AS-K21 Refinishing in Poland

[TimF]

You will all be aware that we have been planning to get the AS-K21 "refinished" for a while now. Well, the moment has arrived and the factory in Poland is ready to start work.

Susan and Derek Ward volunteered to tow the K21 to the factory behind their motorhome the 1000km or so across Holland and Germany and into Poland.

The plan was activated and the voyage started on Tuesday 5th April.

Susan and Derek took the overnight ferry from Hull to Rotterdam. Wednesday 6th saw them travel as far as Dresden and today (7th) they are aiming to reach the factory in Poland. They are planning to return after a few day's rest with another trailer containing someone else's glider on which the refinishing work is now complete.

I am aiming to provide the occasional update to this post to let you know how the work is progressing.

Here are a few Qs and As which you may be wondering about.

What is refinishing?
Over time and exposure to UV, the original gel coat on a glider degrades and begins to show signs of cracking. If left untouched, this gets worse and the underlying glass fibre structure starts to deteriorate as well. Refinishing involves removing the gel coat (by hand) so that the underlying structure can be inspected. If necessary any repairs are made to the structure before a new gel coat layer is applied. Then a coating of 2-part polyurethane paint is applied to protect the new gel coat from exposure to UV in the future. This process is applied to all exterior surfaces of the glider. At the same time we are having the cockpit interiors resprayed, new placards added and damaged upholstery replaced so the glider will be refreshed to a nearly "as new" appearance. I say "nearly" since we are not having the canopies replaced nor the instrument panels refurbished (that might be the subject of a future exercise!)

Why Poland?
Quite simply they could carry out the work fairly quickly (UK companies were offering slots 2 or 3 years away) and they have a good reputation. There are at least 3 gliders to my knowledge at the club which have been refinished by the same company in Poland.

How long will the K21 be away from the Club?
The K21 is expected to be away from the Club for 10 to 12 weeks while the work is carried out. This is dependent to some extent on what they find when the gel coat is removed.

Tim Fox

[algibson]

Hello Tim.
That assembly looks suspiciously as if it might contain additional weapons for the Ukraine War Effort.

Last all hope they don’t become involved in an international scandal.

Now that would be a story to tell your grandchildren.

Stay Safe
Alan.

[TimF]

An update from Susan and Derek on Friday 8th April ......


Greetings from Poland and a little update of what’s all been going on.

The journey from Milfield to Hull on Tuesday was very uneventful, as was the overnight crossing. The only moment of stress was when the lady at the ticket window denied all knowledge of our T1 document, which we had to collect, and grumpily dismissed us. We assumed that the next window would give it to us, but there was no next window and we were almost on the boat, without the all-important T1.

Eventually, we spoke to someone, who spoke to someone else and we were directed to drive out of the port, park, walk to a ‘special’ window just behind the grumpy lady, pass on our LRN number so we could get our T1!

I guess this would all get much easier if you were doing it on a frequent basis………..

Once at the other side, and exiting the port there were no checks at all, other than passports. I think that this was due to us been directed into the ‘passenger lane’ rather than the ‘freight lane’, but not sure really. Once off the boat we made good progress through Holland and arrived at our planned overnight stop in Germany a little early to pack in for the day. So we carried on until 10pm and got to our planned overnight stop for day 2 on day 1, which was close to Dresden.

Thursday morning we decided we would just make a dash for the Refinish factory, which is not really called that, so we could get the trailer unhitched and spend a few days as ‘tourists’. This plan worked and we spent the night in the factory car park, which was lovely and quiet, compared to the lorry park of the night before.

The K21 paperwork was handed over this morning (Friday) and we left the factory around lunch time, having forgotten to measure the ASW24 trailer, (needed for the return ferry booking). A quick trip back up the hill to the factory / gliding site and a quick measure of said trailer and off we went, again.

We have arranged to collect the returning glider on Tuesday (12/4/22) morning, and have booked the ferry, Dunkirk to Dover, for Thursday. We will then drop off the glider at a mutually agreed place with our contact, Paul Crabb. The glider belongs to a private owner based at Stratford on Avon Gliding Club, and I imagine he will be very pleased to get it back!

