REPAIR SUGGESTIONS
Can you drill all the way through the pod/boom? I know this will kill the ballast, but if you mounted some blind nuts into the pod from the bottom this would hold it all together.
(John Erickson)
My suggestion for you, since it's already off, is to glue a thick block across the pod and insert a threaded rod for the screws.
(Tom)
One possible fix, or just a preventive modification.
1) Get some longer bolts which extend down as far as possible without interfering with the ballast tube or servo wires.
2) Do whatever is needed to get the bolts extended past the current bolt anchors, and farther down into the pylon. This may require drilling through the bolt anhors with a tap drill for that bolt size. (i.e. don't touch the eleanxisting threads), and chasing down the appropriate tap.
3) Pot the longer bolts into the pylon with a mixture of epoxy and milled glass. The mixture can be injected through the existing holes, and/or maybe through the pylon access hole. The bolts should be well waxed. Polishing them also helps to get a clean release.
4) Potted threads tend to be tight after potting, so maybe chase them with a bottoming tap for a looser fit.
(Mark Drela)
I would suggest that you drill cross holes in the sides of the pylon below each hold down screw. Insert a hardwood dowel in each hole. Drill and tap the hardwood dowel from the top to take the hold down screw from the wing. You will probably need longer hold down screws.
(Rick Eckel)
Clean up the cured epoxy around the edges with some 60 grit. Make sure you get everything shinny, keyed and scuffed. Remove the wire harness. Procure some small carbon fiber sock material. 1/4 inch diameter should be good. Cut a length that will fit the perimeter of the wing hold down about a 1/4 inch from the edge. Make up some slow cure epoxy and some fairly thick slurry with cotton flocking. Wet the tube out on plastic and lay it in place on the pod side of the wing mount. Using the tube as a cam apply a seam of flocking around the edge of the ount. Use some of the epoxy to wet the top cap where it will touch the flocking and the tube. If there is any place that the bolt hold down can touch the pod sides apply a coat of cotton flocking slurry. Push the top plate ito position and it it goes down all the way tape the edge with packing tape. If it wll not go down rearrange the sock by pushing it toward the center of the mount. Now turn the fuselage upside down and clean the excess epoxy off the exterior of the fuse pod. Keep the fuselage upside down ove night.
(Larry Jolly)
For adhesive I would say WELD epoxy is the stuff you want to use here and I would install a pair of new t-nuts between two layers of .050 carbon sheet under the original saddle cap. Also a piece of 1/16 inch ply sheet above the t-nut heads between the carbon layers. Put this sandwich together and install on the pylon wet taking care to get it straight and level.
(Dave Corven)