Quote Originally Posted by D Egan View Post
Thanks much or the input and detail. These panels could also be made out of simple aircraft-grade plywood; do you feel that would be wiser? (We are not concerned with the higher cost or effort with carbon fiber. Our primary goal with carbon fiber would be weight savings.) However, the potential for any protective material to 'rub away' causing the two materials to come in contact and corrode aggressively over time concerns us. What are your thoughts compared to plywood?
Your wings could fall off in flight too, but the odds of that happening are almost nil. I would think the odds would be the same for any carbon fiber product installed properly.

Carbon fiber is not only used for weight savings, but strength too. I have a carbon fiber panel in my RV-10 and I don't believe that plywood would be strong enough to support my panel layout unless it was 1/2" thick or more. (too many holes) I would install an aluminum panel if carbon fiber wasn't an option.

In my particular case, the aluminum fuselage is primed AKZO epoxy primer and top coated. The carbon fiber is incapsulated in epoxy resin, then primed, and top coat applied. It would take quite a bit of rubbing to wear through all those layers with a panel that is rigidly installed to the fuselage (movement is severely restricted)

If this really keeps you up late at night, put it on your conditional or annual inspection checklist.