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Ventus Repair

We had a Ventus come in with a few dings that needed some attention. The canopy had busted off it's hinges from a gust of wind while sitting on the ground. There was also some rough spots on the belly and winglets, all of which we were able to put back into proper running order.

As you can see the ole' Ventus is looking much better after a bit of TLC to the belly.

Here the canopy is repaired with the hinges reinstalled and frame repainted.

And here's what a repaired winglet looks like.

Monitor Bridge

What's a monitor bridge? Well, it's a 19" rack mount unit with a track on top for placing a monitor or anything else, such as speakers, that sits or is mounted to a console top. Typically they house intercom stations, router heads, speakers, power conditioners and the likes but most any standard 19" rack mount device will fit. These are well suited for Television/Film, Military, Police, Mobile Command Stations, Drone Operations or any area where minimizing weight is a priority.

These are used when weight savings is a must. For instance, an aluminum 3 rack unit bridge weighs in at 14lbs. the same thing in carbon fiber is just 2.2lbs! We've built a number of these for James Cameron's Cameron/Pace Group.

The construction is a carbon fiber/foam core sandwich which creates great strength with very little weight. Elements are precision cut using water jet technology.

Incorporated into the design are magnetic latches which allow for a tool free access to the rear of the bridge.

Bridges can be custom designed for your exact needs. Let us know if we can help you out.



Std Cirrus Repair

We had a customer come in with some major damage to his Std. Cirrus. The glider had been involved in a midair collision and received substantial damage to the left wing and fuselage. The wing had been busted up in two places as well as having the aileron knocked off. The wing was a total loss. The owner was able to locate a replacement wing so there was hope.

The damage that needed to be fixed was located at the wing root of the fuselage. Here you can see some of the damage that needed to be repaired.

With a replacement wing and repairs made the owner was back up and flying in short order.


ASW27 Repair

We recently had an ASW27 come in to the shop with a bit of runway rash on the belly. It wasn't too bad but did need some attention. Along with fixing up the ding there was some previous damage to the forward section of the nose that needed to be cleaned up as well.

The damaged areas were sanded, cleaned and prepped for the repair. The repair was made with a hot bonder under vacuum. The function of the bonder is to control the rate at which heat is applied to the repair area so as to complete the cure of the epoxy resin. In this case the heat source was a silicone heating pad (orange pad in photo) that was placed over the top of the repair and under vacuum.

Vacuum is applied to evacuate off gases from curing of the resin so as to remove any resin voids and to compact the repair ply's. Vacuum is maintained throughout the curing and cool down cycles.

The results of the bonder/vacuum repair are excellent. With the fiberglass repair cured it is ready to take a close-up look at the repair. Through a lupe the repair is examined for resin content and voids.


The next step was to fill with an epoxy filler to restore the shape of the fuselage. This is a multiple step process of applying filler, sanding and repeating the process until the shape is reclaimed. Once the filler is completed the primer is sprayed on. One last pass with fine sandpaper then the repair is ready for paint. For this repair an acrylic urethane was used as that was what the sailplane was painted with. 

The final results are as good as new!





Rare Bear Modifications

The "Rare Bear" is a highly modified F8F-Bearcat. The Bear is the fastest piston powered, propeller driven airplane holding the speed records for both the 3km closed course and time to climb. Dave Cornell, crew chief of the Rare Bear racing team, wanted to make the Bear faster and came to Davis Composites for some help.

There were two issues that he wanted addressed. The first was to design and build a new tail cone. One that could withstand the extreme pressures generated at speeds over 550mph! The old aluminum tail cone had collapsed due to the extreme pressure. One other thing that needed to be incorporated into the design, a 3" steam vent. This was a vent for the oil boil off system. Instead of having the oil cooler having air flow through it to cool the oil and create drag, the cooler sits in an enclosed take of alcohol and water which creates the steam that needs to be vented.

We designed a carbon fiber/nomex honeycomb tail cone with a steam vent and an antenna window in the bottom. It is much stronger and lighter than the previous aluminum tail cone.

The next challenge was to modify the air inlets in the wings. This was done to reduce drag and increase the air flow to the carburetor.

The new shape was achieved by shaping high density foam and then vacuum bagging carbon fiber over the foam and on to the plane. Once the resin had cured, the bag was removed and the inlets were filled, primed and painted. A perfect blend into the wing.