Rebuilding the Ultra Stick Lite   

Normally when a wing of an ARF is sheered off, it is totaled but because the plane is a favorite and discontinued, heroic effort to rebuild is in order.  The fuselage has minimal damage with the landing gear mounting structure pulled out and a few other minor issues but as can be seen in this pic, the wing suffered major damage with more than two rib bays completely destroyed.  It is a plus however that the wing tip and most of the outer two ribs survived as that section might simply be spliced back to the wing.

Note: Images can be seen full size by a right click and then choosing View


Right wing section



Left wing half

A technique is chosen to use temporary rails to hold the two wing sections in alignment and allow the splicing of the leading and trailing edges and spars.  Some small straight oak rails were ripped on the table saw and these tack glued to the outside of spars and TE.  Then the sheered off section was aligned and also tack glued to these rails.  This technique saved having to position the wing and broken section on a building board and also makes clamping in the new spar sections easier.


Alignment rails attached to main wing section



Outer wing section attached to rails



New spar sections spliced in



Spruce spars are spliced in



Leading and trailing edges are spliced in



1/16 plywood spar webbing to reinforce spar splices



Two full ribs are fitted for replacement



All broken rib sections are replaced



Diagonal bracing replaced



Removing the temporary rails  by sawing the tack glue  spots



Sheathing