Orion/Highlite Reinforcement

The Orion/Highlite fuselage tends to crack in one of two places, and this has happened to every one I know who has one except the one guy who followed my suggestion and fixed it before it happened.  If you reinforce the area BEFORE it cracks, it is unlikely to crack and will end up lighter than if it cracks and then you have to reinforce the area around the crack even more.  This will add very little weight, and is well worth it.  It is also easier to do before you have the gear in and while you have to cracks to fix.
Look at the front of the wing saddle where the two holes for the alignment pegs on the front of the wings fit.  The fuse cracks along this saddle or along the side of the fuse about 1/2 inch back from this point.  This happens when you hit a wingtip on a poor landing, causing the wing to twist.  The nylon bolts flex and/or break, but even if they break the two pegs in the holes cause this portion of the fuse to twist and crack. 
Take some fiberglass and epoxy and thicken/ strengthen the entire area where the holes are and on around to about 1 inch back towards the tail.  Do this on the inside of the fuse only so that you do not alter the surface that the wing rests on in any way.  You should go about 3/4 inch down from the top of the wing saddle -- no need to reinforce all the way to the bottom of the fuse, as the cracks start at the top of the wing saddle and go down.  Don't worry about covering the back side of the two holes -- you can carefully drill through the new epoxy and fiberglass after it dries (just be sure not to fill the holes  with epoxy so you have a starting point to drill from).  Make sure that your reinforcement tapers down in thinness on the back 1/4 inch or so, giving a gradual transition from reinforced to normal fuse, so that there is no sudden change creating a new likely cracking point.

If any of this is unclear email me and I will be happy to answer any questions....

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