Michael Horowitz wrote:
I could use some brainstorming on how to approach the rusted cluster
shown at http://members.cox.net/mhorowit/cluster/ - Thanks, Mike

You're going to have to cut the cluster out and fabricate a new one that
you splice in with truncated sleeve and rosette weld repairs per AC43.

1. Make a bracing fixture to hold the fuselage in alignment in the area
of the repair.
2. Cut the cluster out about 12" out on each tube or as far as you have
to go to get unrusted metal..
3. Do a splice repair on the longeron tube with truncated sleeves per
the standard method, temporarily tacked in place.
4. Prepare and fit the diagonal tubes to duplicate the original cluster
and tack them them with splice sleeves at each junction with the old tubing.
5. When everything is fitted peachy keen weld 'er up.

John