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Bent aluminum fuselage... Fix?

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Kamikuza
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Bent aluminum fuselage... Fix?

Postby Kamikuza » Fri Jan 22, 2016 11:47 am

Fat Bastard strikes again.

Finally got out on my used LF Fun Foil today; got to grips with body dragging and the feel of getting up on the board and some just off the water hovering, but the wind dropped and I had a fairly fruitless time...

Got back to shore and noticed the fuselage had bent. When I did a dry-run assembly of the foil, I noticed the LE of the mast foot wasn't square: like it had been dropped or compressed from bottoming, so the point was a few mm "up". Figured I was being OCD so I didn't bother with it.

But now the fuselage nose is bent up a half inch, maybe. The bend, front the front bolt on, neatly matches the curve of the bottom of the mast :-?

File the mast square, bang the fuse flat and get on with it or ignoring it? Am I courting catastrophic failure?

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Re: Bent aluminum fuselage... Fix?

Postby Icharus » Fri Jan 22, 2016 1:21 pm

some pics would be nice
- I successfully reshaped my sroka after a serious crash - but I had a lot of good advice on how to stop aluminium fracturing.

Lets see where the issue is.

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Re: Bent aluminum fuselage... Fix?

Postby Starsky » Fri Jan 22, 2016 1:24 pm

Kamikuza wrote: The bend, front the front bolt on, neatly matches the curve of the bottom of the mast :-?
??? the bottom of the mast is not square?

Is the fuse solid aluminum?

Icharus wrote:but I had a lot of good advice on how to stop aluminium fracturing.
This is probably a great opportunity to share that info

Here is a little insight into annealing aluminum to avoid fracturing

http://www.millerwelds.com/resources/co ... g-aluminum

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Re: Bent aluminum fuselage... Fix?

Postby Starsky » Fri Jan 22, 2016 1:39 pm

Also Google "work hardening" and "fatigue."

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Kamikuza
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Re: Bent aluminum fuselage... Fix?

Postby Kamikuza » Fri Jan 22, 2016 3:21 pm

Yeah, the "nose" of the foot of the mast has rounded, from the front bolt hole to about 3 mm. Like it was dropped and compressed the material a little.

So the fuse is bent up from the leading bolt hole too. The very nose of the fuse is about a half inch high... Haven't checked, but I think it's a straight bend from that point.

Fuse is solid I think. Bend will be less than 10 degrees is my guess.

Hoping I can carefully OH so carefully file down the mast, and that'll solve the issue for a straightened/new fuselage...

Pics tomorrow...

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Re: Bent aluminum fuselage... Fix?

Postby Eltreato » Fri Jan 22, 2016 4:16 pm

Did you run aground hard?

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Re: Bent aluminum fuselage... Fix?

Postby Icharus » Fri Jan 22, 2016 4:57 pm

my advice is to find a local machine shop and ask them to skim it flat - if you 3mm will take a while to file.

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Re: Bent aluminum fuselage... Fix?

Postby windmaker » Fri Jan 22, 2016 5:10 pm

That's something that should never happen whatever your weight unless you (or the previous owner) hit something. Now the AOA of the front wing is completely wrong and your foil want fly properly.
Filling will only make the fuselage more fragile, try packing the front with chemical metal and pray it doesn't get worst...

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Re: Bent aluminum fuselage... Fix?

Postby Starsky » Fri Jan 22, 2016 5:40 pm

Wonder if it was run aground and the fuse straightened before resale. Then it bent back once loaded. How does the front end of the fuse/wing look?

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Re: Bent aluminum fuselage... Fix?

Postby Denisesewa » Fri Jan 22, 2016 8:03 pm

I've cut down a couple LF masts for people, carefully cut with a hacksaw marked out with tape and then draw filed it flat and re-tapped the holes, I think I'd machine it flat then flip the mast so the end you fixed is inserted into the baseplate ( Assuming the end thats in the baseplate now is square and undamaged), at least then you would have a fresh surface for the fuse to sit against , rebending that small of a bend in the fuse I dont think I would anneal it, generally when you anneal aluminum and then bend it the process of bending work hardens the aluminum so it regains some of its strength lost in the annealing process, but that slight of a bend might not be enough to work harden it leaving it super soft. I'm sure there are others on here with more insight to bending aluminum.


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