The link below is to the gliding site / airfield where the Refinish Factory is located. They seem to share some grassed areas with a ski slope, so that could be fun……

https://goo.gl/maps/a4YQnDxeuKgv88wd6

Should be home by Easter Flying week, and the tug might have arrived by then



Just to explain, the T1 document is the temporary export customs document which is necessary to take items into Europe and avoids having to pay VAT upon re-entry to the UK. Another "benefit" of Brexit!

Tim

[TimF]

Susan and Derek set off from Poland on Tuesday (12th) morning towing a trailer containing a newly refinished glider for its owner in the UK.

They reached Dunkerque on Thursday morning and caught the noon ferry to Dover. After successfully negotiating the inland customs post near Dover, they were back on the road heading to Watford Gap services on the M1 to hand over the glider to its owner. This was completed at 8pm after a long day.

I'm hoping we will see them back at Milfield over the Easter weekend.

I will try to persuade Susan and Derek to write a few words here about their trip and experiences along the way.

My thanks to them both for undertaking this journey of over 2500km on behalf of the Club.

Tim

[BarryL]

A terrific job well done. Glad it all went (mostly) smoothly.
Thank you both, Derek and Susan.

Barry

[Grunau Baby]

The journey home……..

The Refinish Factory with our K21 delivered to the front door....

We dropped our K21 at the refinish factory on Thursday night and did the official hand over on Friday morning, and then set off for the camp site down by the lakeside that we had been told about by Greg, our contact at the factory. Unfortunately, the camp site was rather closed and we needed some services after 3 days on the road.
Our trusty phone app, searchforsites, (highly recommended), showed several camping spots at a small town about 40 kms away called Oswiecim, better known world wide as Auschwitz. The following day we concluded that it was somehow disrespectful to do the tour, but also disrespectful to not do the tour, so went ahead with a somber day on Saturday, following the guides around the infamous sites of Birkenau and Auschwitz.
There are no words to describe this experience here, but more detail at;

https://goo.gl/maps/7y57Pk7wDjPSv5jV8

(right click to open in new window)

After a few more days without a glider attached to the back of our van, we had a rendezvous with Jerzy from the Refinish Factory on Tuesday morning at 9am. All went well, mostly, and we were off on our way to the planned overnight stop at Nossen, near Dresden in Germany.

Collecting the return glider from Jerzy

We had used this truck stop on the way to Poland, so we knew the ropes this time, and also knew to get there early, as it fills up fast with huge lorries.
Some good food, schnitzel and beer, was enjoyed and then it was off to bed to try and sleep amongst the lorries coming and going all night long and the constant stopping and starting of the engines to keep their refrigeration functioning.

Tucked up with the lorries at Nossen, Germany.


An early start saw us on the road for 7am on Wednesday morning heading for Asten, in The Netherlands a drive of over 600 kms. A fill up with fuel for the van and ice cream for us kept us going till around 6pm when we drove into the secure parking area and parked up for the night.

Eat, sleep and drive had become the norm and we were up at 4.30am for the 256 km drive to Dunkirk, hoping for the 10.00am ferry to Dover. The tail lights on the trailer decided not to work, so a repair was needed, and thick fog meant we arrived at the port at 9.30am, but two searches and two passport checks meant the ferry sailed on time at 10.00am without us….but we were first in the queue for the noon one.

The short ferry crossing from Dunkirk to Dover was uneventful, which is more than can be said for the visit to the Inland Border Facility at Sevington, Kent. This is something to be avoided at all costs, but sadly now has to be endured by all HGV Drivers entering and exiting the UK, another ‘benefit’ of Brexit.
Speaking to other freight drivers who were in the same situation as us brought forth many sweary words and uncomplimentary comments about UK in general, and Kent police in particular.
My companion had to be ordered to keep quiet and stay put, by me! He took to his WhatsApp to vent his anger.

At Tim’s request I include the frantic / desperate exchanges during the hour we were there…………..

