Documente Academic
Documente Profesional
Documente Cultură
August 1, 2019
TRANSMITTAL LETTER
New and revised pages were inserted in this manual in accordance with
the current List of Effective Pages. All pages in the old manual that
needs to be replaced with revised pages were removed. Discard the old
manual upon receipt of this revised manual.
54-02-00
54-10-00
54-20-00
54-30-00
54-40-00
Allowable damage 101-184 Revise text and illustra-
tion to show different
configurations (Internal
CV log 19-03221)
The information contained in this document is Goodrich proprietary information and is disclosed in confidence. It is the property of Goodrich and shall not be
used, disclosed to others or reproduced without the express written consent of Goodrich, including, but without limitation, it is not to be used in the creation,
manufacture, development, or derivation of any repairs, modifications, spare parts, design, or configuration changes or to obtain FAA or any other government
or regulatory approval to do so. If consent is given for reproduction in whole or in part, this notice and the notice set forth on each page of this document shall
appear in any such reproduction in whole or in part. The information contained in this document may also be controlled by the U.S. export control laws.
Unauthorized export or re-export is prohibited.
Copyright License:
Customer is authorized to copy these materials for its own use only, provided that all copyright notices, proprietary legends, confidential markings, and other
restrictive notices appearing on the original materials are preserved on all such copies.
It is customer’s sole responsibility to ascertain and ensure that all materials are current and appropriate for the use to which they are put and Goodrich assumes
no responsibility whatsoever in that regard. Customer agrees to indemnify and save harmless Goodrich against all claims and liability of whatever nature,
including those of third parties (including contractors and vendors to customer) where and by whomsoever brought, resulting from customer’s use of materials
or other information, consultation, assistance, or training furnished or any other performance in connection with this agreement by Goodrich or from the
manufacture, sale, delivery, resale of any product by customer. In no event shall Goodrich be liable for any special, incidental, indirect or consequential or
punitive damages.
RECORD OF REVISIONS
Repair 005 201 Feb 1/19 Repair 010 201 Aug 1/19
202 Feb 1/19 202 Aug 1/19
203 Feb 1/19 *203 Aug 1/19
204 Feb 1/19 204 Aug 1/19
205 Feb 1/19 205 Aug 1/19
206 Feb 1/19 *206 Aug 1/19
207 Feb 1/19
208 Feb 1/19 Repair 011 201 Feb 1/17
202 Feb 1/17
Repair 006 201 May 1/19 203 Feb 1/17
202 May 1/19 204 Feb 1/17
203 May 1/19 205 Feb 1/17
204 May 1/19 206 BLANK
Repair 007 201 Aug 1/19 Repair 012 201 Feb 1/19
*202 Aug 1/19 202 Feb 1/19
203 Aug 1/19 203 Feb 1/19
204 Aug 1/19 204 Feb 1/19
205 Aug 1/19 205 Feb 1/19
206 BLANK 206 Feb 1/19
207 Feb 1/19
Repair 008 201 Feb 1/17 208 Feb 1/19
202 Feb 1/17
Repair 006 201 Feb 1/19 Repair 009 201 Feb 1/19
202 Feb 1/19 202 Feb 1/19
203 Feb 1/19 203 Feb 1/19
204 Feb 1/19 204 Feb 1/19
Repair 053 201 May 1/19 Repair 056 201 Feb 1/17
202 May 1/19 202 Feb 1/17
203 May 1/19 203 Feb 1/17
204 May 1/19 204 Feb 1/17
205 May 1/19 205 Feb 1/17
206 May 1/19 206 Feb 1/17
207 May 1/19 207 Feb 1/17
208 May 1/19 208 Feb 1/17
209 May 1/19 209 Feb 1/17
210 May 1/19 210 Feb 1/17
211 May 1/19 211 Feb 1/17
212 May 1/19 212 Feb 1/17
213 May 1/19 213 Feb 1/17
214 May 1/19 214 Feb 1/17
215 May 1/19 215 Feb 1/17
216 May 1/19 216 BLANK
217 May 1/19
218 May 1/19 Repair 057 201 Feb 1/19
219 May 1/19 202 Feb 1/19
220 BLANK 203 Feb 1/19
204 Feb 1/19
Repair 054 201 Feb 1/17 205 Feb 1/19
202 Feb 1/17 206 Feb 1/19
203 Feb 1/17 207 Feb 1/19
204 Feb 1/17 208 Feb 1/19
205 Feb 1/17
206 Feb 1/17 Repair 058 201 Feb 1/19
207 Feb 1/17 202 Feb 1/19
208 Feb 1/17 203 Feb 1/19
209 Feb 1/17 204 Feb 1/19
210 Feb 1/17 205 Feb 1/19
206 Feb 1/19
Repair 055 201 Aug 1/18 207 Feb 1/19
202 Aug 1/18 208 Feb 1/19
203 Aug 1/18 209 Feb 1/19
204 Aug 1/18 210 Feb 1/19
205 Aug 1/18 211 Feb 1/19
TABLE OF CONTENTS
Subject Page.
No.
Nacelle Introduction................................ 54-00-00 1
Abbreviations................................... 2
Nacelle Parts.................................... 3
Major Engineering Drawings....................... 4
Principle Nacelle Dimensions.................... 6
Nacelle Stationlines............................. 6
Nacelle Radials.................................. 6
Nacelle Zones and Panels......................... 10
Aerodynamic Smoothness........................... 17
Damage Types..................................... 29
Bulk Material Supplier’s List.................... 30
Consumable Materials Index....................... 30
Alphanumeric Index............................... 32
Materials Index.................................. 38
Suppliers Names Addresses........................ 50
Cautions, Warnings and Dangers................... 56
Damage Inspection................................... 54-01-00 1
Types of Damage.................................. 1
Corrosion Damage................................. 4
Composite Structure Tap Test..................... 4
Heat Damage...................................... 7
Acoustic Treatment Blockage Area Limits.......... 8
Damage Cleanup...................................... 54-01-01 1
Nick, Scratch, and Gouge Removal................. 1
Corrosion Damage Removal......................... 4
TABLE OF CONTENTS
Subject Page.
No.
Repair No. 061 -Blocker Door Assembly -Replace 54-30-00
the Bearing Assembly (VRS2141) 201
Repair No. 062 -Pre-Cooler, Heat Shield Peeled
or Missing Top Skin Repair
(VRS2554)............. 201
Repair No. 063 -Thrust Reverser, Translating
Sleeve, Metallic Inner Barrel
Inner (Perforated) Skin Disbond
Damage at Aft Latch Area
(VRS2551)..................... 201
Repair No. 064-Thrust Reverser, Blank Cascade
Panel Assembly (VRS2096)...... 201
Repair No. 065-Translating Sleeve, Inner Skin
Aft Edge (Ramp) Chafing Damage 201
Repair......
Repair No. 066-Translating Sleeve, Corrosion
Damage aft for Forward Split 201
Line
Repair No. 067-Thrust Reverser, Inner Fixed 201
Structure, Lower Bifurcation
Skin Corrosion Repair (CV13-
3762)........................
Repair No. 068-Thrust Reverser, Translating 201
Sleeve Aft Latch Housing And
Keeper Housing, Loose or Missing
Fasteners and Hole Damage
(CV15-1916) ..................
Repair No. 069-Thrust Reverser, C-Duct Fixed 201
Structure Heatshield Repair the
Small Hole (VRS2001-VRS2002)....
Repair No. 070-Thrust Reverser, Translating 201
sleeve Inner Skin at Blocker
Door Islands (CV16-0642).
TABLE OF CONTENTS
Subject Page.
No.
Repair No. 071-Translating Sleeve (Configura- 201
tion 2) Acoustic Panel Perfo-
rated Inner Skin Small Dent
Repair (CV17-01072).
TABLE OF CONTENTS
Subject Page.
No.
Repair No. 009 - Common Nozzle Assembly Aft
Ring Blend Repair............... 201
Repair No. 010 - Common Nozzle Assembly Rubbing
Block Repair.................... 201
Repair No. 011 - Common Nozzle Assembly Outer
Barrel, Outer Skin, Metallic
Patch Repair.................... 201
Repair No. 012 - Acoustically Treated Jet Pipe
-Pin Weld Reair................. 201
Repair No. 013 - Common Nozzle Assembly- 54-40-00
Doubler Weld Repair the
perforated inner skin and Dent
of the Acoustic Panel Repair.. 201
Repair No. 014 - Common Nozzle Assembly-
Inner Perforated Skin Dent and
Disbond Patch Repair.......... 201
TABLE OF CONTENTS
1. Introduction
A. Purpose
54-10-03
- Subject
- Section (Inlet Cowl)
- Chapter (Nacelle)
(4) The sections about the inlet cowl, fan cowl, and thrust
reverser are further subdivided into topic identified by
page number blocks:
C. Service Bulletins
D. Revisions
2. Abbreviations
3. Nacelle Parts
13526A
Nacelle Parts
Figure 1
6. Nacelle Stationlines
7. Nacelle Radials
13527A
13528A
TOP
NAC RAD 360° NAC BUTT LINE 100.0
NAC RAD 0° VERTICLE CENTERLINE
OF NACELLE
NAC WL 100.0
NAD RAD 90° NAC RAD 270°
HORIZONTAL
CENTERLINE
OF NACELLE
Nacelle Radials
Figure 4
B. The zone number has five letters and numbers. See the table
that follows.
(2) The second digit indicates which nacelle and the nacelle
part.
(3) The third digit indicates the side of the nacelle and the
nacelle part.
(4) The first letter indicates the sequence of the access door
within the zone, when you move from top to bottom and from
front to rear.
(5) The second letter indicates the side of the nacelle, left
or right.
13530
13531
13532
13533
9. Aerodynamic Smoothness
Allowable damage
Repairable damage
Damage which makes the replacement of parts necessary
B. Allowable Damage
C. Repairable Damage
(1) There are two types of repairs that can be done on the
nacelle. These are:
(3) Some repairs are time limited. These repairs are given as
practical solution to field repair problems.
D. Non-repairable Damage
To be supplied
ITEM SUPPLIER
NUMBER DESIGNATION SPECIFICATION USAGE CODE
01-012 Isopropanol Alcohol Analar Grade OMAT Solvent Cleaner VK6835
VU1185
LOcal
01-031 Acetone Commercial Grade Thin ceramic V70657
mixture for K6835
spray V81348
application LOCAL
01-201 Distilled or Commercial grade To clean V06337
Deionized water components LOCAL
01-275 Chromate Conversion Alodine 1200S Use for V71410
Coating coating VK0519
Aluminum VK6835
VK7625
01-438 Solvent Turco Solvent 6646 Pre-bond V71410
solvent cleaner
01-452 Phosporic acid Turco W0-1 Solvent cleaner IVAE347
01-457 Solvent Methyl Isobutyl Pre-bond V71361
Ketone solvent cleaner
01-471 Cleaner/Passivator PASA-JELL 101 To clean VIAE367
surface
01-477 Cleaner/Passivator PASA-JELL 101 To clean IVAE367
OMAT:1/276 surface
01-508 Fumed Silica Cab-o-sil grade M5 To clean VIAE462
surface
02-007 Teflon Tape Self Adhesive Coated To prevent over VK2096
Glass Fabric tape run of resin
ITEM SUPPLIER
NUMBER DESIGNATION SPECIFICATION USAGE CODE
02-036 Masking Tape Scotch No. 8402 or To prevent V76381
Polyester Film 8403 overspray V07963
(MYLAR)
02-087 Tymex nylon brush 1/2 x 1-3/4 To clean the Local
components
02-088 Tymex nylon brush 1 x 1-3/4 To clean the Local
components
02-091 Cleaning cloth Cleaning cloth To clean the Local
components
02-097 Lint free gloves Lint free gloves To give Local
Misc 00127-00 protection to
the hands and
materials
02-099 Lint free cloth Lint free cloth To clean the Local
Misc 00125 components
02-107 Plastic, Kraft Paper Plastic Kraft paper To mask area Local
that is not
damaged
02-111 Eye Glasses safety To give Local
protection to
the eyes
02-119 Lockwire MS9226-04 (0.032 in) To lock with Local
wire
02-122 Temporary marker No Blot Ink Pencil, To identify VK6835
Style No. 705 processes
02-127 Lockwire MS9226-03 (0.025 in.) To lock with Local
wire
02-129 Marker Airmarker LN 9051 To identify VIAE28
MTH 337 (MTU Ref) process
02-134 Masking Tape TESA 7469 P-35 To hold the V83334
PMC4134 patch in V99742
position VIAE358
02-147 Lockwire MS 20995C32 To Lock with Local
wire
ITEM SUPPLIER
NUMBER DESIGNATION SPECIFICATION USAGE CODE
02-156 Lockwire MS20995N32 (0.8mm) To Lock with Local
wire
02-158 Release Agent Frekote 33 To clean V51563
surface
02-160 Teflon tape Tynaflor P.T.F.E. To prevent Local,
0.5 in. unwanted epoxy VK6835
bond
02-161 Teflon tape Tynaflor P.T.F.E To prevent Local,
2.0 in unwanted epoxy VK6835
bond
02-162 Syringe, Injection To fill voids Local
with epoxy
02-163 Nylon bagging film 2 mil To contain a V85670
vacuum
02-164 Phenolic 5 mil To fill V80524
microballoons structural
repairs
02-165 Graphite fabric AH370-5H, 0.0145 in. Structural V0CZA6
material
02-166 Breather cloth RC-3000-10 To vacuum and V85670
cure repair
processes
02-167 Fiberglass fabric Type 181 Structural Local
layer
02-168 Nonporous parting To cure repair Local
film materials
02-169 Porous parting film To remove Local
excess resin
02-170 Silicone rubber 0.125 in. thick To ensure Local
sheet 0.125 in. wrinkle free
thick pressure
02-171 Aluminum alloy sheet 2024-T3, 0.063 in To maintain Local
contour
02-172 Aluminum alloy plate 2024-0, 0.125 in Misc. use Local
ITEM SUPPLIER
NUMBER DESIGNATION SPECIFICATION USAGE CODE
02-178 Masking Tape No. 250 To prevent local
overspray
02-182 Metal foil tape Aluminum foil tape Misc use 76381
no. 428B
02-206 Indicator paper ALKACID Misc Use Local
02-207 Indicator paper pHYDRION Misc Use Local
02-214 Aluminum alloy sheet 2024-T3, 0.050 in. Misc use Local
02-215 Aluminum alloy sheet 2219-T62, 0.050 in. Misc use Local
02-216 Aluminum alloy sheet 2219-T81, 0.050 in Misc use Local
02-219 Aluminum alloy sheet 2219-T62, 0.064 - Misc use Local
0.074 in
02-220 Aluminum alloy sheet 2219-T62, 0.025 in. Misc use Local
02-221 Aluminum alloy sheet 2219-T62, 0.090 in Misc use Local
02-224 Silicone Adhesive Flashtape 2 To prevent V85670
Polyester Tape unwanted
cleaner or
passivator
02-245 Aluminum Alloy 2219-T81 Misc use Local
02-255 Titanium Sheet 0.05 in (2,27 mm) Misc use Local
Thick (AMS4901)
02-257 Aluminum Laminated 1.01n Wide, 0.094 in Misc use Local
Shim Thick Comp I, Type
II, Class I MIL-S-
22499
02-265 Tape, Double Layer D/W 498 pressure To secure an V60890
Sensitive Tape PMC object
4480-1 Thru -8
02-300 Expanded Copper CU 040CX Lightning- V0KWM1
Screen (ECS) strike
protection
02-320 Titanium Sheet, Ti- AMS 4919, Duplex Use to patch Local
6A1-Sn-4Zr-2Mo, Annealed, 0.063 IN. damaged skin
0.63 in.
