Kevin broke a primary in flight, a complete accident. Luckily the feather wasn't fully dettached and we are able to reuse it. I've never imped feathers before, so it was a good learning experience for me. The first step of the process was already done because we could use the broken feather and not need to find a substitute. This saves a lot of time. The next step is to file down a piece of carbon fiber into a small toothpick like piece that can be inserted into the shaft of the feather.
The carbon is strong, light, and easily filed down to the appropriate size.
Before making any permanent attachments, we checked that the piece fit snuggly into both sides of the broken feather. Add super glue, and place the carbon piece inside to secure the two sides together. The picture below is an example feather I practiced on.
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