14/04/22, 14:17 - EK Ward: We are at Inland Border Facility...thick as mud and twice as slow. We may be here a considerable time...
14/04/2022, 14:23 - Paul Crabb: I think it's a new system to smooth the flow of goods into and out of the UK... wait a minute, we had something a few years ago that used to do that but the government tells me this new way is so much better for everyone
14/04/2022, 14:26 - EK Ward: A mass employment system and huge money wasting exercise. Somewhat Kafka in outlook. Disfunctional. A bit like the film "Brazil" but without any humour or redeeming features .And insulting the staff will not be tolerated....
14/04/2022, 14:30 - Paul Crabb: Are you stopping at Challock GC tonight ?
14/04/2022, 14:31 - EK Ward: No..we are spending the night at Inland Border Facility...
14/04/2022, 14:32 - Paul Crabb: Did they indicate that it would take that long ?
14/04/2022, 14:33 - Susan Ward: Derek is staring to fume a little.
14/04/2022, 14:33 - Susan Ward: Take all comments with salt
14/04/2022, 14:34 - EK Ward: No...they are unable to indicate anything. IQ not high enough.
14/04/2022, 14:34 - Susan Ward: Absolutely ludicrous place with 100s of people aged 12 trying to organize others?
14/04/2022, 14:35 - Susan Ward: Not allowed out of vehicle without hi vi's vest
14/04/2022, 14:36 - Paul Crabb: Have you got one with you ?
14/04/2022, 14:36 - Susan Ward:

14/04/2022, 14:37 - Susan Ward: Might get detained for taking photo. Not allowed.
14/04/2022, 14:37 - EK Ward: How many Border Force employees does it take to make a decision/give you the right instructions/speak to you coherently...I have lost count...they are all talking gibberish. I was going to ask them some questions about importing an aero plane but I fear I would die in the attempt...
14/04/2022, 14:37 - Paul Crabb: Looks very similar to the Birmingham inland customs facility - officials outnumbered vehicles by 10 to 1 - but that was at the height of lockdown
14/04/2022, 14:41 - EK Ward: Aah! It must be worse now. Good job they knew we were coming!
14/04/2022, 14:42 - Tim Fox: This is what you'd expect in a third world country - oh I forgot - that's what we've become after Brexit!
14/04/2022, 14:47 - EK Ward: After half an hour and a couple of dozen jobsworths we got past the entrance and got to enter the rest of the facility. We went round a corner and a car pulled up in front with a large illuminated "Follow Me" sign in the back. So I set off to follow and some oick shouted " Do not follow that car...park over here...reverse in...you must be straight...do not get out of your vehicle...drone, drone..."
14/04/2022, 14:51 - Susan Ward: I do have my own high vi's jacket.....so now I can walk back and forth from van to office unaccompanied
14/04/2022, 14:52 - Paul Crabb: Does not sound like there is any problem with the paperwork, I assume you sit around until they say you are clear to go .
14/04/2022, 14:53 - Susan Ward: Waiting for text to return to office for 3rd time....
14/04/2022, 14:54 - Susan Ward: I cannot really believe what I am seeing
14/04/2022, 15:18 - Susan Ward: Leaving Inland Border post now. Hope to never return. Paperwork completed.

We had to be involved in this process to prevent double VAT being charged on the work done on the incoming glider, and to ‘close the T1’.

Slightly traumatized and in disbelief at what we had just seen with our own eyes we set off for Watford Gap services, where we had agreed to hand the glider over to its owners. This helped to remind us why the southern ports and the London M25 are best avoided, especially at rush hour the day before a bank holiday.

Des and Ian reunited with their ASW24

The hand over was made, in the twilight, to two very happy owners and we were free again to go where we pleased.


Back to Milfield on Friday concluded the trip of 2550 miles and 5 countries.

[Bernie Hartnett]

Well done the Wards for enduring all that hassle!

[Tom Farquhar]

I take my hat off to you two.
I would rather stay at home and nail my feet to a board.

Tom

[TimF]

Progress update, 11 May 2022

I have received some pictures of the work that has been carried out on our K21 in Poland - see attachment below. The ailerons, elevator and rudder have now been removed. The pictures show that the most of the work of removing the gel coat is now complete (just a bit left to do on the fuselage). This has revealed the underlying glass matrix below. There was always a risk that the UV damage to the gel coat could have gone deeper and damaged the underlying structure making the repairs more extensive. So far this has been found not to be the case which will save time and money

What has also been revealed are the dents and blemishes that have happened over the years together with previous repairs. You may not be aware that the aircraft was damaged in the original delivery to the club around 1995 (the trailer was rolled) resulting in repairs to the wings, fuselage and canopies. These repairs are evident in the pictures.

