Thanks for the guidance - when I calculate with the jury struts, I find that sleeving over the dent is more than adequate.
And yes, the aircraft is registered, no worries there. The "fat ultralight" was more to create a mental picture than to describe the legal status. I believe that for EAA...
Many thanks to all for the help. I think I understand now that what I'm 'repairing' is the lost critical buckling load, which is so tremendously lower than the tensile strength. Given that there are indeed jury struts, I would in all probability be fine sleeving it, riveting appropriately, and...
I did my homework - much easier than I expected - which is usually a bad sign for me.
For critical buckling load,
For 1.5" x 0.035thick, 6061-T6 Al, cylinder, simply supported,
Area moment of inertia = 0.043 in4
Young's Modulus = 1.00E+07 psi
L = 109 in.
Fcr = 359.2 lbf
Good thing there...
Thanks for the prompt and helpful reply!
For the strength of the tube, I used the cross sectional area of 0.1618 sq.in. and 42000 psi for the TENSILE strength of 6061-T6, and get 6765 lbf. This would be the force the strut would experience just before it fails, the wings fold up over my head...
I'm rebuilding a 'fat' ultralight, and discovered a dent in one of the wing struts. Replacement tubing is expensive (to me) to ship at 9' in length, and it's a shame to waste an otherwise 'good' part.
I looked at AC43.13 and only found help on splicing tubing on longerons/webs.
My thought is...