ITEM SUPPLIER
NUMBER DESIGNATION SPECIFICATION USAGE CODE
02-321 Aluminum Sheet 2024-T, 0.050 in Misc use local
Thick
02-322 Aluminum sheet 2024-T3 0.025 in. Misc use Local
02-323 Aluminum Sheet 2024-T3 0.045 in. Misc Use Local
02-324 Aluminum Honeycomb AL 5052 4.1 PCF Misc use Local
core 0.0025 in. foil
02-331 Stainless Steel Wire Gordon “18 To remove scale VIAE418
Brush or surface
damage
02-334 Porous film release A5000P3 To prevent VIAE78
OMAT 2/154 (RR-REF) unwanted resin VIAE74
02-349 Cheese Cloth unsized 40X 32 Misc use V2A851
Yarns/inch V4N020
GA 100-2 V80769
Local
02-357 Al-clad sheet Misc use
02-360 Aluminum Sheet 2024-0 0.010 to 0.100 Misc use Local
in. thick sheet
02-367 Non-porous parting A5000 To prevent VIAE78
Film OMAT: 2/131A (RR Ref) unwanted resin VIAE74
04-005 Jointing Compound DTD 900/4586, Hylomar To fill joint VK3504,
Aerograde Medium gaps VK6835
05-016 Garnet paper 60 grit, Grade 0.5, To remove Local
A-A-1201 Class 2 corrosion and
to smooth
scratches
05-019 Waterproof silicon 400 grit, A-A-1047A To finish Local
carbide abrasive smoothing
paper process
05-020 Waterproof Silicon 320 grit, A-A-1047A To contour Local
carbide abrasive composite
paper repairs
ITEM SUPPLIER
NUMBER DESIGNATION SPECIFICATION USAGE CODE
05-021 Waterproof silicon 240 grit, A-A-1047 To contour Local
carbide abrasive composite
paper repairs
05-022 Waterproof abrasive Aluminum Oxide No. To roughen the V62596
paper 240 surface
05-057 Jointing Compound DELETED
05-064 Waterproof Silicon 240 grit, A-A-1047A To contour Local
carbide abrasive composite
paper repairs
05-073 Aluminum Oxide 300 grit To finish Local
Abrasive Paper smoothing
process
05-074 Aluminum Oxide 180 grit To remove Local
abrasive paper material
05-081 Waterproof silicon 150 grit, A-A-1047 To remove Local
carbide abrasive carbon material
paper
05-112 Emery Paper A-A-1049 To roughen the V4197
Grade 0 surface VA2549
Grit size 400 IAE302
05-126 Scotch Brite MIL-A-9962A, Type 1, To clean Local,
Grade A surfaces VK0993
05-127 Metal Marking Crayon Best White -352 To mark V70362,
Col-Erase 1286 White temporarily V32988
ITEM SUPPLIER
NUMBER DESIGNATION SPECIFICATION USAGE CODE
07-157 Primer Converter 910X456 Catalyst for VONYS9
910X456 primer system
06-131 Marking Pen Sharpie Marker No. To mark V86874
30001 Black, No. permanently
30002 Red, No. 30003
Blue
07-023 Chromate conversion MIL-C-5541, Alocrom To increase Local,
coating 1200/MP0002 corrosion V71410
resistance and
prepare for
paint
07-028 Alodine 1200 MIL-C-5541 To increase Local
Chemical conversion corrosion
coating resistance and
prepare for
paint
07-066 Primer thinner, Use TL52-66 To thin primer
07-139 for spray
application
07-067 Primer converter, X337 Catalyst for
Use 07-140 primer system
07-071 Primer base, Use 463-7-26 Base component
07-137 of coating
system
07-072 Primer converter, X-369 Catalyst for
Use 07-138 primer system
07-073 Thinner TL-102 To thin primer Local
for spray
application
07-085 Epoxy Varnish TVZ 119/121 Protective VK4585
coating for VK1270
composite
materials
07-098 Clear Polyurethane Polyurethane 683-3-2 Base component V98502
of coating
system
ITEM SUPPLIER
NUMBER DESIGNATION SPECIFICATION USAGE CODE
07-106 Chromate conversion Alodine 1500 To increase Local
coating corrosion
resistance and
prepare for
paint
07-115 I Primer Class M Primer Converter V0S4B8
EC-178
07-116 Thinner TR-19 V0S4B8
07-126 Water Soluble Primer 44-GN-11(Base) Base component V5M511
of coating
system
07-127 Water Soluble Primer 44-GN-11 (Catalyst) Catalyst V5M511
component of
primer system
07-128 Water Soluble Primer DM Water (Thinner) To thin primer V5M511
07-137 Catalyst EC-213 Catalyst V91342
component of
primer system
07-138 Primer base 10-P20-13 Base component V91342
of coating
system
07-139 Catalyst EC-117 Catalyst V91342
component of
primer system
07-140 Epoxy primer 10-P4-2 Base component V91342
of coating
system
07-152 Red Fluorescent Color no 38903 Paint VIAE431
Paint and clear VK6835
lacquer
07-156 Primer Base 513X384 Base component VONYS9
of coating
system
07-158 Thinner 020X364 To thin primer VONYS9
ITEM SUPPLIER
NUMBER DESIGNATION SPECIFICATION USAGE CODE
07-160 Ceramic Coating CeRam-Kote 54 TZM Protective VIAE438
Part A agent VIAE439
07-161 Ceramic Coating CeRam-Kote 54 TZM Protective VIAE438
Part B agent VIAE439
08-021 EA934NA Adhesive Two Part Pack, Hysol To bond V33564
EA 934 NA composites and
metals
08-024 Sealant PR-1422 To seal VONYS9
V51563
08-028 EA956 Adhesive Two Part Epoxy, Hysol To bond V33564
EA956 composites and
metals
08-029 Primer base, 463-6-27 Base component
Use 07-140 of coating
system
08-030 Sealant 90-006, Two Part Pack To seal and V71984,
waterproof VK6835
08-031 Silicone Rubber DOW CORNING RTV 732 To seal and V51563
Compound liquid proof VK6835
VK7550
Primer, adhesion/ PR-1200 Base component V71984,
promoter of coating Vk6835
system
Aerodynamic Sealant DAPCO 2100 To seal and V1XNT8
waterproof
08-034 Adhesive EA956/L3,Hysol, Two- To bond V3364,
Part Epoxy composite VK4585
materials
08-043 Cold Curing Silicone Deleted
Compound
08-050 Resin EA9390, Hysol, Part A To repair V3364,
and B composite VK4585
materials
ITEM SUPPLIER
NUMBER DESIGNATION SPECIFICATION USAGE CODE
08-051 Sealant tape GS-213 To seal vacuum VK4585
bag
08-052 Non-perforated FEP 100-R-WT/A4000 VIAE252
release film White VIAE74
VK4585
08-056 Phenolic Deleted
microballoons, Use
02-164
08-057 Breather fabric Airbleed 10 To ensure gas VIAE78
removal
08-058 Dry carbon fiber 3K-70-PW (Dry) Structural VK4585
fabric material
08-059 Dry carbon fiber 3K-135-8H (Dry) Structural VK4585
fabric material
08-061 Perforated release NF.0025(P) To aid spread VIAE480
film of bonding VK4585
agent
08-063 Aluminum honeycomb 1/4 in. - 5056-0.0025 Structural V04621,
core (5.2 PCF) 0.76 material VK4585
08-065 Aluminum honeycomb 1/4 in. - 5056-0.0025 Structural V04621,
core (5.2 PCF) 0.79 material VK4585
08-066 Aluminum honeycomb 3/8 in. - 5052-0.0015 Structural V04621,
core (2.3 PCF) 0.82 material VK4585
08-071 Aluminum Honeycomb 3/16 in Structural V04621
Core 5052-0.0015 material VK4585
(3.1PCF) 0.5
08-072 Potting compound CG 1305 2-Part Filler or VK1007,
adhesive VK4585
ITEM SUPPLIER
NUMBER DESIGNATION SPECIFICATION USAGE CODE
08-078 Adhesive EA9321 For potting, V33564
core splice and
faying surface
08-085 - Deleted -
08-086 Bonding Film FM350 NA Use for bonding V28174
Adhesive OMAT: 8/231
08-087 Bonding Film FM350 NA Use for bonding V28174
Adhesive OMAT: 8/225
08-088 Forming Adhesive FM-410-1, Grade 50 Use for bonding V28174
OMAT: 8/224
08-089 Foaming Film FM-410-1, Grade 100 Use for bonding V28174
Adhesive OMAT: 8/224
08-090 Foaming Film MA562, Grade 50 Use for bonding VS0090
Adhesive
08-093 I primer Class M Catalyst for
bonding agent
08-104 Epoxy Paste Adhesive EA9394 Hysol Use for bonding V33564
VU3167
VK3504
IAE200
08-121 Adhesive Loctite 680 Use for bonding V05972
08-125 Sealant PR-1422B-1/2 (SEMKIT Use to seal VF0229
CARTRIDGE)
08-127 Fine-Mad Scotch Deleted
Brite
08-131 Adhesive EA9396 Use for bonding V33364
OMAT: 8/197
08-132 Bleeder material DRY G120 Glass/105 To aid bleed IAE421
GSM/ Crow Foot bonding agent K6835
MIL-C-908AC TYpe III
OMAT: 2/155
08-136 Adhesive Film FM300-2M Use for bonding V84518
OMAT: 8/238
ITEM SUPPLIER
NUMBER DESIGNATION SPECIFICATION USAGE CODE
08-137 Adhesive Primer BR-127 Use for bonding V84518
OMAT: 8/238
08-138 Pre-impregnated M20/40%/G904 Structural V84518
graphite fabric OMAT: 8/242 material
08-139 M20 Glass, Prepreg M20/39%/120 Glass Structural V84518
Fabric, Fiberglass material
08-140 Sealant PR1995 Class B To seal VONYS9
Primerless
08-141 Sealant, Proseal 870 B-1/2 Seal surface VONYS9
Polysulphide two areas
part
08-143A Potting Compound, EPOCAST 1614-A1 Edge and VIAE432
Epocast 1614-A1 cavity filler
08-144 Polystop LP Sikkens POLYSTOP LP SIKKENS Filler VIAE436
Stopper Stopper
08-146 Sealant, PR-1436 G B2 Seal Surface VONYS9
Polysulphide area
12-012 Cushioning felt BS 4060 A97/2G To absorb VIAE266
vibration or
reduce impact
between
composites
12-024 Tacky tape Bag sealant To seal vacuum V53309
bag
12-028 Thermal insulation MIN-K To control V0UHC8
material 36 x 36 x 1/8 in. heating of
16lbs ft3 density selected areas
flexible/mid-range/
square stitched (MRS)
Melting point: 1200°F
(649°C) Steady State
Service
12-029 Foil (pattern) CRES sheet type 321, To protect Local
0.016 in. thermal
insulation
ITEM SUPPLIER
NUMBER DESIGNATION SPECIFICATION USAGE CODE
12-030 Foil (plain) AMS 5510, .003/.004 To protect the Local
in. smooth 321 thermal
insulation
U2-0007 Chromate conversion Bonderite M-CR 1500 To increase Local
coating corrosion
resistance and
prepare for
paint
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INCLUDE
MANUFACTURER'S INSTRUCTIONS, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY
CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY
INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES INSTRUCTIONS
ON HOW TO SAFELY USE, KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW TO SAFELY USE,
KEEP, AND DISCARD CHEMICALS.
DAMAGE INSPECTION
1. Types of Damage
The terms specified here are guides to help you determine the type of
damage that the component has.
A. Composite Structures
2. Corrosion Damage
A. Equipment
A small rod, with 0.375 inch (9.52 mm) diameter ball on one end.
It may be bought locally or made from mild steel or brass.
(a) Tap the panel surface with the ball end of the rod.
(c) Note any change of pitch in the sound given out from
the panel. This shows a delamination at that
location.
(2) Test the outer surface of the panel. Mark the areas that
indicates a change in pitch of the sound.
