Go on to Stringer Finish Work

Main Stringer Installation:

One of the trickier parts of this repair was the installation of the main stringer sections, because access was limited to fuel tank bay. Access from the top would have required separating the deck/console liner from the hull - which would be a massive project in itself. So, I had to figure a way to lap-joint about 18 inches of new stringer and then bond it to the adjoining structural components.

After some thought, I came up with a plan . . .

- I put a 4" hole in the stringer sections to allow internal access

- Installed the internal tabbing on the 3 mating sides - top, bottom, bulkhead

- Installed the stringer section

- Using the access hole, I then smoothed out the tabbing pieces.

- Then, I applied the external tabbing and the outside lap joint.

Here is the stringer section set in place to check the fit.

Then there was the internal tabbing pieces using 1708 cloth

Here is the stringer section installed with the internal tabbing wetted out. I used a mechanic's mirror and a flash light to check my workmanship inside the chamber, since I could only feel my way around in there.

The final step was to do the outside tabbing and lap joint.  The cockpit floor sits on top of the stringer box, so I was able to prop it up about an inch so that I could tab the stringer to the top portion of the stringer box. That should give it its original strength, if not more.

I put a layer of 18 oz roving over the main stringers to seal things up and add a bit of strength. Here are a few pics . . . of course the roving is a little tough to see in these pictures since it is just wetted out.

Starboard stringer looking forward. . . . and the Port stringer near the bulkhead.

I installed a larger conduit than the original in the starboard stringer so that it would be easier to feed the fuel lines through.

I was also evaluating the gap and loose fit of the cockpit floor as it rests on the stringer box (below right).  My plan was to apply some urethane foam between them to secure the floor to the stringer box.

The  stringer compartments were then filled with foam.