An Expensive Ding

We've had an incredible string of bad weather here this Spring with almost constant rain since we got back from the Bahamas. We finally got a nice stretch of sunny, if windy days, and I washed the plane in anticipation of starting the summer flying season. It looks great all cleaned up.

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Ding and crack on aft side

Fine crack on forward side

Of course, in my world, it always seems I have to work a little extra for each step. An inspection before my next flight shows that a crack has propagated from a stone ding in the leading edge guard on one of the blades. It is hair fine, but it is there.

I am sorely tempted to ignore it, since the guard is not structural and is not delaminated from the blade at all. However, I have learned the hard way not to ignore anything out of the ordinary. I called the manufacturer, Aerocomposites, in Connecticut. They referred me to the company that does their repairs and overhauls, American Propeller Service, in California. Predictably, I am told that the guard will need to be replaced as it could delaminate and depart at any time.

!*!!##**!!! (or words to that effect)

I am kind of ticked off. The supposedly invulnerable leading edge guard obviously isn't. I will have to pay a local prop shop $1,000 to dismantle and reassemble the prop, shipping to and from California ( for the prop made only 2 hours drive from here in Pennsylvania)  and at least $1,000 to have the guard replaced, the blades refinished, painted and balanced.

I am told that this is unusual and just bad luck. Most of these are holding up well, even on pushers. I'll buy that this time.

The good news is that I'll have a new looking prop for the unveiling of the paint job at Oshkosh. The bad news is that I'm out quite a bit of cash to maintain a year old propeller.

Once again, I go back to those words of wisdom from Duane Swing at Velocity - " Don't hate it, fix it!"

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I took off work today and removed the prop. Having done it multiple times, I can do it myself in about 40 minutes. It doesn't weigh much, but it is a little nerve wracking trying to get the last few bolts removed while holding the prop with oil soaked hands and trying not to drop it when if finally comes loose.

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There was no way the prop was going into my Infiniti. Incredibly, the prop sort of fits in my wife's Prius, which I usually refer to as her Clown Car because of its size.

I dropped it off for disassembly and shipment to California. With any luck, it's supposed to be back in 3 weeks all shiny and new looking. By then, it will be time to take a few tune up trips and head to Oshkosh.

I hope some of the folks following the blog will be able to stop by, say hello and check out the finish paint and revised interior in person.



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