How to repair a foam-core wing

[Franco Gozzi]

I have just crashed my EXTRA 230 and I got some damages including a broken wing.
Höw can I thoroughly repair a foam-core wing :confused:

Thanks and appreciation for your help.
Franco

[Straick]

I would just buy a new wing. When repairing it, you have to be carefull to get the wing back to the original shape. 1 busted body and electronics taught me this on an ABC that came down from about 250 feet, no control(Wing folded at the repair). If you do find any ways that work, please let me know. I don't like to buy new parts, but accidents happen.

[Franco Gozzi]

Straick,

the crack in the wing was neat but not broken apart.
So that I opened the crack and I poured inside it a two components polyuretane resin that a friend of mine gave to me. I believe it is the resin they use to produce fiber glass things (it has a strong ammonia smell).
The upper side the wing was still intact as well as the balsa covering so I upside-downed the wing and applyed 5 Kg weight on it overnight.
By this way the two sides of the crack pushed on each other up to make the resin squeeze throughout the crack and get the excess out.
Then I repaired the back side balsa sheet, which was broken along the crack, by applying a layer of fiber and epoxy.
When everything was cured I sanded the protruding chips off and I finally covered by Oracover.
Before mounting the all thing and go to the flying field I made some test for safety.
The plane is an over 2 meter wing span Extra 230 that I have been flying since March 2005 with no problem, apart of a couple of hard landings which has got nothing to do with the repair.

Regards,
Franco