Corrugated aluminum

Discussion in 'Sheet Metal' started by addaon, Dec 22, 2010.

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  1. Jun 16, 2011 #21

    Maules

    Maules

    Maules

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    Location:
    Papenburg,Germany & the USA ( Seattle )
    .020 Corrugated skins made to measure, can you supply these to Chehalis ?

    I am re-building 2 different Maules, and want to re-skin the Flaps & Ailerons with Cessna type corrugated Skins , and also use the Flap Trailing Edge Bulb on both the Flap & Aileron.

    The Maule Flaps are rectangular/square/parallel , without any deviation ( unlike some Cessna Flaps )

    Dimensions Flap skins as presently installed:

    114-5/8” Long x 11-5/8” Wide for the Flap to its trailing edge.


    Dimensions Aileron Skins as presently installed:

    60” Long x 11-5/8” Wide for the Aileron to its trailing edge.


    Please give me a FOB price quotation for .020 Skins & the appropriate Trailing Edge Bulb material.

    Cordially, Erik van Veenen
     
  2. Jun 16, 2011 #22

    Dan Thomas

    Dan Thomas

    Dan Thomas

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    I just use a skilsaw and carbide blade. Lotsa noise but it works.

    Dan
     
  3. Jun 19, 2011 #23

    pylon500

    pylon500

    pylon500

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    The main reason for using corrugated skin is to be able to delete some of the internal stiffening normally used to support the skin.
    If you look closely at Cessna and Piper control surfaces, you find very few ribs as the skins support themselves.
    I did a lot of work on DHC-2 Beavers that also used corrugated skins on the controls, although the flaps and ailerons had flat skins on the top surface and as such had 'half ribs' riveted to the underside of these upper skins.
    These skins were all 0.016" even on an aircraft the size of a Beaver.
    Reskinning Maule surfaces with 0.016" would probably be sufficient, any thicker may require rebalancing of at least the ailerons.
    Surprisingly, Cessna replacement skins are not too expensive, however trying to order 'undrilled' skins is a bit difficult?
    The hardest part will be trying to keep the trailing edges straight while riveting (clamp with 1/2" square wood strips top and bottom) and avoid too much riveting pressure.
    The bulb material helps here...
     
  4. Jun 19, 2011 #24

    BBerson

    BBerson

    BBerson

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    I reskinned a set of Maule flaps. I made flat .016" skins bent at the trailing edge, same as original. Not that difficult, the hardest part is drilling or grinding out the original pop rivets.
    BB
     
  5. Jun 25, 2011 #25

    Marc Bourget

    Marc Bourget

    Marc Bourget

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    What trailing edge radius did you achieve? Was the material 2024 ?

    Marc
     
  6. Jun 25, 2011 #26

    BBerson

    BBerson

    BBerson

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    Same as original (2024-t3 .016")
    The radius is not very critical, .016" can be pressed almost flat. The original radius is easy on a sheet metal brake. Hand forming with some 2x4 might work also. I also used a vacuum cleaner to vacuum form a 17' long piece of .020" that worked.
    Bill
     
  7. Jul 9, 2013 #27

    rebinga

    rebinga

    rebinga

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    Hi Jan - I sure would love to purchase some full size skin that looks very much like what you've pictured here. Can you help? Thanks for any assistance! ~Rebecca
     

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