Ultralight aircraft prop repair, propeller repair, repairing non structural damaged ultralight aircraft propeller blades.

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Repairing non structural damaged ultralight aircraft propeller blades.

If you own an ultralight  you have probably had a few things introduce themselves to your prop over the years.

Or if you are flying on a wood prop have noticed some  hair line cracks forming at the tips.

As long as none of these are severe in nature - they can be repaired easily with some house hold ingredients, Crazy Glue and Baking Soda!

There are two types of repair that can be done using the following procedure. One is the repair of a prop tip - this is where a split is found at the tip of a wood prop. The other is where a prop had been nicked by something striking it, either wood or composite.

When you mix house hold baking soda with  super-glue, (there are a number of kinds of "Crazy Glue", if your are working on composite props you need one kind, wood props another) its strength increases tremendously.

When doing repairs mix VERY small amounts, 1 mg of crushed baking soda with 2 ml of glue can be mixed in an old tablespoon. Once mixed immediately apply it to the damaged area, if it is a crack at the end of the prop blade try moving the parts to allow better penetration.

Where possible make a SMALL "V" groove on each side of the blade where the crack is. You will have to work fast, the baking soda will make the glue harden very quickly. Use a small paint brush to apply several thin layers rather than one heavy layer.

As each layer hardens, lightly sand the area, clean and apply the next layer.

Once the crack or split has been sealed and repaired you can use a two pat epoxy as a filler. To do this mix a small amount of baking soda into the active part of the epoxy, mix and then add the hardener.

Again apply in thin layers,  when applying the epoxy allow it to become tacky and then use your finger tip, dipped into a dishwashing mixture of 20 ml of water to one drop of water, to spread the epoxy around. The soap solution will stop it from sticking to your finger.

Once set, sand lightly and reapply until you have a nice smooth finish. When finished the prop needs to be balanced. To do this lightly sand a wood prop, and then clean it with acetone. Composite props need only be cleaned with acetone.

You balance a prop using a prop balancer and adding weight to the light end of the prop, by apply either layers of clear coat or paint.

CAUTION: Prop repair can and should ONLY be done on small nicks and cracks - a prop that has major damage to it should be replaced. I have been in a plane that lost a prop blade in flight - it tore the engine off the plane before I could shut the engine off!!!!

See also protecting your prop.
If you own an ultralight  you have probably had a few things introduce themselves to your prop over the years. Or if you are flying on a wood prop have noticed some  hair line cracks forming at the tips. As long as none of these are severe in nature - they can be repaired easily with some house hold ingredients, Crazy Glue and Baking Soda!

There are two types of repair that can be done using the following procedure. One is the repair of a prop tip - this is where a split is found at the tip of a wood prop. The other is where a prop had been nicked by something striking it, either wood or composite.

When you mix house hold baking soda with  super-glue, (there are a number of kinds of "Crazy Glue", if your are working on composite props you need one kind, wood props another) its strength increases tremendously.

This is NOT prop damage it is prop neglect! This will result in dry rot, and an unbalanced propeller This is NOT prop damage it is prop neglect! This will result in dry rot, and an unbalanced propeller
This is too much damage to repair! This prop SHOULD not be flying, it should be a wall clock! This is too much damage to repair! This prop SHOULD not be flying, it should be a wall clock!
This composite prop can be repaired but requires the uses of the right kind of "Super Glue." This composite prop can be repaired but requires the uses of the right kind of "Super Glue."

The prop must be properly balanced after the repair

 

The prop must be properly balanced after the repair This wood prop can also be repaired. The damaged area must be cleaned, and the proper glue for wood repair used.

The prop must be properly balanced after the repair

CAUTION:
Mix baking soda and super glue together ONLY in a well ventilated area, using a breathing apparatus for protection! The fumes can be very toxic!!! Wood props left with nicks and will allow moisture to enter the prop effecting its balance, and allowing dry rot to start.

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