4. Heat Damage
COLOR QUALITY
Metallic Acceptable
Straw Acceptable
Gold Acceptable
Blue Acceptable
Green Acceptable
Purple Acceptable
Reddish Brown Reject
Dark Gray Reject
Light Gray Reject
White Reject
(1) 3.33 x(Inlet blocked area) + 0.54 X (Fan Case blocked area
+ Thrust Reverser blocked area) + 0.53 x (CNA blocked
area) + 4.3 x (Hot Stream blocked area) <= 1000
(2) 1.63 x(Inlet blocked area) + 0.43 X (Fan Case blocked area
+ Thrust Reverser blocked area) + 4.9 x (CNA blocked area)
+ 11.11 x (Hot Stream blocked area) <= 1000
2 3
1 4
INDEPENDENT CUMULATIVE
REPAIR AREA BLOCKAGE LIMIT BLOCKAGE LIMIT
ZONE
ZONE in² (A) (B)
DESCRIPTION
LOCATION (m²) in² in²
(cm² ) (cm² )
A5S432b
DAMAGE CLEANUP
A. Aluminum Alloys
B. Titanium
(5) Support drums for drum sanders must have an outer layer of
rubber or other flexible material at least 0.10 inch
thick.
(6) Do not stay in one area too long and do not use too much
pressure or speed (2000 surface feet per minute, maximum)
on local areas. Parts with heat marks which cannot be
removed with methyl ethyl ketone (MEK) must be replaced.
V2500
METAL OR 350 SCOTCH-
MATERIALS ABRASIVE STAIN- MESH BRITE
TO BE ALUMINUM SILICON FABRIC ALUMI- LESS OR TYCRO
PROCESSED RESTRICTIONS OPERATION OXIDE CARBIDE GARNET OR PAD NUM STEEL FINER WHEELS
CORROSION
FERROUS DOES NOT APPLY 150-
REMOVAL 180- FINE TO X X X 5A OR 75
NICKEL TO STEEL HEAT FINER
OR FINER ULTRAFINE MEDIUM
AND TREATED TO
FAIRING
COBALT STRENGHTS TO
ALLOYS 220,000 PSI 7S
AND ABOVE FINISHING 400 X X X
FINE
ALUMINUM CORROSION
DO NOT USE 60- VERY FINE 5A
ALLOYS REMOVAL 7/0 X X
SILICON CARBIDE FINER AND MEDIUM
OR FINER
EXCEPT ABRASIVE. ULTARFINE
FAIRING
CLAD GRINDING IS
ALUMINUM NOT PERMITTED
FINISHING 400 X X
Figure 1
54-01-01
GRINDING IS
STRUCTURAL REPAIR MANUAL
CARBIDE ULTARFINE
FAIRING
ALLOYS ABRASIVES.
GRINDING IS
Information subject to the limitation contained in the title page section of the manual.
NOT PERMITTED FINISHING 400 X X
CORROSION
REMOVAL 80- 80- 5A OR 75
Rohr, Inc., a subsidiary of Goodrich Corporation, operating as Goodrich Aerostructures; Goodrich Proprietary
OR FINER FINER MEDIUM
TITANIUM GRINDING IS FAIRING
NOT PERMITTED
CLEANING 150- 7S
AND 180-
13559
FINER FINER FINE
FINISHING
Feb 1/17
Page 3
DAMAGE CLEANUP
GOODRICH AEROSTRUCTURES
STRUCTURAL REPAIR MANUAL
C. Composites.
(1) Remove the corrosion with rotary files, rubber backed disc
sanders, carbide tipped scrapers, aluminum wool, aluminum
oxide abrasive papers, etc. See Figure 1.
(a) Blend the edges of the damage area into the areas
which adjoin it.
B. See the allowable damage section to make sure that the part is
serviceable after the corrosion has been removed. Corrosion
damage is the same as a gouge.
GENERAL REPAIR
B. Fastener Installation
C. Primer Application
(2) If no other cracks are found, make the hole 1/16 inch
(1.58 mm) larger.
(3) If cracks are found, make the hole larger by 1/16 inch
(1.58 mm) increments until the crack is removed.
(4) Ream the hole to the finished size for installation of the
fastener.
(1) Drill a 0.25 inch (6.12 mm) hole at each end of the crack.
Make sure the centers of the holes are 0.10 inch (2.45 mm)
beyond the end of the crack.
(2) Check to see if the crack has continued to the other side
of the hole.
3. Repair Sealant
B. Remove all grease, oil, dirt, and other foreign materials from
the part surface.
C. Taper the ends of the remaining seal for a minimum of 0.5 inch
overlap onto the new sealant.
NOTE: Send the ends of the remaining seal to help the new
seal to stick to it.
(1) Apply the sealant into the seam between the two parts.
Refer to Table 1 - Sealant and Adhesion Primer/Promoter
Combination.
SEALANT COMES
OUT THIS SIDE FLOW GUN
INJECTION
HOLE
FLOW GUN
(1) Cover the surface next to the slot with masking tape.
(3) Smooth the sealant and press it into the slot with a
spatula.
(1) Clean the fastener of all oil, grease, dirt and other
foreign material.
E. Remove the water with clean acetone, or solvent and let the
surface dry.
NOTE: You must refer to 54-01-00 Acoustic Treatment Blockage Area Limits
before you do repairs to acoustic areas of the thrust reverser.
REPAIR 001
EDGE EROSION REPAIR
LEADING EDGE OF COMPOSITE PARTS
(VRS2082)
1. General
D. There are not any limitations to the size of this repair except
those described in the context of this repair.
2. Reference Information
VRS2082
A. Standard tools
Paint brush
Spray tools
Standard shop tools
Wet film thickness gauge
E. Component Material
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND
GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU
OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED.
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USED,
KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
B. Clean the surface with a Comat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface clean and dry
before the solvent dries.
C. Apply 02-178 masking tape to cover the rivet row behind the
leading edge of the part to prevent the CoMat 07-160 ceramic
coating from being applied to the heads of the Monel rivets.
G. Clean the repair area with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Clean the surfaces before the
solvent dries.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND
GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU
OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED.
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USED,
KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP AND DISCARD CHEMICALS.
A. Mix the CoMat 07-160 ceramic coating Part A. Use a paint shaker
machine to mix thoroughly for four to six minutes at 72°F
(22°C).
CAUTION: ALWAYS POUR COMAT 07-160 CERAMIC COATING PART A INTO COMAT
07-161 PART B. DO NOT MIX BY POURING COMAT 07-161 PART B
INTO COMAT 07-160 CERAMIC COATING PART A.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND
GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU
OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED.
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USED,
KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP AND DISCARD CHEMICALS.
CAUTION: COMAT 07-160 CERAMIC COATING MUST BE APPLIED ONLY WHEN THE
AMBIENT TEMPERATURE AND THE REPAIR SURFACE IS ABOVE 40ºF
(4ºC). DO NOT APPLY COMAT 07-160 CERAMIC COATING IF THE
REPAIR SURFACE IS WET OR IF THE RELATIVE HUMIDITY IS
GREATER THAN 85%.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED REPAIR SURFACE. THIS PREVENTS CONTAMINATION.
B. Use a wet film thickness gauge to measure the depth of the CoMat
07-160 ceramic coating. Apply more coats as necessary until a
film thickness of 6 to 8 mils (152 to 203 microns) is reached.
Make a note of how many coats were applied to obtain the proper
thickness.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND
GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU
OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED.
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USED,
KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP AND DISCARD CHEMICALS.
CAUTION: COMAT 07-160 CERAMIC COATING MUST BE APPLIED ONLY WHEN THE
AMBIENT TEMPERATURE AND THE REPAIR SURFACE IS ABOVE 40ºF
(4ºC). DO NOT APPLY COMAT 07-160 CERAMIC COATING IF THE
REPAIR SURFACE IS WET OR IF THE RELATIVE HUMIDITY IS
GREATER THAN 85%.
A. Examine the CoMat 02-178 masking tape and replace any that was
damaged from preparing the repair surfaces. Make sure all rivet
heads are covered with CoMat 02-178 masking tape. Refer to
figures 201, 203, 204 and 205 for proper application of CoMat
02-178 masking tape.
B. Clean the repair area with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Clean the surfaces before the
solvent dries.
E. Remove the CoMat 02-178 masking tape from the edge of the
repair 20 minutes after the final spray of the CoMat 07-160
ceramic coating has been applied to allow the edge of the
coating to feather itself onto the surface of the part.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND
GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU
OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED.
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USED,
KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP AND DISCARD CHEMICALS.
CAUTION: DO NOT USE A TACK RAG ON THE COMAT 07-160 CERAMIC COATING.
DO NOT APPLY ANY SOLVENTS TO THE CERAMIC SURFACE. THE NEW
CERAMIC SURFACE IS ABLE TO ACCEPT THE COMAT 07-098 CLEAN
POLYURETHANE COATING WITHOUT FURTHER PREPARATION.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE COMAT
07-160 CERAMIC COATING. THIS PREVENTS CONTAMINATION.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND
GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU
OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED.
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USED,
KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP AND DISCARD CHEMICALS.
10. Apply the Aerodynamic CoMat 08-140 Sealant to the Leaded Edge Area
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND
GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU
OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED.
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USED,
KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE NEW
COMAT 07-160 CERAMIC COATING. THIS PREVENTS
CONTAMINATION.
A. Make sure that all old CoMat 08-140 sealant has been
successfully removed from the joint area (refer to step 4A).
B. Apply the CoMat 08-140 sealant to the joint between the lip
segment and the outer barrel fwd edge. Make the CoMat 08-140
sealant flush with the aft edge of the lipskin and the fwd edge
of the outer barrel. Refer to 54-00-00 for Aerodynamic
Smoothness requirements.
REPAIR 002
MOISTURE REMOVAL PROCESS
(VRS2371)
1. General
2. Reference Information
Reference Title
PCI-V2500-1IA (PCI) Overhaul Processes and Consumables Index
SAE ARP4977 Drying of Thermosetting Composite Materials
A. Standard tools
B. Drying of part locally 12 in. (30 cm) around damaged area using
heat blanket.
C. Inspect
C. Inspect
HEAT BLANKET
COMAT 02-166 COMAT 02-163
PIECE OF HONEYCOMB
THERMOCOUPLES
NOTE: Use rigid screen as required to prevent core damage during cure
cycle.
Figure 201
PIECE OF HONEYCOMB
COMAT 02-163
ADJUSTABLE
VACUUM COMAT 02-166 INTAKE VENT
LINE LINE
VACUUM
COMAT 02-166 THERMOCOUPLES LINE
HEAT BLANKET
VACUUM BAG
A5S125
NOTE: Use rigid screen as required to prevent core damage during cure
cycle.
Figure 202
REPAIR 003
GENERAL - SURFACE PREPARATION OF ALUMINUM DETAILS USING PHOSPHORIC
ACID NON TANK ANODIZE (PANTA)
(VRS2369)
1. General
NOTE: The general procedures listed herein are to be used with the
general repairs and specific repairs included in this
Structural Repair Manual.
Refer to the specific repair section for the repair limits and
material of the component before using these repair
instructions.
2. Reference Information
Reference Title
PCI-V2500-1IA (PCI) Overhaul Processes and Consumables Index
SAE ARP1575 Surface Preparation and Priming of Aluminium
Alloy Parts for High Durability Structural
Adhesive Bonding - Hand Applied Phosphoric
Acid Anodizing
4. Instructions
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
PHOSPHORIC ACID
GAUZE
CAB-O-SIL
PLATE
GAUZE
GAUZE
A5S403
DC POWER
SOURCE RECTIFIER
A
STAINLESS STEEL SCREEN
(+)
GAUZE
(-)
PLATE
SCREEN (-)
JELLED ACID
GAUZE
JELLED ACID
GAUZE
JELLED ACID
GAUZE
JELLED ACID
PLATE (+)
JELLED ACID
A5S402
POLARIZED FILTER
A5S404
REPAIR 004
GENERAL - COMPOSITE REPAIRS
VACUUM BAGGING PROCEDURES
1. General
2. References
Reference Title
SAE ARP5143 Vacuum Bagging of Thermosetting Composite
Repairs
A. Standard tools
B. Consumable Materials
CAUTION: USE COMAT 02-097 LINT FREE GLOVES TO MOVE OR TOUCH CLEANED
AREAS OR CONTAMINATION WILL OCCUR.
NOTE: When using a heat blanket, check the size of the blanket,
since this will determine the location of the vacuum bag
sealant tape. Ensure that no damage will occur to the part
when applying vacuum pressure. Remove any part or hardware
that can be damaged by this procedure.
(1) Put the heat blanket over the breather cloth. Make sure it
extends a minimum of 2 in. (51 mm) around the edge of the
material to be cured.
M. Put four to five layers of CoMat 02-166 breather cloth over the
heat blanket. This will insulate the heat blanket and prevent
damage to the nylon bagging film.
P. Connect the vacuum source and smooth the bag by hand pressure
as the air is removed. Remove all air from under the vacuum bag.
A minimum vacuum 22 in.Hg (75 kPa) is necessary.
3 LAYERS OR LESS
- 1 Ply of CoMat 08-132 bleeder cloth
PREPREG MATERIAL AND/OR
ADHESIVE FILM OVER 3 PLIES
- Add 1 ply of CoMat 08-132 bleeder cloth
every 3 plies
Table 1
VACUUM
GAUGE VACUUM PORT
VACUUM PORT BREATHER
BAG FILM CLOTH PAD HEAT BLANKET
CoMat 02-163 CoMat 02-166 (OPTIONAL)
BREATHER
CLOTH
INSULATION CoMat 02-166
BREATHER (OPTIONAL)
CLOTH
CoMat 02-166 CAUL PLATE
(OPTIONAL)
THERMOCOUPLE
NON POROUS
BREATHER PARTING FILM
CLOTH CoMat 02-168
CoMat 02-166 BLEEDER
REPAIR ASSY MATERIAL
THERMOCOUPLE CoMat 08-132
PERFORATED
RELEASE FILM
CoMat 08-061
A5S548
MONITORING THERMOCOUPLE
HEAT BLANKET (ON HEAT BLANKET)
E
REPAIR AREA
MONITORING
THERMOCOUPLE
(ON PART) MONITORING THERMOCOUPLE
(ON HEAT BLANKET)
CONTROL THERMOCOUPLE
MONITORING (ON PART)
THERMOCOUPLE
(ON PART)
HEAT BLANKET
POWER CABLE
NOTE:
- RECORD THERMOCOUPLES LOCATION USING SAME NUMBER INDICATION AS THE
TEMPERATURE RECORDER.
