Fabric Failure Story

Post-War Aeronca Champ airplanes
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Lostdutchman
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Fabric Failure Story

Post by Lostdutchman »

Image
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So theres a good story behind these photos. It was a beautiful mostly sunny day in January. I thought it might be fun to do some flying. After preheating the airplany and melting the 40 pounds of ice from the belly, I made an airplane shaped hole in the sky.

I was about 20 miles from town enjoying some slow flight when the plane shot to the left quite suddenly. I had a flight instructor ( Boss)in the back. I thought he was moving around and kicked the rudder. The rudder felt fine to me so i didnt think anything of it until he advised me to look out at the wing. I cant see the wing tip without bending down. (6'3" and the champ fits nice) I instantly shreaked like a girl and chopped the power back and started a decent from about 1000' AGL.

The plane flew fine other than the crab the rest of the way back to town. The reture trip was uneventful. When we got back to town and on the ground, I thanked the good Lord for the safety. It was quite an experience. Now that I have done it I will let you all know it was not fun and not to try it at home. It appears to have been a tear at the aft edge of the leading edge cuff. The reinforcement tape had ripped off and cought around the lift strut leaving the big rip to tear. The fabric job was not done correctly. It looked good from the outside.

I am still trying to get some spars so I can start the recover. I shared this with the fAA list and was finally able to get the pictures to show. Does any one know where I can get some seat cushions? Mine are shaped like the inverse of my butt :P
Jason Vink
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1947 L16A
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Post by 7ACDriver »

Every now and then there are some pretty nice ones for sale on e-bay, they are new and made of leather. I have been seing them on and off for almost 2 years. I saved a picture of them.
http://s600.photobucket.com/albums/tt90 ... 07c9_1.jpg
Here is a link also of someone that makes them:
http://www.airtexinteriors.com/catalogu ... mblies.htm
I got mine recovered, here is a picture: I got pockets made in back and also in front of each of each seat to store stuff.
http://s600.photobucket.com/albums/tt90 ... G_0727.jpg
On this picture, the seat frame wasn't painted yet. I got it done afterwards. That is when I saw that both seats tubing in the back were cracked!I guess 60 years of wear and tare will do that. Remember if you do get them recovered the foam and material used must be aviation specs.
Hope this helps
Good luck with your recovering!
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Hugh Lalande 1946 Champ (6980) CF-VPL
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Post by 7ACDriver »

Here is a view of the back seat pocket:
http://s600.photobucket.com/albums/tt90 ... G_0821.jpg
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Hugh Lalande 1946 Champ (6980) CF-VPL
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joea
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Post by joea »

Jason,

Thanks for the photos. Still shaking my head at this happening and its the first time I have ever seen something like this on an Aeronca. Hope its the last!

Joe A
Paul Agaliotis
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Post by Paul Agaliotis »

Jason,
It looks like the leading edge material abraded the Dacron cloth. Typically there is some kind of protection on the edge of the skin. There should also be some kind of barrier so the fabric doesn't stick to the leading edge, ACA uses rymple cloth.
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jerrymjr
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Post by jerrymjr »

Actually we glue to the leading edge. Too much surface area to pass up!!
The metal spar leading edge has 'inward kink' so the fabric does not bear against the edge of the metal.
Jerry Jr @ ACA
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Post by joea »

Jerry,

Ever seen something like this happen before?

Any idea what might have caused it to happen?

Sure hope that it does not happen again!

Joe A

PS the guy I fly with just dropped a Citabria at your shop last weekend. You guys are doing an overhaul on it and believe that he worked with your Father. Small world but then I have been pushing him to get a taildragger for a while now! :)
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Post by MikeB »

I can see not wanting a sharp edge at the end of the leading edge. Wouldn't it help to have a reinforcing (2 inch fabric) tape at that spot? That is, down the whole length of the edge. I just looked at all three Champs at our airport and none (including mine) have a tape there. Maybe there's a reason??? I didn't cover my wings so I can't take the credit or blame for it but I'm going to pay more attention to the fabric at that point on the preflight.

Mike
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Post by Paul Agaliotis »

Mike,
I use a piece of masking tape on all the edges, ribs included. The leading edge gets a piece of light Dacron felt material. This keeps the fabric from sticking to the leading edge material. The top and bottom pieces of fabric have about a 15" overlap. This gives you a nice smooth D section with a double layer of fabric. If the fabric is glued to the leading edge material you will get a little defect or wrinkle in the finish at each leading edge joint as you use the airplane.
In Jason's case I would look at possibly a wing cover or rope used to secure the covers abrading the fabric. I see the Cub in the background has some installed. Alaska has a very tough environment to operate in.
Paul
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Post by flyingfool »

Sure gives one an appreciation and faith in these Aeronca's and their ability to stay flying even with what appears to be staggering odds! Glad to know people made it home safely!

I have some totally nieave thoughts on this. So please bear with my post and please educate me where I run astray.

