Wing spar; that's got to be a real challenge. Repaired or replaced? How you got the FAA to buy off would be a very interesting story by itself, that I'd be interested in hearing.
For an aircraft mechanic or technician to have his/her work approved, they have to have an A and P certificate (air frame and power plant). This is obtained by schooling and testing.
Once the work is accomplished, it has to be approved by the FAA. Approval is done by an IA (inspection authority) person. A person who is an IA is a legal extension of the FAA. When an IA signs off on a repair, modification or replacement, then his butt is on the line for the approval. Several members of our group have an A&P certification, and our main pilot is an IA. So, we're covered for all of the work we do on the plane. Sometimes our IA person takes a close look at what we do and says OK, sometimes he makes suggestions as to what may be a better way to accomplish something.
In our group, we have aircraft electricians, hydraulic guys, airframe guys (me for one, I used to do airframe, sheetmetal, structural repairs on B52s at Tinker AFB, plus, I was the 747 airframe technician for 12yrs on the E4B). EVERYONE in the group has some kind of former (and some still working for the USAF) military aircraft background.
Now, for the broken wing spar.
A wing spar is the major structural member in the wing, like the back bone.
The wings of an A26 have a forward and rear spar with 4 BIG lugs where the wings plug into the fuselage. At sometime when the former group in Ark had the plane they managed to BREAK, NOT crack, but BREAK the rear, lower spar on the right wing. The plane was permanently grounded because they had no way to repair or replace the spar----------------and FAA WOULD NOT grand a Ferry Flight permit to fly it to a repair facility (assessed as unsafe to fly again).
So, it sat for 7yrs. Our group went over to Ark, disassembled it and trucked it to Okla City for repair-----------------and a TOTAL (air)frame off restoration has resulted.
This has already been to long, so, I'll try to make the rest short.
Several years ago, Douglass (they made the A26) and Boeing merged into the Boeing Airplane Co. As luck would have it, some Boeing engineers learned about our broken spar. LITERALLY, several months later, a 30ft long wooden crate arrived at the hanger (from Boeing) with FOUR, that's correct, FOUR wing spar caps inside the crate--------------DONATED-----including shippiing-----------by Boeing!!!!!!!!!!!!!!!!!!
The right wing was virtually disassembled (thousands of rivets and nuts and bolts) and the broken spar removed. Holes in the new spar had to be ABSOLUTELY, PERFECTLY, 100% matched to the holes in the old spar-------------IT WAS ULTRA TIME CONSUMING for a group of guys that had never undertaken that kind of task!!!! But we got it done!
Below are pictures of the lug that was broken off of the spar cap. This is the part (4 per wing) that plugs each wing into the side of the fuselage. Once the wing is installed into the structure of the fuselage, big pins are inserted through holes in the structure and the holes in the lugs, then bolted in place.
The next picture shows the new spar cap installed in the right wing with the broken lug below it. Each spar cap is about 30ft long. The 4 spar caps that Boeing made and donated to us were machined from ONE, repeat, ONE solid alum billet! Think about that, one solid chunk of solid alum about 3ft x 3ft x 30-35ft long!
The next picture is right after we installed the wings.
The videos are installing the right wing into the fuselage-------------EXTREMELY tedious task! But as can be seen today, we got it done.
This is what I do, all day long, EVERY Saturday. In 1yr, I MAY miss 4 Saturdays. So far this year, I have missed 3 Saturdays. I usually open the hanger 6:30-7:00, turn on the lights, get fans going in the summer, make coffee, and work on the plane until 5-7pm, shut down the hanger and go home and crash. For this 76yr old man (for 4 more days) that's a hard days work------------and by the end of the day it only seems like 10min. Beats bustin' knuckles on a Chevelle!