- INSTALL AT LEAST (2) THERMOCOUPLES TO MONITOR HEAT SOURCE.
- INSTALL AT LEAST (3) THERMOCOUPLES TO MONITOR AND CONTROL BONDLINE
TEMPERATURE.
- THERMOCOUPLES SHALL BE ISOLATED FROM PART.
- THERMOCOUPLES SHALL BE PLACED TO REPRESENT AREAS OF HIGHEST AND LOWEST
HEAT UP RATE.
- LOCATION ON FIGURE TO BE USED AS AN EXAMPLE.
A5S549
INCORRECT CONDITION
CORRECT CONDITION
A5S550
BREATHER MATERIAL
A5S551
VACUUM LINE
BREATHER MATERIAL
MOUNTING PAD
4.0 IN 4.0 IN
(101.6 mm) (101.6 mm)
VACUUM LINE
A5S552
REPAIR 005
GENERAL - PASTE AND/OR LIQUID ADHESIVE
MIXING AND CURING
(VRS2373)
1. General
2. References
3. Consumable Materials
A. Consumable Materials
4. Instructions
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND
GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU
OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED.
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USED,
KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP AND DISCARD CHEMICALS.
(2) The target Resin content for a typical wet lay-up laminate
is 50% by weight. Therefore, the weight of the mixed resin
should equal the weight of the fabric. It is recommended
that 20% be added to the gross weight of the mixed resin
to account for transfer inefficiencies.
(3) Determine the weight of the resin and the weight of the
hardener.
(1) Determine the total bond area of the repair. This is the
total area that will be covered with adhesive.
(4) Determine the weight of the resin and the weight of the
hardener.
D. Curing of Adhesives
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(4) Two part adhesive accelerated cure cycle: cure the repair
area to the temperature specified in TABLE I (accelerated
cure).
Table 1:
Mix
Ambient Ratio
Pot Life
Cure Accelerated by Density
CoMat Minutes/
(min. @ Cure Weight (mixed
material lb. (kg) @
77°F/ (±10°F/±5°C) (resin/ g/ml)
77°F(25°C)
25°C) curing
agent)
NOTE:
(1) Heat application methods as per applicable SRM.
(2) The cure condition specified for the individual adhesive
type is the minimum time required at the indicated
temperature to provide adequate adhesive bond strength for
part usage.
(3) Density to be used as reference only. Always refer to
manufacturer data sheet.
(4) Cure cycle defined in applicable SRM take precedence over
Table I and should be referred to for further guidance.
(5) The pot life times are based for 77°F (25°C). At 90°F
(32ºC), these times are reduced by 50%.
(6) RT stands for room temperature.
Table II
NOTE:
(2) The base resin and hardener should be mixed first before
adding the additive to have a more homogeneous mix.
REPAIR 006
GENERAL - ADHESIVE PRIMER APPLICATION
(VRS2374)
1. General
2. References
PCI-V2500-1IA (PCI) Overhaul Processes and
Consumable Index
3. Consumable Materials
A. Consumable Materials
V2500
54-02-00 REPAIR 006
Page 201
May 1/19
Printed in the U.S.A.
Rohr, Inc., a subsidiary of Goodrich Corporation, operating as Goodrich Aerostructures; Goodrich Proprietary
Information subject to the limitation contained in the title page section of the manual.
U.S Export Classisfication: EAR 9E991
GOODRICH AEROSTRUCTURES
STRUCTURAL REPAIR MANUAL
4. Instructions
CAUTION: USE CLEAN, WHITE GLOVES THAT ARE LINT FREE TO MOVE OR
TOUCH SURFACE THAT HAS BEEN PREPARED BY THIS PROCEDURE
OR CONTAMINATION WILL OCCUR.
V2500
54-02-00 REPAIR 006
Page 202
May 1/19
Printed in the U.S.A.
Rohr, Inc., a subsidiary of Goodrich Corporation, operating as Goodrich Aerostructures; Goodrich Proprietary
Information subject to the limitation contained in the title page section of the manual.
U.S Export Classisfication: EAR 9E991
GOODRICH AEROSTRUCTURES
STRUCTURAL REPAIR MANUAL
(6) The primer is to be cured after the air dry cycle using
certified explosion proof heat sources at 240°F to
260°F (115°C to 126°C) for 30 minutes. The repair parts
may be cured in an oven.
V2500
54-02-00 REPAIR 006
Page 203
May 1/19
Printed in the U.S.A.
Rohr, Inc., a subsidiary of Goodrich Corporation, operating as Goodrich Aerostructures; Goodrich Proprietary
Information subject to the limitation contained in the title page section of the manual.
U.S Export Classisfication: EAR 9E991
GOODRICH AEROSTRUCTURES
STRUCTURAL REPAIR MANUAL
CAUTION: USE CLEAN, WHITE GLOVES THAT ARE LINT FREE TO MOVE OR
TOUCH SURFACE THAT HAS BEEN PREPARED BY THIS PROCEDURE
OR CONTAMINATION WILL OCCUR.
(5) The primer is to be cured after the air dry cycle using
certified explosion proof heat sources at 240° to 260°F
(115° to 126°C) for 30 minutes. The repair parts may be
cured in an oven.
V2500
54-02-00 REPAIR 006
Page 204
May 1/19
Printed in the U.S.A.
Rohr, Inc., a subsidiary of Goodrich Corporation, operating as Goodrich Aerostructures; Goodrich Proprietary
Information subject to the limitation contained in the title page section of the manual.
U.S Export Classisfication: EAR 9E991
GOODRICH AEROSTRUCTURES
STRUCTURAL REPAIR MANUAL
REPAIR 007
GENERAL - WET LAYUP PROCESS
(VRS2375)
1. General
2. Reference
A. Standard Equipment
Spatula
Roller
Plastic squeegee
Knife or shears
B. Consumable Materials
4. Instructions
NOTE: Figure 201 is for a typical repair ply layup and is for
reference only. Refer to the specific repair for all repair
ply layup information.
E. Determine the amount of resin mix required for each fabric ply.
Refer to SRM 54-02-00 General REPAIR 005 (VRS2373) Paste and/or
Liquid Adhesive Mixing and Curing.
G. Cover the fabric with the second piece of CoMat 02-168 parting
film.
H. Press the resin through the fabric by working over the parting
film with a squeegee or roller. This impregnates the fabric
with resin and removes entrapped air.
I. Work excess resin to the edges of the fabric such that the
fabric weave is barely visible.
K. Make a template for each ply using CoMat 02-036 mylar. Mark the
ply number and ply orientation on each template. The
orientation should be the same as in the original structure.
Refer to the repair for this information.
(1) Clean the work surface and the cutting tools with CoMat
01-438 solvent. Shears or a knife and a straight edge
should be used for cutting repair material.
M. Apply a light coat of resin over the repair area. Refer to SRM
54-02-00 General REPAIR 005 (VRS2373) Paste and/or Liquid
Adhesive Mixing and Curing.
N. Remove the CoMat 02-168 parting film from one side of the
smallest ply repair layup. Place the exposed face against the
repair area with the proper orientation and overlap all around.
O. Use a plastic squeegee over the CoMat 02-168 parting film that
covers the repair area to remove wrinkles and entrapped air. Do
not apply excessive pressure because it will produce a ply
deficient in resin.
P. Remove the CoMat 02-168 parting film from the ply and the next
larger ply of the layup. Place the next ply on the repair area
with the proper orientation and overlap all around. Refer to
the specific repair for this information.
R. Place CoMat 02-036 mylar over the layup and use a roller or
spatula to squeeze out air bubbles and excess resin. Push the
roller from the center of the layup to the edges.
REPAIR 008
GENERAL - FABRICATION AND INSTALLATION OF A BACKUP PLATE
(VRS2377)
1. General
B. Consumable Materials
3. Instructions
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH
PREIMPREGNATED FABRICS. THIS PREVENTS CONTAMINATION.
A. Cut the plies for the backup plate. The backup plate must
overlap the damage cutout by 1.0 in. (25,4 mm) all around when
installed.
B. Put all the plies into position on a hard surface that has the
same contour as the repair area. Once cured, the backup plate
must fit on the repair area with light finger pressure.
(1) Drill four 0.098 in. (2,5 mm) diameter holes through the
backup plate. Locate the holes as shown in Figure 201.
(3) Bond the backup plate to the backside of the skin around
the cutout. Apply adhesive to the mating surface of the
backup plate and the inner surface of the skin per
SRM 54-02-00 REPAIR 005 (VRS2373), Paste and/or Liquid
Adhesive Mixing and Curing. Put the backup plate through
the cutout and onto the inner surface of the skin. Make
sure the plate has an equal overlap around the cutout. Use
a rod as shown in Figure 201. Twist the lockwire until the
backup plate is firmly in place.
NOTE: Do not apply too much tension to the lockwire. This
can cause the plate to be warped.
(4) Apply more adhesive to fill the lockwire holes. Cure the
backup plate to the inner skin. Refer to
SRM 54-02-00 REPAIR 005 (VRS2373), Paste and/or Liquid
Adhesive Mixing and Curing.
F. Remove the rod and cut the lockwire at the backup plate.
Lightly sand with CoMat 05-020 and CoMat 05-021 abrasive papers
to remove sharp edges.
G. Clean the repair area. Use dry air blast and a CoMat 02-099 lint
free cloth made moist with CoMat 01-438 solvent. Rub the
surfaces clean before the solvent becomes dry.
REPAIR 009
GENERAL - HONEYCOMB CORE REPAIR PROCESS
(VRS2372)
1. General
2. References
A. Standard tools
B. Consumable Materials
4. Core Removal
A. Method A:
NOTE: This type of damaged core removal is used when the core
will be replaced with a new piece of core, method 1, 2 and
4.
(1) Clean the area using a piece of CoMat 01-438 or CoMat 01-
457 solvent and a clean coMat 02-099 cloth. Wipe the area
dry before the solvent evaporates.
(3) If only one skin has been damaged, use the core slicer to
separate the core. Then completely remove separated core
in the damage cleanup hole area down to the opposite skin
inner surface. High-density core can be removed using
needle nose pliers and gently pulling in a twisting
motion. Core can be removed also using a 90° router motor
and an 80 grit abrasive disk. Use care not to damage
adjacent core areas or sand into opposite skin. DO NOT
REMOVE REMAINING ADHESIVE AT THE BOTTOM OF CUTOUT.
(4) Vacuum core and sanding residue from repair area. Wipe
inner skin surface using CoMat 02-099 clean, dry lint free
cloth. Mask area properly to prevent contamination.
NOTE: This type of damaged core removal is used when the core
will be replaced with paste adhesive, method 3.
(1) Clean the area using CoMat 01-438 or CoMat 01-457 solvent
and a clean CoMat 02-099 cloth. Wipe the area dry before
solvent evaporates.
(2) Locate and drill a hole through the panel in the center of
the damaged area. The hole will permit the fit of the
below described Hockey Stick tool in the damaged core
area.
(3) Protect the outer skin of the panel using a guide template
for the hockey Stick tool. Attached the template in place
using adhesive tape or equivalent to prevent damage to the
outer skin.
(4) Carefully start removing the core up to 1.5 in. (38 mm)
diameter (unless specified in applicable repair). In some
cases different Hockey Stick tools may be required to
achieve proper diameter. DO NOT REMOVE REMAINING ADHESIVE
AT THE BOTTOM OF THE CUTOUT.
(5) Vacuum the core and sanding residues from the area. Wipe
inner skin surface using CoMat 02-099 clean, dry lint free
cloth. Mask the area properly to prevent contamination.
5. Method 1: Core Plug Repair Using 250°F Film Adhesive Process. Refer
to Figure 203
NOTE: Make sure that the repair cavity has been cleaned and that the
surface preparation has been performed in accordance with the
applicable repair.
E. Carefully insert the core plug into the cavity. Make sure that
the core ribbon direction matches existing core and the
adhesive was not wiped off walls during core installation.
(1) Install CoMat 08-052 release film on top of core plug and
repair area approximately 2 in. (50,8 mm) larger than the
heat blanket. Use CoMat 02-265 tape to secure it.
(3) Cure the repair area using heat blanket, oven and/or other
explosion proof certified equipment as follows. Heat the
repair area at a rate of 1 to 6°F (1 to 4°C) per minute to
bring all thermocouples within the cure temperature range
specified in step 4.
G. Inspect the core sidewall bond to make sure the adhesive was
properly expanded and that no gap exists.
H. Remove any residual foaming adhesive and sand core flush to the
repair area as per Figure 3. Vacuum clean the core plug and
repair area. Wipe skin surface clean with a CoMat 02-099 clean
dry lint free cloth.
NOTE: Make sure that the repair cavity has been cleaned and
that a surface preparation has been performed in
accordance with the applicable repair.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
D. Carefully insert the core plug into the cavity. Make sure that
the core ribbon direction matches existing core.
(1) Install CoMat 08-052 release film on top of core plug and
repair area approximately 2 in. (50,8 mm) larger than the
heat blanket. Use CoMat 02-265 tape to secure it.
(2) For partial penetration repairs, add dead weight over the
core plug to make sure proper contact with bottom skin.
(3) Cure the repair area using a heat blanket, oven and/or
other explosion proof certified equipment in accordance
with SRM 54-02-00 REPAIR 005 (VRS2373), Paste and or
Liquid Adhesive Mixing and Curing.
G. Inspect the core sidewall bond to make sure that no gap exists.
H. Remove any residual adhesive and sand core flush to repair area
as per Figure 204. Vacuum clean core plug and repair area. Wipe
skin surface clean with a CoMat 02-099 clean cloth.
NOTE: This method must not be used for damage larger than 1.0 in
(25,4 mm) in diameter.
