Backcountry Pilot • Airframe Welding???

Airframe Welding???

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Airframe Welding???

Hey guys I was taxiing out today for my maiden voyage after a long break from flying the Maule. 2 years. Anyway I stepped on the left brake and felt something break mechanically. After investigating I found the lower bracket of the brake reservoir on the rudder pedal that attaches to the airframe itself had broke in half. My question is can this be welded safely without ruining anything. My biggest concern would be fire and or frying the avionics? If I ground the welder as close to the break, would this be the best way? Also what type of welder would be best. Any help would be appreciated. It's killing me sitting here not flying the maule.
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Re: Airframe Welding???

Farmaule, Service Bulletin 24 addresses this and should have been attended to as should ALL SBs and SLs.
Although not Mandatory for Pt 91 operations it is highly advisable that All are complied with especially as the fleet gets older.
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Re: Airframe Welding???

FARMAULE wrote:Hey guys I was taxiing out today for my maiden voyage after a long break from flying the Maule. 2 years. Anyway I stepped on the left brake and felt something break mechanically. After investigating I found the lower bracket of the brake reservoir on the rudder pedal that attaches to the airframe itself had broke in half. My question is can this be welded safely without ruining anything. My biggest concern would be fire and or frying the avionics? If I ground the welder as close to the break, would this be the best way? Also what type of welder would be best. Any help would be appreciated. It's killing me sitting here not flying the maule.


Sorry to hear about this Trebor. Glad it happened while taxiing and not landing! Hope you get back in the air soon.
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Re: Airframe Welding???

Thanks guys. Jeremy I responded on the Maule forum. You been flying much Evan? Your welcome anytime. You guys should swing by after the OBP flyin. Any other repair ideas would be great guys. The SB as I read it only shows how to inspect.
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Re: Airframe Welding???

Picture = 1000 words! :?:

I am curious what the fracture looks like? 99% sure TIG would do it.

How about calling the factory? They were very nice to me when I visited. Ray took me flying and had a blast.
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Airframe Welding???

Airplane tube welding is typically tig, or oxy acetylene. I think some manufacturers even use mig but that's rarely used for repairs.
Your not going to fry any radios as long as you clamp close. Use lots of strategically placed sheet metal, welding blankets and wet rags to protect the surrounding fabric and other important parts. Tig would be best up there. If you gas weld you will need to remove everything near by.
Should be no problem if you are handy with a tig. If you are a farmer I have seen farmer airplane welding and you should hire a good welder. :)
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Re: Airframe Welding???

Hire it out. Welding isn't hard to stick two pieces of metal together but it's years of practice to pull off something you'd put your name on. The shame of hiring a pro is much shorter lived than the shame of an ugly and possibly weak weld.

If it's the tab/fork I'm thinking of where the master cylinder clevis bolts to the fuselage tubing, it will be quick but alignment and getting it prepped and cleaned will be important. Ditto on the picture being worth a thousand words.
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Re: Airframe Welding???

Posting this for Trebor:

Image

Image
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Re: Airframe Welding???

Image
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Re: Airframe Welding???

I would definitely talk to the factory before welding it together. If they have an SB, I would guess there is an (SI) "service instruction" too.

The design looks weak. Sorry about that.

You will get her fixed quick I'm sure, it looks easily accessible.

Keep us informed and get her done!
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Re: Airframe Welding???

Ghetto fix idea. Just drill a new hole in the leftover tab. Remount the master cylinder. You could fly it to get repaired later then.... Don't know if the geometry would work out...
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Re: Airframe Welding???

The SB covers the tab breaking the weld at the airframe tube. Maule is looking into it for me now. I thought about the new hole but...we will see what Maule has to say. Then I may just have to drill a new hole.
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Re: Airframe Welding???

Well Maule was on top of there game. Parts and a drawing are in the mail and no charge. Now I need to find a welder I can trust. Not myself
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Re: Airframe Welding???

FARMAULE wrote:Well Maule was on top of there game. Parts and a drawing are in the mail and no charge. Now I need to find a welder I can trust. Not myself


Excellent! Be very careful choosing a welder. Get references and take your time. Somebody who understands the minute complexity of TIG, aircrafts, and chomoly is ideal.

Asking for sample welds first on some scap 4130 is OK. 4130 vacuum melt rods which are low Oxygen (etc) are used on engine mounts and airframes. They cost more however.

https://en.m.wikipedia.org/wiki/41xx_steel

Note: I guess it's 4130?
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Re: Airframe Welding???

Do not use 4130 rod!!!!!!!
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Re: Airframe Welding???

4. ER70S-2 is highly recommended for welding 4130 chrome moly tubing in many applications.

5. ER80S-D2 is recommended for welding 4130 chrome moly tubing if a higher strength, less ductile weld is required. If your weld will be heat treated to obtain optimum strength, then use a filler metal which matches the chemistry of your tubing, which neither 70S-2 nor 80S-D2 wires do.


http://www.usaweld.com/TIG-Filler-Rod-s/33.htm
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Re: Airframe Welding???

I used 4130 to repair engine mounts. If stress relieving is used. Very expensive.

This high quality welding rod is produced from vacuum melted material. This material has ultra-low levels of oxygen, hydrogen, and nitrogen and is extremely low in trace elements. This rod is cleaner than standard rods and is the best available for 4130 welding.

Note: Price per pound,(approx. 32 rods per pound).

If Mfg. Test Reports are required, there's a minimum $15.00 charge per order. Please indicate P/N 01-01133 in the Special Instructions Box during the checkout process.


http://www.aircraftspruce.com/catalog/mepages/4130steelwire.php?clickkey=48367

Material information sheet:
http://www.aircraftspruce.com/catalog/pdf/03-27600tech.pdf
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Re: Airframe Welding???

Yes it does look like a shitty design!

I can't tell but, is that a battery cable running under the break?
If so that could short and torch your plane in short order.

PAMR MX Ghetto fix idea may be better if it works out. It should be less stress on the rest of the bracket (shorter arm).
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Re: Airframe Welding???

Yes that is the batt cable. I plan on disconnecting it at both ends before welding
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Re: Airframe Welding???

Thanks for all the help guys finally back in business. Image
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