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Thread: Outboard Spar Corrosion Repair, '63 Musketeer

  1. #1
    Guest
    Guest

    Outboard Spar Corrosion Repair, '63 Musketeer

    Hi all,
    I've been lurking here and researching about the baby Beeches for a
    while now, and my partners and I are considering the purchase of a '63
    Musketeer. I was originally interested in the Beeches due to their
    good cabin size and affordable market value. The plane we've picked
    out has corrosion in the right outboard wing spar, and the purchase
    price reflects such. We know it will be a great deal once everything
    is made right, but I'm looking for a little experience with this
    repair. Have any of you ever had this done or even performed the
    repair (A&P's)? We know there is a spar repair kit we will be able to
    get from Beechcraft soon for $1800, and the estimated labor is about
    $2500-$3000 from what we've heard. Are there any major hangups or
    other things to look out for, or is this generally an in & out job?

    Thanks for your help, I can't wait to join the Musketeer family!

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  2. #2

    $2500-3000? I wish!!

    Just got my '74 Sundowner out of the shop after 10 months and two new outboard wing spars. Thanks to Mike Relihan for the help with the spar and inspection kits. My A&P took some photos of the project and I'm trying to get those to post. Lots of rivets to drill out, bonding to undo (the spar is also "superglued" together along with the rivets). It's a much beefier wing than Piper or Cessna and about two-three times the work according to my A&P.

    I had my guy do some extra work, but the labor alone to have both replaced was about $13k. (I paid for extras like repainting the entire portion of the wing, not just over the rivets...).

    If you'd like more details, email me at toddf213@aol.com

    Todd in MN
    N6562R

  3. #3
    Guest
    Guest

    Outboard Spar Corrosion Repair, '63 Musketeer

    >> my partners and I are considering the purchase of a '63 Musketeer.
    The plane we've picked out has corrosion in the right outboard wing
    spar, and the purchase price reflects such. Have any of you ever had
    this done or even performed the repair (A&P's)? We know there is a
    spar repair kit we will be able to get from Beechcraft soon for $1800,
    and the estimated labor is about $2500-$3000 from what we've heard.<<

    You are talking about the REAR spar extension in the aileron area? If
    the main spar is corroded, you should be looking for a new wing.

    There is nothing that a competent sheet metal mechanic can't take care
    of. However having an A&P certificate in one's pocket doesn't mean
    you are skilled at sheet metal, only that you should be able to
    INSPECT sheet metal work and determine that it is done properly and
    airworthy.

    I suggest that you have someone that is a sheet metal specialist that
    is familiar with structural repairs handle this, and not give the
    local FBO a chance to butcher your wing.

    There is quite a bit of disassembly to do in order to get the old spar
    out. Drilling out a couple hundred rivets without over-sizing the
    holes is important.

    I find it interesting that only ONE WING has corrosion severe enough
    to require replacement of the aft spar. It is quite common to find
    that BOTH are equally corroded.

    The problem comes from the fact that the part in question is 2024
    alloy and because of the way Beech formed it, they used 2024-TO (dead
    soft temper), and then heat treated it to bring back the strength
    after forming the sharp radii in the bends. But they didn't put ANY
    corrosion prevention on the part, and didn't use ALCLAD 2024 like the
    rest of the skins, etc. because the Alclad tends to diffuse into the
    base alloy when the heat treatment is done, and this weakens the part.

    For the lack of 50 cents worth of Zinc Chromate in 1963, you now have
    a very expensive job to do. This problem basically covers ALL models
    and all but the very last years of production when Beech finally
    started putting ZC on bare aluminum parts.

    --Bob Steward A&P IA
    Birmingham, AL



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