1) The blue color seems to be odd to me. Was this razorback (fiberglass) covering? What is the age of this fabric? No matter if installed 100% correctly or not. EVERYTHING ages and most things loose strength or degrade over time. How long is glue good for? I don't know, but sooner or latter it's going to give up and fail. Apparently something reach this point on this aicraft.

2) It appears to me that the only thing holding this bottom fabric in place is what appears to be about a glued 2 inch or so overlap of aparently the top peice of fabric. Is this legal? 2 inches seems totally inadequate to me! At lest on a wing.

3) The fabric has blue color and then there are blotches of white which can be seen from the front views. This would seem to indicate that there was inadequate penetration of whatever the blue stuff is. And/or the glue held in some places and not in others. In either case not good!

4) The front view also shows a rip in the fabric parallel with the fuselage. Any fabric that I have ever seen and tried to rip by hand I was unable to rip at full strength of my hands/arms. Or if any did rip it was small. It would seem odd that the wind moving at Champ speeds should have been strong enough to have been able to rip the fabric. Which leads me to wonder how strong the fabric(dacron) really was.

5) I wonder if this was fiberglass/razorback if the punch testing of the fabric was ineffective at accurately measuring the strength of the fabric. Rather it was mearly measuring the hardness of the surface where the punch test was applied. In other words. The surfce could be hard as a rock but the fabric underneath not have any strength what so ever. And being hard on the surface would not have even made a dimple when doing the punch test. This would have given the false impression that everything was fine!

6) It sure would seem to make sense for there to be some sort of fabric protector at the rear edge of the leading edge wrap. I agree with MikeB above that a 2 inch tape glued to the rear edge would seem to provide extra protection. Paul A suggests installing a peice of masking tape. I have found masking tape to loose 100% of its adherence after a fairly short period of time. Usually any adhesive on the tape turns to a yellowish/white dust and the tape falls off. I guess since it is surrounded by shrunken fabric it would have no place to go and therefore stay in place and continue to provide some protection. But I would also think that if there is enough vibration/abbrasion to chew through dacron fabric, exactly how long would it take to wear through a single thickness of masking tape?

7) As probably you can tell by now, I know little/nothing about fabric covering an aircraft with what I've said above. But with the beating a leading edge takes, it would seem like common sense that I would want a double thickness of fabric over the entire leading edge. Obviously with the overlapp completely glued to each other. It would also seem reasonable to glue the piece on the bottom to be glued to the leading edge material. Soemone in the post above suggested that these NOT be glued to the leading edge wrap. That may be 100% true. But I don't understand why. I could see stopping the glue on the aluminum wrap an inch or two away from the edge to avoid some funcky things happening with the fabric at the rib locations.

8) Maybe this gives us all a good reason to go with sewn envelopes instead of blankets? I personally hate seeing the sewn joint. But that is just me!

Again. I do not intend this to be a flame or like I'm some kind of expert. Becasue I'm not by any stretch of the imagination. I just want to offer my thoughts and continue learning.

I'd really like to recover my Chief at some point in the next few years as it was last re-covered in the early 1980's. Everything looks/tests good now and it appears to have always been hangared etc. But maybe the pictures of the Champ above also was testing OK etc. But it still has been a number of years and I just want to check things out and keep it safe, looking good and hopefully increase its value!
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Post by Paul Agaliotis »

flyingfool,
All of your questions are valid and this forum should be a place to find solutions and answers. I don't believe anyone will find your musings or questions inflammatory.
Some of the manufactures use a dye in the dope to identify and assist in the application of the dope. The blotching could be the tape, being viewed from the inside.
The straight break in the fabric is confusing. I would assume the fabric was worn by the leading edge and at the low temperatures of Alaska caused a cracking of the fabric due to temperature not overload. Dacron is tough stuff but UV radiation will break it down in a short time.
The fabric cannot be allowed to drum on the structure and the masking tape does a good job of protecting it. If the fabric moves around on the protection it will wear through just about anything.
The socks were used with Grade A and the habit is still carried out today. My Father-in-Law still uses this method on the Dacron coverings. It had to do with strength and shrinkage. Remember your old Levi's they shrink one in the waist and two in the length, same with Grade A.
Paul
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Post by MikeB »

Superflite uses a antichaffing tale that resembles "duct tape". The salesman said "No it's not duct tape" ( but I think it is, for whatever that's worth). Having said that, it appears the ends of the leading edge is a spot to be checked carefully. Especially if a polyurathane type paint is used as they tend to flex less in cold weather. I proved that by taking an inspection cover cutout and bending it 180 degrees in warm weather. Later I was going to demonstrate to a friend of mine how flexible it was except the weather was near zero. Bad demonstration as the paint cracked all over the place :oops: . Of course the paint can be broken but the fabric still good. Unsure of Poly-Fiber but the old 'dope' system is pretty flexible regardless of the temperature. Mu understanding is that the new Stewart System is also. Paul makes a good point regarding a felt type covering over the leading edge. If you look at the Oshkosh type winners, they all seem to have a very smooth leading edge. Can't hurt with the airspeed either.

I think the blue color is 'Dac-proofer' (spelling ???) which is a 'dope' type system if I remember correctly.

Mike Berg
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