Hi Cody,
I think you can repair/rebuild that outboard end of the spar. Better to do that than try to use one from salvage/wrecked plane, since the spar usually breaks in a crash and would probably be damaged on any salvaged plane.
If you can find a new spar that is an option, but they are hard to find.
If you want to repair:
One way to do it would be to could cut the damaged portion off squarely, then hot-wire a foam plug with the length and taper as inside of the portion of the spar you are replacing. After cutting off the damaged part off the spar you feather the undamaged portion back 1” per ply of carbon to allow you to lay up the unidirectional plies overlapping the feathered plies by 1” corresponding to the number of plies and weight of carbon as on the good portion of the spar. Jig the hotwired plug to be perfectly aligned with the remaining undamaged spar then layup the top side with carbon fiber overlapping the tapers*** (make sure the uni-fibers are straight). After it cures, flip the spar over and lay up on the bottom side with the same number of plies, overlapping the plies from the top layup on front and back of the spar by about an inch. Make sure you use peel ply on the front and back of the spar when you lay up the top side, so your bottom side layup will bond properly. You will probably want to sand slightly after the repair to smooth out the areas where the feathered plies are. Be careful not to damage your layups***. Then you will want to wrap the repair with one BiD ply at 45 degrees for shear strength.
If you are unsure about the number of plies and weight of the carbon fiber, you can take a piece of the damaged section that you cut off and carefully examine it and or destroy it to find out how many plies. If it was fiberglass, you could probably burn it and find out, but I am pretty sure that would incinerate carbon fiber….maybe some else knows for sure.
***See the composite repair instructions in the Quickie plans for how to feather and do layup repairs. The unidirectional carbon is available from aircraft spruce. Wear a mask when sanding. The carbon fiber dust is nasty.
I am sure that the composite experts in this group (I am NOT a composite expert!) will improve on my suggestions, so stand by to see if they chime in. Good luck.
By the way, if there are still bottles of epoxy from the original kit, throw them away. They are way too old by now to use.
Cheers,
jay
From: main@Q-List.groups.io <main@Q-List.groups.io> On Behalf Of Cody
Sent: Saturday, November 07, 2020 11:29 PM
To: main@Q-List.groups.io
Subject: [Q-List] Beginning labor pains #photo-notice
Today my friend and I went into labor pains. We brought our baby "Gypsy Wind" to the hospital and made some contact with the doctors. Bruce, and Jim. So far we've got a mess of parts scattered and un-confirmed. We have found the fuselage is a little warped from sitting in pieces for 30 years. But there's a plan to fix that. We found the damage to one of the spare on the outboard edge to be more significant than we thought. Does anyone have a spar available? Maybe out of a crashed q200?
