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Diamond DA40 - Major  Wing and Landing Gear Mount Repair


This Diamond DA40 tore the left main gear leg off of the wing spar mounting during an aborted crosswind takeoff.

Fuselage arriving at Mansberger
Aircraft; notice left main gear leg is gone.
This is the gear leg mount broken
off of the wing spar and subsequent
damage through top wing skin.

Here lower skin and spar damage are
visible where the gear leg was torn off.
Damaged lower skins
removed and damaged spar cap
is scarfed in preparation for repairs.
Spar repairs completed and new
landing gear mount bonded in position.
Pre-molded panel bonded in
place and ready for skin scarfing.
Scarf completed and layup template
drawn in place for material cutting.
Lower skin layups completed.
Top skin damage removed in
preparation for skin panel.
Top skin panel in place, scarf completed
and layup template drawn in place
for material cutting.
Top skin layups completed. Repair areas primed in high
build urethane sanding surfacer.
After final contouring,
anti-static primer is applied.
Final Imron applied to top surface. Completed lower surface. Completed DA40 returned to service.