B. Verify for core cell and back skin corrosion or damage using a
light source. Report any anomaly to Goodrich Customer Support.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
C. Clean the damaged area using clean light air pressure (dry
line, no oil) and CoMat 01-438 or CoMat 01-457 solvent. Allow
it to dry for 30 minutes.
E. Cure adhesive per SRM 54-02-00 REPAIR 005 (VRS2373), Paste and
or Liquid Adhesive Mixing and Curing.
8. Method 4: Core Plug Repair Using 350° Film Adhesive Process. Refer to
Figure 206
NOTE: Make sure that the repair cavity has been cleaned and that a
surface preparation has been performed in accordance with
the applicable repair.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
E. Carefully insert the core plug into the cavity. Make sure that
the core ribbon direction matches existing core and the
adhesive was not wiped off walls during core installation.
(1) Install CoMat 08-052 release film on top of core plug and
repair area approximately 2 in. (50,8 mm) larger than the
heat blanket. Use CoMat 02-265 tape to secure it.
(3) Cure the repair area using heat blanket, oven and/or other
explosion proof certified equipment as follows. Heat the
repair area at a rate of 1 to 6°F (1 to 4°C) per minute to
bring all thermocouples within the cure temperature range
specified in step 4.
G. Inspect the core sidewall bond to make sure the adhesive was
properly expanded and that no gap exists.
H. Remove any residual foaming adhesive and sand core flush to the
repair area as per Figure 3. Vacuum clean the core plug and
repair area. Wipe skin surface clean with a CoMat 02-099 clean
dry lint free cloth.
A. Inspect rework area for heat damage or disbond. Use visual and
tap test methods. Report any discrepancies to Goodrich
Engineering.
Figure 201
Figure 202
Figure 203
Figure 204
Figure 205
Figure 206
REPAIR 010
GENERAL - PRE-IMPREGNATED MATERIAL HANDLING AND CURING
(VRS2378)
1. General
2. References
A. Consumable materials
4. Instructions
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(7) Ply layup. Plies can be laid up using either the flat ply
collation (all plies properly oriented and stacked on a
flat surface) or by individual ply technique (plies laid
up individually on the part).
(2) Cure the repair area with heat blanket, oven and or other
explosive proof certified equipment.
TABLE 1
REPAIR 011
GENERAL - STRUCTURAL ADHESIVE HANDLING AND CURING
(VRS2376)
1. General
2. References
A. Consumable materials
4. Instructions
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
TABLE 1
FILM ADHESIVE
CoMat SOAK TIME CURE TEMPERATURE
(Material)
±5 min ±10°F(± 6°C)
08-084 - Deleted -
08-085 - Deleted -
08-086 65 350°F(177°C)
08-087 65 350°F(177°C)
08-136 120 250°F(121°C)
FOAMING ADHESIVE
CoMat SOAK TIME CURE TEMPERATURE
(Material)
±5 min ±10°F(± 6°C)
08-089 65 250°F(121°C)
08-089 65 350°F(177°C)
NOTE:
4. The cure condition specified for the individual adhesive type is the
minimum time required at the indicated temperature to provide adequate
adhesive bond strength for part use.
5. Cure cycles defined in applicable SRM take precedence over TABLE 1 and
should be referred to for further guidance.
REPAIR 012
GENERAL DAMAGE BLEND REPAIR FOR METALLIC PARTS
(VRS2548)
1. Applicability
2. Consumable Materials
3. Repair Instructions
A. Damage Blend Repair for Steel Alloys, Nickel and Cobalt Alloys
parts.
(1) Use the applicable medium from Figure 1 to remove the damage.
Blend surface damage to 10 to 1 blend ratio, see Figure 2. Make
the area smooth. Blend edge damage to 10 to 1 blend ratio, see
Figure 3 Detail A or B.
(2) Make sure that a 2X diameter is maintained from all bolt holes
and features of the part that is to be repaired.
(3) Use the applicable medium from Figure 1 for finishing. Polish
the damage area smooth.
(4) After the blending the damage area, make sure that the blend is
not larger than the allowable damage limits. See applicable
inspection/repair Task and Figure 3.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
(5) Clean the area with a clean CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent.
(1) Use the applicable medium from Figure 1 to remove the damage.
Blend surface damage to 10 to 1 blend ratio, see Figure 2. Make
the area smooth. Blend edge damage to 10 to 1 blend ratio, see
Figure 3 Detail A or B.
(2) Make sure that a 2X diameter is maintained from all bolt holes
and features of the part that is to be repaired.
(3) Use the applicable medium from Figure 1 for finishing. Polish
the damage area smooth.
(4) After the blending the damage area, make sure that the blend is
not larger than the allowable damage limits. See applicable
inspection/repair Task and Figure 3.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
(5) Clean the area with a clean CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent.
(1) Use the applicable medium from Figure 1 to remove the damage.
Blend surface damage to 10 to 1 blend ratio, see Figure 2. Make
the area smooth. Blend edge damage to 10 to 1 blend ratio, see
Figure 3 Detail A or B. The blending strokes must be parallel
with the edge of material until blending ratio is achieved.
(2) Make sure that a 2X diameter is maintained from all bolt holes
and features of the part that is to be repaired.
(3) Use the applicable medium from Figure 1 for finishing. Polish
the damage area smooth.
(4) After the blending the damage area, make sure that the blend is
not larger than the allowable damage limits. See applicable
inspection/repair Task and Figure 3.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
(5) Clean the area with a clean CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent.
REPAIR 013
LOCAL PASSIVATION USING PASAJELL 101 METHOD
(VRS2330)
1. Applicability
2. Consumable Materials
CoMat 01-433 Distilled or Deionized Water
CoMat 01-438 Solvent
CoMat 01-471 Cleaner/Passivator Pasajell 101
CoMat 02-099 Lint-free Cloth
CoMat 02-182 Metal Foil Tape
CoMat 02-206 Indicator Paper
CoMat 02-224 Silicone Adhesive Polyester Tape
CoMat 02-331 Stainless Steel Wire Brush
CoMat 05-073 Aluminum Oxide Abrasive Paper
CoMat 05-074 Aluminum Oxide Abrasive Paper
3. Repair Instructions
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND
GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU
OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED.
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USED,
KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP AND DISCARD CHEMICALS.
A. Damage Blend Repair for Steel Alloys, Nickel and Cobalt Alloys
Parts.
(1) Clean the area with a clean CoMat 02-099 lint free cloth
made moist with CoMat 01-438 solvent.
(3) Clean the area with a clean CoMat 02-099 lint free cloth
made moist with CoMat 01-438 solvent.
(1) Using a CoMat 02-099 lint free cloth apply CoMat 01-471
solution to the repair area. Saturate the cloth and dab on
the area. Do not rub.
(3) After 5-10 minutes, remove the gel with a clean CoMat 02-
099 lint free cloth saturated with CoMat 01-433 water. If
possible without contaminating other areas, wipe or flush
the area with CoMat 01-433 water for 2 minutes to remove
the CoMat 01-471, Pasajell 101. Continue to wipe or flush
until no trace of
CoMat 01-471 remains.
1. General
A. The inlet cowl has a leading edge (lip skin), an intake barrel, an
outer barrel, and an aft bulkhead.
C. The intake barrel (pre SBN 70-0909) has three acoustic panels and
post SBN 70-0909 has two acoustic panels. The panels form the
inside diameter of the engine air inlet duct and also provide sound
absorption at the engine air inlet area.
D. The outer barrel has LH and RH skin panels of bonded carbon fabric.
The panels are reinforced at stress points, such as door cutouts,
edges, and frames with additional plies of carbon fabric and carbon
tape.
2. Structure Description
3. Structure Identification
The purpose of the tables is to help you to easily locate and identify
components which may be damaged. This is then used to help you to:
Outer Skin Segment (RH) - A1 Hybrid (Post SBN 70-0626) & A5.
Figure 5A (Sheet 2)
Outer Skin Segment (RH) - A1 Hybrid (Post SBN 70-0626) & A5.
Figure 5A (Sheet 9)
Rear Bulkhead (Lower) - A1 Hybrid (Post SBN 70-0626) & A5 (Pre SBN 70-0908)
Figure 6A (Sheet 1)
Rear Bulkhead (Lower) - A1 Hybrid (Post SBN 70-0626) & A5 (Pre SBN 70-0908)
Figure 6A (Sheet 2)
Rear Bulkhead (Lower) - A1 Hybrid (Post SBN 70-0626) & A5 (Pre SBN 70-0908)
Figure 6A (Sheet 3)
Rear Bulkhead (Lower) - A1 Hybrid (Post SBN 70-0626) & A5 (Pre SBN 70-0908)
Figure 6A (Sheet 4)
Rear Bulkhead (Lower) - A1 Hybrid (Post SBN 70-0626) & A5 (Pre SBN 70-0908)
Figure 6A (Sheet 5)
Rear Bulkhead (Lower) - A1 Hybrid (Post SBN 70-0626) & A5 (Pre SBN 70-0908)
Table 6A
Rear Bulkhead (Lower) - A1 Hybrid (Post SBN 70-0626) & A5 (Pre SBN 70-0908)
Table 6A
Rear Bulkhead (Upper) - A1 Hybrid (Post SBN 70-0626) & A5 (Pre SBN 70-0908)
Figure 7A (Sheet 1)
Rear Bulkhead (Upper) - A1 Hybrid (Post SBN 70-0626) & A5 (Pre SBN 70-0908)
Figure 7A (Sheet 2)
Rear Bulkhead (Upper) - A1 Hybrid (Post SBN 70-0626) & A5 (Pre SBN 70-0908)
Figure 7A (Sheet 3)
Rear Bulkhead (Upper) - A1 Hybrid (Post SBN 70-0626) & A5 (Pre SBN 70-0908)
Figure 7A (Sheet 4)
2 FACING SHEET
Rear Bulkhead (Upper) - A1 Hybrid (Post SBN 70-0626) & A5 (Pre SBN 70-0908)
Table 7A
Rear Bulkhead (Upper) - A1 Hybrid (Post SBN 70-0626) & A5 (Pre SBN 70-0908)
Table 7A
1 INTAKE BARREL
(Rad 305.075 - 54.925)
1 INTAKE BARREL
(Rad 305.075 - 54.925)
1 INTAKE BARREL
(Rad 305.075 - 54.925)
A2A- Adhesive (Facing Sheet) 0.005 Adhesive Film, Type II, Grade
A2E II, Weight 0.18 +0.018 kg/m2
(0.037 +0.004 lb/ft 2)
1 INTAKE BARREL
(Rad 54.925 - 176.012)
1 INTAKE BARREL
(Rad 54.925 - 176.012)
1 INTAKE BARREL
(Rad 54.925 - 176.012)
A2A- Adhesive (Facing Sheet) 0.005 Adhesive Film, Type II, Grade
A2D II, Weight 0.18 +0.018 kg/m2
(0.037 +0.004 lb/ft 2)
A7A- Adhesive (Facing Sheet) 0.005 Adhesive Film, Type II, Grade
A7C II, Weight 0.18 +0.018 kg/m2
(0.037 +0.004 lb/ft 2)
1 INTAKE BARREL
(Rad 176.012 - 305.075)
1 INTAKE BARREL
(Rad 176.012 - 305.075)
1 INTAKE BARREL
(Rad 176.012 - 305.075)
1. Introduction
This section contains the allowable damage limits for both sheet metal
and bonded panel structural components of the V2500 inlet cowl. Any
damage which is found to be more than the allowable damage limits should
be repaired in accordance with the procedures found in 54-10-00, Repairs,
Page Block 201.
2. Zones
Each of the individual components is divided into zones. The zones which
are affected by the different types of allowable damage are identified in
the figures and tables which follow.
3. Section Organization
A. General
(3) Damage - All damage limits assume that exposed edges do not
extend above the skin contour. Any such damage should be
reworked to remove or feather the extensions. Holes and
cracks in the pressure boundaries must be sealed with
applicable tape material. Allowable damage is classified as
either unlimited usage or time limited.
B. Inlet Cowl Lip Skin Structure - Allowable Damage (See Figure 101
and Table 101).
The allowable damage zones for the inlet cowl lip skin structures
are:
K1 - Lip skin, inner intake surface (between 135 and 225 degrees).
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENT LIMITS INTERVALS
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENT LIMITS INTERVALS
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENT LIMITS INTERVALS
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENT LIMITS INTERVALS
The Allowable damage zones for the inlet cowl outer barrel
structure are:
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
D. A5 (serial no. N7354 and sub) - Inlet Cowl Titanium Rear Bulkhead
Structure - Allowable Damage (See Figure 103 and Table 103).
ZC - Titanium Rear bulkhead web (PPR 111o - PPR 180o - PPR 249o)
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Z1 Not acceptable.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Z1 Not acceptable.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Z1 Not acceptable.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
The Allowable damage zones for the inlet cowl 3 panel acoustic
inner barrel structure are:
K, L, M - Splice joints.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
The Allowable Damage zones for the inlet cowl aluminum acoustic
inner barrel structure are:
K, L - Splice Joints.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
The Allowable damage zones for the inlet cowl anti-ice exhaust
panel grille are:
C - Grille
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
The Allowable damage zones for the inlet cowl aerodynamic sealant
are:
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
GENERAL REPAIR
1. General
The repairs given in this section are for structural damage which
goes beyond the limits shown in the Allowable Damage section. The
repairs show you how to restore a part to it’s original strength and
configuration. Procedures to refinish a repaired area are also given.
2. Adhesive Preparation
Some repairs call for the use of certain adhesives. The following are
the procedures to use in the preparation of the adhesives.
A. EA956/L3 Adhesive
B. EA956 Adhesive
C. EA934NA Adhesive
The number of carbon fabric repair plies used is equal to the number
of damaged plies. See the Structural Identification section to find
the number of plies in the damaged area. You cannot examine the
damaged skin to count the plies. Cured carbon plies are very
difficult to separate at ply interfaces.
