpark) dug out a page from a 4P manual and it showed a requirement for =
three=20
bid, two inches wide.&nbsp; After all of the paint and filler was =
removed, it=20
was determined that the joint was sound, with no delamination's or =
structural=20
failures yet, just to much flex.&nbsp; Eventually this flex would have =
caused=20
the joint to fail, and if at full pressurization, could have been=20
catastrophic.</DIV>
<DIV>&nbsp;</DIV>
<DIV>I&nbsp; talked to a professional builder, and he said they always =
use=20
carbon fiber for this part of the construction, which makes a lot of =
sense since=20
the fuselage is made of carbon fiber.&nbsp; I have put in three bid, six =
inch=20
wide, carbon fiber over both inside and outside, for strength and=20
stiffness.&nbsp; This is in addition to the two bid, e-glass that was =
already=20
there.&nbsp; Since I have had to tear up the plane, I decided to do both =
sides=20
to be sure I don't have to do this repair again.</DIV>
<DIV>&nbsp;</DIV>
<DIV>The point I am trying to make is, if you own an ES-P, you need to =
keep a=20
close eye on this joint to see if yours is strong enough.&nbsp; My plane =
has at=20
least 1/8 inch of micro fairing over the outside, and that may have =
contributed=20
to the paint cracking since micro doesn't flex very well.</DIV>
<DIV>&nbsp;</DIV>
<DIV>Just a friendly warning!!!</DIV>
<DIV>&nbsp;</DIV>
<DIV>Cliff Scheel</DIV>
<DIV>N272CS</DIV>
<DIV>Dry Creek Airpark</DIV>
<DIV>&nbsp;</DIV></BODY></HTML>

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