The first picture shows the leading edge of the left wing near where it joins the fuselage. This shows a number of dents that have almost certainly been caused by people sitting on the wing complete with parachute. This is clearly avoidable - please resist doing this in future.

Once all the gel coat has been removed, the next stage will be to fill all the blemishes and start the work of applying the new gel coat. After that a new coat of polyurethane paint will be applied to protect the new gel coat from future UV damage. More pictures to follow I hope.

Tim

K21_JAD_Progress_May_11_2022.pdf

(1.24 MiB) Downloaded 319 times

[TimF]

I've now had another update on the progress of the refinishing of our K21.

The new gelcoat and protective paint layer has been applied (though it looks like there is still some finishing being done in places) and they have now started adding the markings on the wings rudder and fuselage. The cockpit interiors have also been repaired where necessary and they too are being repainted. The attached file shows a selection of photos.

K21_JAD_Progress_June _8_2022.pdf

(741.95 KiB) Downloaded 325 times

You will note that we have decided to go for a change of colours from red to blue. This will bring the aircraft into line with most of our other gliders.

Today the factory has estimated they will have all the repainting done this week (w/c 6 June) and will start re-assembling everything in w/c 13 June. Their best estimate to have it completed is 22 to 24 June.

The UK agent is starting to organise transportation and customs clearance.

Watch this space for when we expect to get JAD back to Milfield !

Tim

PS, it is likely that we will have to collect JAD from an airfield somewhere around in the Midlands - Husbands Bosworth has been mentioned though not yet confirmed. I will be looking for volunteers to collect the aircraft and bring her home. Any takers please?

[algibson]

Hello.
These people certainly know their buisiness
The K 21 has never looked as smart.
The blue finish is going to look fabulous.

Stay Safe
Alan

[stuart]

They do a very thorough job - JAD will look as good as new when it returns.

Great decision to change the colour to blue!

[TimF]

Nearly there!

I've heard today that the refinishing work on our K21 is almost complete and arrangements are now being made to transport it back to the UK.

It looks like it should be ready for us to collect from Hus Bos around 8th July.

I've had a couple of members who have said they would be willing to collect it on behalf of the club, so I can now check to see who is available at the time.

I expect we will be carrying out an inspection when when the aircraft is back at the club to make sure everything has gone back together successfully and that t has survived the road trip ok.

Hopefully more soon on exactly when it will be back in service.

Tim

[TimF]

Our K21 newly-refinished K21 made its return to the Borders Gliding Club on Saturday 9th July.

Geoff towed her the last part of the journey back from Hus Bos - thanks Geoff.

A glimpse inside the trailer revealed a very shiny looking glider with a new colour scheme!

The current plan is to carry out the re-rigging and thorough check-over during the week commencing 11 July and the glider should be ready to start flying again on the weekend of 16/17 July.

I'll post some pictures here once she is re-rigged.

In the meantime here are some pics of her arrival and the first glimpse inside the trailer.

Tim

PS if the trailer pic is not the right way up, just click on it to open it - it should be ok then. Sorry I don't know how to fix this!

[TimF]

We rigged the newly refinished K21 today - she looks great! See pictures attached.

Thanks to Geoff, Andy, Ken H, Bernie, Robbie, Ian Lowes and Paul Forrest for helping to make this happen.

It went together well and it is evident that the factory has done a good job both in the refinishing and the re-assembly. Woe-betide anyone who sits on a wing (with or without a parachute) in future!

The electrics and instruments checked out as far as we could ascertain, though the check flight should confirm that the Altimeters and mechanical varios are working ok.

This work should ensure that our K21 is good for years to come - I hope you approve of the result!

Geoff and/or Andy are hoping to carry out the check flight later this week, so she should be ready for club use at the weekend.

The hangar looks a bit busier now! (see pic)

Tim

PS if anyone can tell me how to get the pictures in the right orientation, please shout!