Both the original skin and the repair material must be clean and dry
before the repair can be started. Water on the surface or in the
materials will make the repair weak. All water must be removed before
the repair can be done. Use heat lamps at 230ºF-250ºF (115ºC-127ºC)
for one hour.
Drain holes are in the lower part of the inlet cowl outer barrel to
permit moisture to be vented. If these holes are closed during
repair, they must be reopened.
4. Titanium Structures
The forward and aft bulkheads are made of titanium. The bulkhead is
made up of sections of sheet titanium spliced together to form the
bulkhead. Formed titanium inner and outer cap angles are attached to
the edges of the web and to the outer barrel and inlet lip.
Repairs to the forward and aft bulkheads must be sealed to keep the
pressure (approximately 2 psi maximum) between the inner and outer
barrels.
The acoustic panels form the inner barrel of the inlet cowl. Their
main purpose is to reduce the noise that comes from the engine inlet
area. The panels are also the main load-bearing structure for the
inlet cowl.
Woven wire cloth is bonded to the perforated inner skin of the panel.
It contributes to the noise reducing ability of the panel.
005 AIR INTAKE COWL AFT OUTER BARREL SURFACE DAMAGE REPAIR
(VRS2805) (REF 71-11-00)
006
(VRS2814) CANCELLED
008
(VRS2819) CANCELLED
009 AIR INTAKE COWL T2P2 PROBE ACCESS PANEL OPENING INTER-
(VRS2844) FACE LAND REPAIR
(REF 71-11-00)
011
(VRS2809) CANCELLED
016 AIR INTAKE COWL HAND BLEND AND POLISH PROCEDURE REPAIR
(VRS2867) (REF 71-11-00)
019 AIR INTAKE COWL LIPSKIN INTAKE SIDE EDGE PATCH REPAIR
(VRS2732) (REF 71-11-00)
1. General.
Gouge
Cracked/split
Impact
NOTE: On the A1 hybrid (serial no. V299 and sub) and A5 Air Intake
Cowl (serial no. N5001 to N7353) do not use this repair on
the titanium plate. Refer to Fig. 201.
2. Referenced Information.
A. Standard equipment
B. Special Tools
D. Repair parts
None.
E. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Aft bulkhead Carbon fiber composite
honeycomb core sandwich
WARNING: USE THE CORRECT PROCEDURE AND EQUIPMENT WHEN YOU MOVE THE
COWL. MAKE SURE THE COWL IS HELD CORRECTLY DURING THE REPAIR
PROCEDURE.
CAUTION: BE CAREFUL WHEN YOU MOVE THE COWL. DO NOT POSITION THE COWL
DIRECTLY ON TO A HARD SURFACE.
A. Referring to Fig 202 examine the repair area to assess the amount
of damage and, using the standard workshop tools, measure the depth
of the damage. Do this in several places where the extent of the
damage permits. From this information the number of repair plies
should be calculated as follows:
Where doubt can arise over the exact magnitude of the damage
penetration, i.e. deciding between 0.024in. (0,61 mm) and 0.025in.
(0,64 mm), assume the larger figure as the criteria for selecting
the number of repair plies to use. That is, 4 plies rather than 3,
for this example. If on examination it is found that the damage has
fully penetrated the carbon plies and the honeycomb core, repair is
beyond the scope of this document. In this event do SRM 54-10-00
REPAIR No. 004 (VRS 2802).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the damage and repair area of the bulkhead with the
methylethylketone (CoMat 01-076) and lint free cloth
(CoMat 02-099). Wipe the area with a clean piece of lint free cloth
before the fluid dries.
A. Apply the teflon tape to the repair area. Fig 202 shows the
dimensions of the area to be covered with the tape (Repair of 2 ply
damage shown).
B. Make the surface of the repair area rough and remove the sharp
edges from the damage with the abrasive paper (CoMat 05-021). Do
not damage the carbon plies of the bulkhead.
A. Cut the first repair ply so that it has a 2.0in. (50,8 mm) overlap
around the damage. Use carbon fabric (CoMat 08-059) and lint free
gloves (CoMat 02-097). To prevent fraying, the plies may be cut to
the finished dimensions after soaking in adhesive (Ref. step
10.C).
B. Cut the remaining repair plies if they are required using the
carbon fabric and lint free gloves. Cut each subsequent repair ply
2.0in. (50,8 mm) longer and 2.0in. (50,8 mm) wider. There must be a
repair ply for each ply of the bulkhead which is damaged and these
must be covered by a single fiberglass ply (CoMat 02-167). To
prevent fraying, the plies may be cut to the finished dimensions
after soaking in adhesive (Ref. step 10.C).
A. Dry the repair area. Use the heat lamp to keep the repair area of
the bulkhead at 176oF (80 oC) for six hours. The repair materials
must be applied at the end of the six hours.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
C. Cut approximately 1.0 in. (25,4 mm) off each edge of the plies.
Make sure the first ply has a 1.0 in. (25,4 mm) overlap around the
damage. The overlap for each subsequent ply must be 1.0 in.
(25,4 mm). Cut the corners of the repair plies to an angle of
approximately 45 degrees with a length of approximately 0.5 in.
(12,7 mm). Cut the last (fiberglass) ply to the shape defined by
the teflon tape (CoMat 02-007).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. The repair area must be cool after the drying procedure. Clean the
repair area with methylethylketone (CoMat 01-076) using lint free
cloth (CoMat 02-099). Wipe the area with a piece of clean lint free
cloth before the fluid dries.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Fill the damage with the mixture using a clean metal spatula. The
filled damage must be level with the existing carbon plies of the
repair area.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Remove the parting film from one side of the first repair ply and
position the ply over the damage with the adhesive side down. Make
sure the damage is located in the center of the ply. Use the roller
to remove air caught in the adhesive. Remove the remaining parting
film.
NOTE: Make sure that the ply fibres are at 90 degrees to the first
damaged ply.
C. Remove the parting film from one side of the second repair ply (if
it is required) and position it over the repair area with the
adhesive side down. Make sure it has an equal overlap around the
first ply. Use the roller to remove the air caught in the adhesive.
Remove the remaining parting film.
NOTE: Make sure that the ply fibres are at 90 degrees to each
other.
NOTE: The last repair (sanding) ply must touch the teflon tape
(CoMat 02-007) all around.
E. Remove unwanted adhesive from the teflon tape with a clean metal
spatula.
B. Cut the porous parting film (CoMat 02-169). Make sure that the film
is larger than the heat blanket and overlaps the last (fiberglass)
repair ply by at least 3.0 in. (76,2 mm) all around.
C. Cut the breather fabric (CoMat 08-057) into pieces the same size as
the porous parting film (Ref step B. above). The number of pieces
must equal the number of plies used in the repair.
D. Put the porous parting film on to the repair area so that it has an
equal overlap. Put the breather fabric on top of the porous parting
film. Use one layer of breather fabric for each repair ply used.
F. Put four fiberglass tows onto the repair area using one strand of
the fiberglass fabric (CoMat 02-167) in each of four positions
around the repair. Each of the strands must connect the breather
fabric with the area around the silicone rubber sheet.
NOTE: With the fiberglass tows installed, gasses can not collect
below the silicone rubber sheet when the adhesive cures.
G. Put the non-porous parting film (Ref step E. above) onto the repair
area first. Make sure that it has an equal overlap around the
repair area. Put the silicone rubber sheet on top of the non-porous
parting film.
H. Cut two pieces of breather cloth (CoMat 02-166), at least 2.0 in.
(50,8 mm) larger on each side than the silicone rubber sheet. Put
the two pieces of the breather cloth on to the repair area. Put the
heat blanket on top of the breather cloth. The heat blanket must
have an overlap all around the repair area.
J. Put the nylon bagging film (CoMat 02-163) over the repair area so
that the bag overlaps the breather cloth by 2.0 in. (50,8 mm) all
around. Install the vacuum hose from the suction pump so that it
goes directly on to the breather cloth. Attach and seal the film to
the bulkhead with the sealant tape (CoMat 08-051).
A. Decrease the pressure in the repair area with the vacuum suction
pump. During the cure, the reading must show at least 25.0 in.
(635,0 mm) of mercury.
B. Increase the temperature and keep at 190 o - 210oF (88o - 99oC) for
220 minutes. The rate of increase and subsequent decrease must not
be faster than 5.4oF (3 oC) in each minute. Start to measure the time
for the adhesive to cure when the temperature gets to 190 oF (88oC).
the nylon bagging film with its seal and the vacuum hose;
the temperature probes; the heat blanket; the breather cloth;
the silicone rubber sheet; the non-porous parting film;
the breather fabric; the fiberglass tows; the porous parting film
and the teflon tape.
A. Make the repair area smooth. The contours of the repair area must
be smooth and there must not be an edge or step, between the repair
area and the outer skin of the bulkhead. Use the abrasive paper
(CoMat 05-021).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, SRM 54-01-00 Composite Structure Tap Test, to
confirm that the repair is correctly bonded.
1. General.
B. The damage must not be more than 3.0 in. (76,2 mm) long or wide. If
the damage is less than 1.5 in. (38,1 mm) from the edge do
REPAIR No.003 (VRS2817). There must be a minimum of 10.0 in.
(254,0 mm) between damaged areas.
2. Referenced Information.
A. Standard equipment
C. Special Tools
D. Repair parts
None.
E. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Aft Intake Cowl Composite structure
WARNING: USE THE CORRECT PROCEDURE AND EQUIPMENT WHEN YOU MOVE THE
COWL. MAKE SURE THE COWL IS HELD CORRECTLY DURING THE REPAIR
PROCEDURE.
CAUTION: BE CAREFUL NOT TO DAMAGE THE EDGES AND CORNERS OF THE COWL.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. With a hand drill, drill a 0.062 in. (1,58 mm) diameter hole at
each of the marked positions. Drill the hole to the depth of the
delamination.
A. Dry the repair area. Use the heat lamp to keep the repair area of
the outer skin at 176oF (80oC) for six hours. The repair materials
must be applied at the end of the six hours.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. After removing the heatlamps used previously for drying the repair
area, fill a suitable disposable syringe (CoMat 02-162) with the
adhesive.
C. Put the syringe into one of the drilled holes and slowly inject the
adhesive until it starts to come through the other drilled hole.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Using the sonic test equipment (1N20444) and the tap test method,
SRM 54-01-00 Composite Structure Tap Test, examine the repair for
any signs of incomplete filling/delamination.
1. General.
B. The damage can be along the full length of the aft edge, but must
not be more than 0.38 in. (9,7 mm) from the outer skin aft edge and
1.50 in. (38,1 mm) long by 0.50 in. (12,7 mm) from the access panel
recess edges. Only one repair for each access panel recess edge is
permitted. Refer to Fig. 201.
2. Referenced Information.
A. Standard equipment
C. Special Tools
D. Repair parts
None.
E. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Aft Intake Cowl Composite structure
WARNING: USE THE CORRECT PROCEDURE AND EQUIPMENT WHEN YOU MOVE THE
COWL. MAKE SURE THE COWL IS HELD CORRECTLY DURING THE REPAIR
PROCEDURE.
CAUTION: BE CAREFUL NOT TO DAMAGE THE EDGES AND CORNERS OF THE COWL.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Dry the repair area. Use the heat lamp to keep the repair area of
the outer skin at 176oF (80oC) for six hours. The repair materials
must be applied at the end of the six hours.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. After removing the heatlamps used previously for drying the repair
area, fill a suitable disposable syringe (CoMat 02-162) with the
adhesive.
C. Slowly inject the adhesive with the syringe into the delaminated
area until the adhesive begins to flow out from the edges of the
plies.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Using the sonic test equipment (1N20444) and the tap test method,
SRM 54-01-00 Composite Structure Tap Test, examine the repair for
any signs of incomplete filling and or delamination.
1. General.
B. This repair applies to damage through the composite plies and into
the honeycomb core of the aft bulkhead.
NOTE: On the A1 hybrid (serial no. V299 and sub) and A5 Air Intake
Cowl (serial no. N5001 to N7353), do not use this repair on
the titanium plate. Refer to Fig. 201.
2. Referenced Information.
A. Standard equipment
B. Special Tools
D. Repair parts
--------------------------------------------
PART NO. PART IDENT
--------------------------------------------
AMS 5516 CRES, Stainless steel
0.006 in. (0,15 mm)
MBF2110S(5) Composi-Lok
NAS-1587-A3C Washer
E. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Aft bulkhead Carbon fiber composite
honeycomb core sandwich
WARNING: USE THE CORRECT PROCEDURE AND EQUIPMENT WHEN YOU MOVE THE
COWL. MAKE SURE THE COWL IS HELD CORRECTLY DURING THE REPAIR
PROCEDURE.
CAUTION: BE CAREFUL WHEN YOU MOVE THE COWL. DO NOT POSITION THE COWL
DIRECTLY ON TO A HARD SURFACE.
A. Examine the damaged area to assess the amount of damage. The damage
must not be more than the limits.
6. Remove the outer plies, the honeycomb, and the inner plies from the
damaged area (Ref. Fig. 202 and 205).
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE BULKHAED. ONLY
REMOVE MATERIAL FROM THE EDGE OF THE OUTER PLY. DO NOT USE A
LIQUID WITH THE WATERPROOF SILICON CARBIDE ABRASIVE PAPER.
A. Use a marking pen (CoMat 06-131) to make a mark around all of the
damage including cracks and areas of delamination. Make sure that
the cut-out is a regular shape and has a radius of at least 0.5 in.
(12,7 mm).
Measure 1.0 in. (25,4 mm) from the edge of the area for each of the
outer plies (the bulkhead has two outer plies) and add 0.75 in.
(19,05 mm) for an outer layer of fiberglass cloth (CoMat 02-167).
Apply the teflon tape (CoMat 02-007) so that it goes around the
repair area. Make the corners of the strip of tape have a radius at
least 0.5 in. (12,7 mm).
C. Make the surface of the repair area rough. Do not cause damage to
the carbon plies of the bulkhead. Use the abrasive paper
(CoMat 05-021).
