Originally Posted by David Paule
One option is to replace the skins and trailing edge, keeping the spar assembly.
Already did that for the right aileron, which—ahem—didn’t escape the ravages of the rogue tool chest either.
I appreciate the conservative advice—rebuild from all new parts, or just the top and bottom aft skins and wedge, since no other parts were damaged. Sound advice it is, leaving no doubt as to airworthiness.
And I also appreciate the adventurous calls to see what happens with an attempt at straightening. If I got a cosmetic QB second right flap to replace the original, I’d have a stormy day project to work on instead of flying.
But folks, the point of the OP was whether a repair that discarded all crumpled components, but retained as much of the original aluminum as possible was, well, possible? I’m really not excited about re-doing all 8+ feet of a -9 flap (and my building surface for the flaps was recycled long ago), which means I’m lazy and/or immoral for sure. But the engineering question posed was, could one make an acceptable repair from a << 8 ft length of AEX and a 1x4 ft sheet of .020 Alclad. Cheaper than two full skins and AEX, with overlength ship charges to boot.
Cost (along with Schedule and Performance) IS the engineering triangle. I’m curious whether it could be done... but won’t ignore whether it should be, no question.