D. Use a high speed rotary cutter to remove the outer plies, the
honeycomb and the inner plies from the area identified in step A.
Carefully remove the resin which holds the honeycomb to the inner
plies. Make sure you do not cause delamination.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Wear lint-free gloves (CoMat 02-097) and cut three plies of carbon
fabric (CoMat 08-059) so that it has 1.5 in. (38,1 mm) overlap all
around the cut-out.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(2) Apply the adhesive to each ply with the brush (CoMat 02-087)
and cover each ply with another sheet of non-porous parting
film.
(3) Use the roller to force the adhesive into each ply
thoroughly.
NOTE: Make sure that the width of the carbon ply is not more
than the length of the cut-out. This is to allow the
support plate to be inserted through the cut-out in the
lower plies.
(1) Remove the non-porous parting film from one side of two of
the carbon plies.
(2) Remove the non-porous parting film from each side of the
third carbon ply.
(3) Align the three carbon plies and put them with their adhesive
sides together onto a hard, flat surface.
(4) Use the roller to remove unwanted adhesive and air from the
three carbon plies.
A. Get a heat blanket which must be larger all around than the support
plate.
B. Cut a sheet of porous parting film (CoMat 02-169) making sure that
it is larger than the heat blanket and has an overlap of at least
3.0 in. (76,2 mm) around the support plate.
C. Cut one sheet of breather fabric (CoMat 08-057) for each carbon ply
on the support plate. Make sure that the breather fabric has the
same dimensions as the porous parting film.
D. Remove the top layer of the non-porous parting film (CoMat 02-168)
from the support plate.
E. Put the porous parting film (CoMat 02-169) onto the support plate,
making sure that it has an equal overlap around the support plate.
Put the layers of breather fabric on top of the porous parting
film.
F. Cut the non-porous parting film (CoMat 02-168) and silicon rubber
sheet (CoMat 02-170), making sure that the two pieces of material
have an overlap of 2.0 in. (50,8 mm) around the breather fabric
installed in step E above.
G. Put four fiberglass tows onto the repair area using one strand of
the fiberglass fabric (CoMat 02-167) in each of four positions
around the repair. Each of the strands must connect the breather
fabric with the area around the silicone rubber sheet.
NOTE: With the fiberglass tows installed, gasses can not collect
below the silicone rubber sheet when the adhesive cures.
H. Put the non-porous parting film (Ref. step F) onto the support
plate. Make sure that it has an equal overlap around the support
plate. Put the silicone rubber sheet on top of the non-porous
parting film.
I. Put the heat blanket and breather cloth onto the support plate.
(2) Put the two sheets of breather cloth on top of the silicone
rubber sheet.
(3) Put the heat blanket on top of the breather cloth, making
sure that the heat blanket has an overlap all around the
support plate.
(1) Use nylon bagging film (CoMat 02-163) and sealant tape
(CoMat 08-051).
(2) Make sure that sure the vacuum bag has an overlap of
approximately 2.0 in. (50,8 mm) around the breather cloth.
(3) Install the vacuum hose, from the suction pump, so that it
goes directly onto the breather cloth.
(4) Attach and seal the vacuum bag to the cowl with the sealant
tape.
A. Use the vacuum suction pump to decrease the pressure in the repair
area. Make sure it gives an indication of at least 25.0 in.
(635,0 mm) of mercury while the adhesive cures.
B. Use the heat blanket to keep the temperature of the repair area at
190o - 210oF (88o - 99oC) for 220 minutes.
D. Start to measure the cure time when the temperature reaches 190 oF
(88oC).
A. Drill two pairs of holes 0.050 in. (1,27 mm) diameter, a sufficient
distance apart to attach the support plate to a clamp bar with
lockwire.
A. Dry the repair area. Use the heat lamp to keep the repair area of
the bulkhead at 176oF (80 oC) for six hours. The repair materials
must be applied at the end of the six hours.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Attach the lockwire (CoMat 02-127) to the support plate. Make sure
there is sufficient lockwire to hold during the installation and
that the assembly can not fall into the cowl.
D. Put the support plate through the cut-out and onto the inner
surface of the bulkhead. Make sure the plate has an equal overlap
around the cut-out. Put a bar across the repair area and attach the
lockwire to the bar. Tighten the lockwire to hold the support plate
in the correct position.
Gradually increase the temperature with the heat lamp; the rate of
the increase mist not exceed 5.4 oF (3oC) in each minute. Keep the
temperature at 190o - 210 oF (88o - 99oC) for 1 hour. Start to
measure the curing time when the temperature gets to 190 oF (88oC).
15. Prepare the filler plies, the repair plies, and the honeycomb
(Ref. Fig. 204 and 205).
A. Wear lint-free gloves (CoMat 02-097) and cut the lower filler
plies:
Two plies of carbon fabric (CoMat 08-059) and one ply of fiberglass
fabric (CoMat 02-167). The lower filler plies must overlap the cut-
out in the bulkhead inner skin by 1.0 in. (25,4 mm) all around.
Wear lint free gloves (CoMat 02-097) and cut the upper filler
plies:
Two plies of carbon fabric (CoMat 08-059) and one ply of fiberglass
fabric (CoMat 02-167). The upper filler plies must overlap the cut-
out in the bulkhead outer skin by 1.0 in. (25,4 mm) all around.
Wear lint free gloves (CoMat 02-097) and cut the repair plies:
Two plies of carbon fabric (CoMat 08-059) and one ply of fiberglass
fabric (CoMat 02-167). Cut the first repair ply so that it has a
2.0 in. (50,8 mm) overlap around the cut-out in the bulkhead outer
plies. Cut each subsequent repair ply 2.0 in. (50,8 mm) longer and
2.0 in. (50,8 mm) wider.
B. Cut the repair plug from the honeycomb (CoMat 08-063, 08-065,
08-066) to be a good fit in the repair hole. Use lint-free gloves
(CoMat 02-097).
16. Install the lower filler plies (Ref. Fig. 204 and 205).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Put each filler ply onto a sheet of non-porous parting film (CoMat
02-168). Use the brush (CoMat 02-087) to apply the adhesive to the
two sides of each ply. Put another layer of parting film on these
plies and roll the adhesive into the plies so that they are fully
soaked. Do not remove the parting film until the installation
procedure.
C. Cut each lower filler ply to be a good fit in the cut-out. They
must be flat on the support plate and have the same shape as the
cut-out. The edges of the plies must not overlap on the sides of
the cut-out.
D. Remove the non-porous parting film from one side of the first
carbon filler ply. Put the ply into the cut-out, adhesive side
down. The ply must be located correctly and flat against the
support plate. Remove the remaining non-porous parting film and
use a clean metal spatula to keep the ply flat on the support
plate. Repeat this step for the second carbon filler ply and
fiberglass filler ply. Make sure that the plies are flat and
located correctly.
Gradually increase the temperature with the heat lamp; the rate of
increase must not exceed 5.4 oF (3oC) in each minute. Keep the
temperature at 190o - 210oF (88o - 99oC) for 220 minutes. Start to
measure the curing time when the temperature gets to 190 oF (88oC).
When the adhesive has cured, remove the non-porous parting film.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Fill the open cells of the honeycomb in the aft bulkhead and the
repair plug with potting compound. Use a clean metal spatula and
make sure all of the cells are filled.
C. Install the honeycomb plug into the hole and make sure it is flat
against the inner plies. Use a clean metal spatula to remove
unwanted potting compound and make the surface smooth.
Gradually increase the temperature with the heat lamp; the rate of
increase must not exceed 5.4 oF (3oC) in each minute. Keep the
temperature at 113o - 131 oF (45o - 55oC) for between one and two
hours. Start to measure the curing time when the temperature gets
to 113oF (45oC).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
19. Install the upper filler plies and the repair plies (Ref. Fig. 205).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
C. Cut each upper filler ply to be a good fit in the cut-out of the
outer skin. They must be flat on the honeycomb plug and have the
same shape as the cut-out. The edges of the plies must not overlap
on the edges of the cut-out.
D. Cut the first carbon repair ply to its finished dimensions so that
it overlaps the cut-out in the outer skin by 1.0 in. (25,4 mm) all
around. Cut the second carbon ply to overlap the first by 1.0 in
(25,4 mm). Cut the fiberglass repair ply so that it has the same
shape as the area defined by the teflon tape.
F. Remove the non-porous parting film from one side of the fiberglass
filler ply. Put the ply into the cut-out resin side down. The ply
must be located correctly and flat against the honeycomb plug.
Remove the remaining non-porous parting film and use a clean metal
spatula to keep the ply flat on the plug. Repeat this step for the
first and second carbon filler plies. Make sure that the plies are
flat and located correctly.
G. Remove the parting film from one side of the first carbon repair
ply and position it over the damage with the adhesive side down.
Make sure that the damage is located in the centre of the ply. Use
the roller to remove air caught in the adhesive. Remove the
remaining parting film.
NOTE: Make sure that the ply fibres are at 90 degrees to the first
damaged ply.
H. Remove the parting film from one side of the second carbon repair
ply and position it over the repair area with the resin side down.
Make sure it has an equal overlap around the first ply. Use the
roller to remove air caught in the resin. Remove the remaining
parting film.
NOTE: Make sure that the ply fibres are at 90 degrees to each
other.
I. Remove the parting film from one side of the fiberglass repair ply
and position it over the repair area with the adhesive side down.
Make sure it has an equal overlap around the last ply.
NOTE: The fiberglass repair ply must touch the teflon tape.
J. Use the roller to remove air caught in the adhesive. Remove the
remaining parting film. Remove unwanted adhesive from the teflon
tape with a clean metal spatula.
A. Get a heat blanket, which must be larger all around than the repair
area.
B. Cut the porous parting film (CoMat 02-169). Make sure that the film
is larger than the heat blanket and has an overlap of at least
3.0 in. (76,2 mm) all around.
C. Cut one sheet of breather fabric (CoMat 08-057) for each carbon and
fiberglass ply on the repair area, excluding the filler plies. Make
sure that the breather fabric has the same dimensions as the porous
parting film.
D. Put the porous parting film on to the repair area, making sure it
has an equal overlap around the repair area. Put the layers of
breather fabric on top of the porous parting film.
E. Cut the non-porous parting film (CoMat 02-168) and silicone rubber
sheet (CoMat 02-170). The two pieces must be 2.0 in. (50,8 mm)
larger than the breather fabric installed in step D. above.
F. Put four fiberglass tows onto the repair area using one strand of
the fiberglass fabric (CoMat 02-167) in each of four positions
around the repair. Each of the strands must connect the breather
fabric with the area around the silicone rubber sheet.
NOTE: With the fiberglass tows installed, gasses can not collect
below the silicone rubber sheet when the adhesive cures.
G. Put the non-porous parting film (Ref. step E) onto the repair area
making sure that it has an equal overlap around the repair area.
Put the silicone rubber sheet on top of the non-porous parting
film.
H. Put the heat blanket and breather cloth onto the repair area.
(2) Put the two sheets of breather cloth onto the repair area.
(3) Put the heat blanket on top of the breather cloth, making
sure that the heat blanket has an overlap all around the
repair area.
(1) Use nylon bagging film (CoMat 02-163) and sealant tape
(CoMat 08-051).
(2) Make sure that the vacuum bag has an overlap of approximately
2.0 in. (50,8 mm) around the breather cloth.
(3) Install the vacuum hose, from the suction pump, so that it
goes directly on to the breather cloth.
(4) Attach and seal the film to the cowl with the sealant tape.
A. Use the vacuum suction pump to decrease the pressure in the repair
area making sure it gives an indication of at least 25.0 in.
(635,0 mm) of mercury while the adhesive cures.
B. Use the heat blanket to keep the temperature of the repair area at
190o - 210oF (88o - 99oC) for 220 minutes.
D. Start to measure the cure time when the temperature gets to 190 oF
(88oC).
A. When the cure is completed, remove the lay-up materials from the
repair.
A. Make the repair area smooth. The contours of the repair area must
be smooth and there must not be an edge or step between the repair
area and the outer skin of the bulkhead. Use the abrasive paper
(CoMat 05-021)
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, (Ref. SRM 54-01-00) Composite Structure Tap
Test, to confirm that the repair is correctly bonded.
26. Make the fire protection plate (A1 hybrid (serial no. V299 and sub) and
A5 aft bulkheads only).
B. Make the fire protection plate align with the contour of the
structure in the repair area. The plate must fit the contour with
light finger pressure. Make sure a minimum distance of 0.050 in.
(1,3 mm) between fire protection plate and all edges.
C. Make a mark of the holes on the fire protection plate. The edge
distance must be a 0.5 in. (12,7 mm) minimum and the pitch must be
2.80 in. (71,1 mm) maximum. Refer to Fig. 207.
D. Using drills and drilling tools, drill the pilot holes at the
marked locations. Remove the burrs.
F. Drill the holes to their final size, using drills and drilling
tools. Remove all burrs.
H. Remove the sharp edges using the abrasive paper (CoMat 05-021).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
28. Install the fire protection plate (A1 hybrid (serial no. V299 and sub)
and A5 aft bulkheads only).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Apply and even layer of EA934NA (CoMat 08-021) to the repair area
using the brush (CoMat 02-087).
B. Put the fire protection plate into position. Make sure the holes
are aligned.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
1. General.
2. Referenced Information.
A. Standard equipment
B. Special Tools
D. Repair parts
None.
E. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Air intake cowl Carbon fiber composite
WARNING: USE THE CORRECT PROCEDURE AND EQUIPMENT WHEN YOU MOVE THE
COWL. MAKE SURE THE COWL IS HELD CORRECTLY DURING THE REPAIR
PROCEDURE.
CAUTION: BE CAREFUL NOT TO CAUSE DAMAGE TO THE EDGES AND THE CORNERS
OF THE COWL.
A. Attach the lifting sling to the cowl and with the aid of the
rotatable dolly position the cowl so that it is lying horizontally.
A. Referring to Fig. 201 and 202 examine the repair area to assess the
amount of damage and, using the standard workshop tools, measure
the depth of the damage. Do this in several places where the extent
of the damage permits. From this information the number of repair
plies should be calculated as follows:
Where doubt can arise over the exact magnitude of the damage
penetration, i.e. deciding between 0.045in. (1,14 mm) and 0.046in.
(1,17 mm), assume the larger figure as the criteria for selecting
the number of repair plies to use. That is, 4 plies rather than 3,
for this example. If on examination it is found that the damage has
fully penetrated the panel, repair is beyond the scope of this
document. In this event reference must be made to alternative
repair procedures.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. With reference to Fig. 201 and 202 calculate the distance for
positioning the strip of teflon tape (CoMat 02-007) from the edge
of the damage as follows (repair of 2 ply shown): from the edge of
the damaged area measure 1.0 in. (25,4 mm) from each damaged ply of
the cowl, i.e., if 4 plies damaged then measure 4.0 in. (101,6 mm)
from the edge of the damaged area. Add 0.75 in. (19,05 mm) for an
outer layer of fiberglass fabric (CoMat 02-167). Apply the teflon
tape so that it goes around the repair area in a 2.0 in. (50,8 mm)
wide strip. Make the corners at an angle of approximately 45
degrees and approximately 1.0 in. (25,4 mm) length of side.
B. Remove the sharp edges of the damage using the abrasive paper
(CoMat 05-021) and, with a fresh piece of the abrasive paper, make
the surface of the repair area rough.
A. Cut the first repair ply so that it has a 2.0 in. (50,8 mm) overlap
around the damage. Use carbon fabric (CoMat 08-059) and lint free
gloves (CoMat 02-097). To prevent fraying, the plies may be cut to
the finished dimensions after soaking in adhesive (Ref. step 10.C).
B. Cut the remaining repair plies if they are required. Use the carbon
fabric and lint free gloves. Cut each subsequent repair ply 2.0in.
(50,8 mm) longer and 2.0in. (50,8 mm) wider. Cut the last ply
(sanding ply) from fiberglass fabric to give a 1.0in. (25,4 mm)
overlap beyond the teflon tape. There must be a repair ply for each
ply of the panel which is damaged and these must be covered by a
single fiberglass ply. To prevent fraying, the plies may be cut to
the finished dimensions after soaking in adhesive (Ref step 10.C).
A. Dry the repair area. Use the heat lamp to keep the repair area of
the panel at 176oF (80oC) for six hours. The repair materials must
be applied at the end of the six hours.
10. Prepare the repair materials (Ref. Fig. 201 and 202).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
C. Cut approximately 1.0 in. (25,4 mm) off each edge of the plies.
Make sure the first ply has a 1.0 in. (25,4 mm) overlap around the
damage. The overlap for each subsequent ply must be 1.0 in.
(25,4 mm). Cut the corners of the repair plies to an angle of
approximately 45 degrees with a length of approximately 0.5 in.
(12,7 mm). Cut the last ply (fiberglass) to the shape defined by
the teflon tape (CoMat 02-007).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. The repair area must be cool after the drying procedure. Clean the
repair area with methylethylketone (CoMat 01-076) using lint free
cloth (CoMat 02-099). Wipe the area with a piece of clean lint free
cloth before the fluid dries.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Fill the damage with the adhesive using a clean metal spatula. The
filled damage must be level with the outermost existing carbon ply
of the repair area.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Remove the parting film from one side of the first repair ply and
position the ply over the damage with the adhesive side down. Make
sure the damage is located in the center of the ply and at 45
degrees to the damaged ply. Use the roller to remove air caught in
the adhesive. Remove the remaining parting film.
C. Remove the parting film from one side of the second repair ply (if
it is required) and position it over the repair area with the
adhesive side down. Make sure it has an equal overlap around the
first ply. Use the roller to remove the air caught in the adhesive.
Remove the remaining parting film.
NOTE: Make sure that the ply fibres are at 45 degrees to each
other.
NOTE: The last repair (sanding) ply must touch the teflon tape
(CoMat 02-007) all around.
E. Remove unwanted adhesive from the teflon tape with a clean metal
spatula.
B. Cut the porous parting film (CoMat 02-169). Make sure that the film
is larger than the heat blanket and overlaps the last (fiberglass)
repair ply by at least 3.0 in. (76,2 mm) all around.
C. Cut the breather fabric (CoMat 08-057) into pieces the same size as
the porous parting film (Ref step B. above). The number of pieces
must equal the number of plies used in the repair.
D. Put the porous parting film on to the repair area so that it has an
equal overlap. Put the breather fabric on top of the porous parting
film. Use one layer of breather fabric for each carbon ply used in
the repair.
F. Put four fiberglass tows onto the repair area using one strand of
the fiberglass fabric (CoMat 02-167) in each of four positions
around the repair. Each of the strands must connect the breather
fabric with the area around the silicone rubber sheet.
NOTE: With the fiberglass tows installed, gasses can not collect
below the silicone rubber sheet when the adhesive cures.
G. Put the non-porous parting film (Ref step E. above) onto the repair
area first. Make sure that it has an equal overlap around the
repair area. Put the silicone rubber sheet on top of the non-porous
parting film.
H. Cut two pieces of breather cloth (CoMat 02-166), at least 2.0 in.
(50,8 mm) larger on each side than the silicone rubber sheet. Put
the two pieces of the breather cloth on to the repair area. Put the
heat blanket on top of the breather cloth. The heat blanket must
have an overlap all around the repair area.
J. Put the nylon bagging film (CoMat 02-163) over the repair area so
that the bag overlaps the breather cloth by 2.0 in. (50,8 mm) all
around. Install the vacuum hose from the suction pump so that it
goes directly on to the breather cloth. Attach and seal the film to
the bulkhead with the sealant tape (CoMat 08-051).
A. Decrease the pressure in the repair area with the vacuum suction
pump. During the cure, the reading must show at least 25.0 in.
(635,0 mm) of mercury.
B. Increase the temperature and keep at 190 o - 210oF (88o - 99oC) for
220 minutes. The rate of increase and subsequent decrease must not
be faster than 5.4 oF (3oC) in each minute. Start to measure the time
for the adhesive to cure when the temperature gets to 190 oF (88oC).
The nylon bagging film with its seal and the vacuum hose; the
temperature probes; the heat blanket; the breather cloth; the
silicone rubber sheet; the non-porous parting film; the breather
fabric; the fiberglass tows; the porous parting film and the teflon
tape.
A. Make the repair area smooth. The contours of the repair area must
be smooth and there must not be an edge or step, between the repair
area and the outer skin of the panel. Use the abrasive paper (CoMat
05-021).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, SRM 54-01-00 Composite Structure Tap Test, to
confirm that the repair is correctly bonded.
CANCELLATION NOTICE
THE ABOVE SRM REPAIR HAS BEEN CANCELLED AND SHOULD NO LON-
GER BE APPLIED. FOR ACOUSTIC LINER HOLE REPAIRS REFER TO
VRS7504.
1. General.
B. This removes the damaged area, fills the repair area with epoxy
paste adhesive and then an outer ply is installed on top.
C. The damaged area must be more than 10.0 in. (254,0 mm) away from
any adjacent repairs.
2. Referenced Information.
A. Standard equipment
C. Special Tools
D. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Air Intake Cowl Composite structure
4. Prepare the damaged area for repair (Ref. Figs. 201 and 202).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Inspect the damaged area using IAE 1N20444 tapping tool and the tap
test method, (Ref. SRM 54-01-00) Composite Structure Tap Test, to
find all areas of delamination.
C. Mark around the damage with a pencil and make sure all cracks and
areas of delamination are included.
D. Put the teflon tape (CoMat 02-007) in 2.0 in. (50,8 mm) wide strips
approximately 1.0 in. (25,4 mm) away from the mark around the
damage.
E. Use hand tools and a high-speed rotary cutter to remove all the
damage (including cracks) from the facing sheet.
CAUTION: DO NOT DAMAGE THE INNER SKIN AND ADJACENT STRUCTURE WHEN YOU
REMOVE THE HONEYCOMB. IF YOU DAMAGE THE INNER SKIN AND
ADJACENT STRUCTURE YOU MAY HAVE TO DO A DIFFERNET REPAIR.
F. Use a high-speed rotary sander and remove the honeycomb from the
repair area.
H. Let the repair area dry for 6 hours at 176 oF (80oC) with a heat
lamp. The repair materials must be applied immediately after the 6
hours.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Mix the epoxy paste adhesive (CoMat 08-021) in accordance with the
manufacturer’s instructions.
(1) Use the epoxy paste adhesive to fill the repair cut-out until
it is level with the facing sheet.
(2) Make sure the honeycomb cells that can be seen are filled
with epoxy paste adhesive.
(1) Use heat lamps to cure the epoxy paste adhesive for 1 to 2
hours at 113o - 131oF (45 o - 55oC).
E. When the repair is cool, remove the weight, the cawl plate and the
non-porous parting film.
A. Put on lint free gloves (CoMat 02-097). Cut a piece of dry carbon
fibre fabric (CoMat 08-059) 1.0 in. (25,4mm) larger all around than
the area identified by the teflon tape.
NOTE: Make sure that the outer ply is not cut to its correct
dimension until it has been soaked with epoxy paste
adhesive.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Mix the epoxy paste adhesive (CoMat 08-050) in accordance with the
manufacturer’s instructions.
NOTE: After the ply is soaked, the remaining epoxy paste adhesive
(if it is kept cool) can be used in the installation
procedure.
(2) Apply the epoxy paste adhesive to the ply with the brush
(CoMat 02-087) and put a second sheet of non-porous parting
film on top.
(3) Use the roller to force the epoxy paste adhesive into the ply
thoroughly. Make sure the ply is soaked with the epoxy paste
adhesive.
D. Cut the ply so that it is the same shape as the area identified by
the teflon tape.
NOTE: Make sure that the two pieces of non-porous parting film
stays on the ply until the installation procedure.
E. Keep the outer ply and the epoxy paste adhesive cool until the
installation procedure.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Use the brush (CoMat 02-087) and apply an equal layer of epoxy
paste adhesive (CoMat 08-050) to the area identified by the teflon
tape.
(1) Remove one sheet of the non-porous parting film from the
outer ply.
(2) Put the outer ply, with the epoxy paste adhesive side down,
on to the repair area in the correct position for
installation. Make sure the outer ply has an equal overlap
around the repair cut-out and touches the teflon tape.
(3) Use the roller and smooth the surface of the outer ply until
all air bubbles are removed.
(4) Remove any unwanted epoxy paste adhesive with a clean metal
spatula.
(2) Use the heat lamp to keep the temperature of the repair area
between 194o - 200oF (90 o - 93oC) for 220 minutes.
(4) Start to measure the cure time when the temperature reaches
194oF (90oC).
D. When the repair area is cool, remove the lamp, temperature probes,
weight, cawl plate, teflon tape and non-porous parting film.
9. Make the edges of the outer ply smooth (Ref. Fig. 202).
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. ONLY
REMOVE MATERIAL FROM THE EDGE OF THE OUTER PLY. DO NOT USE A
LIQUID WITH THE ABRASIVE PAPER.
A. Rub the edges of the outer ply, with waterproof abrasive paper
(CoMat 05-021) until smooth with the adjacent structure.
A. Remove all unwanted material with a suction cleaner. Make sure that
no particles of the materials stay in the acoustic panel.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Make a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, (Ref. SRM 54-01-00) Composite Structure Tap Test,
to confirm that the repair is correctly bonded.
CANCELLATION NOTICE
THE ABOVE SRM REPAIR HAS BEEN CANCELLED AND SHOULD NO LON-
GER BE APPLIED. IF PREVIOUSLY ACCOMPLISHED, CONTACT GO-
ODRICH FOR DISPOSITION.
1. General.
B. This repair removes the damaged area and installs carbon fibre
fill-in plies, a carbon fibre patch and a fiberglass sanding ply.
2. Referenced Information.
A. Standard equipment
B. Special Tools
D. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Air intake cowl Composite structure
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Mask around the repair area with teflon tape (CoMat 02-007).
Calculate the distance that the tape must be from the damage as
follows:
(1) Measure a minimum of 3.75 in. (95,25 mm) each side along the
panel land.
(2) On the external surface, measure 4.85 in. (123,2 mm) from the
panel edge.
(4) Carefully apply the teflon tape along the marks on the
measured repair area.
(1) Find the center of the damaged area, measure 0.5 in.
(12,7 mm) each side along the panel land and make a mark.
(2) Measure 1.6 in. (40,6 mm) from the panel edge and make a mark
to show the panel land area.
A. Use heat lamps to dry the repair area. Keep the repair area at 176 oF
(80oC) for six hours. The repair materials must be applied
immediately at the end of the six hours.
(1) Wear lint-free gloves (CoMat 02-097) and cut seven pieces of
dry carbon fibre fabric (CoMat 08-059) 1.0 in. (25,4 mm)
larger all around (except at the panel edge) than the cut-out
repair area.
(1) Wear lint-free gloves (CoMat 02-097) and cut one piece of dry
carbon fibre fabric (CoMat 08-059) a minimum of 2.0 in. (50,8
mm) larger all around (except at the panel edge) than the
cut-out repair area.
(1) Wear lint-free gloves (CoMat 02-097) and cut the six
subsequent repair plies from dry carbon fibre fabric
(CoMat 08-059), each piece 0.25 in. (6,3 mm) larger all
around (except at the panel edge) than the previous piece.
(1) Wear lint-free gloves (CoMat 02-097) and cut one piece of
fiberglass fabric (CoMat 02-167) so that it is 0.75 in.
(19,0 mm) larger all around (except at the panel edge) than
the largest ply.
(4) Make sure that the backing plate has a good contour with the
panel land and a good overlap of the cut-out area.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
NOTE: After the plies are soaked, the remaining adhesive (if it is
kept cool) can be used in the installation procedure.
B. Soak the carbon fibre and fiberglass plies with the mixed adhesive.
(2) Apply the adhesive to each ply with the brush (CoMat 02-087)
and cover each ply with another sheet of non-porous parting
film.
(3) Use the roller to force the adhesive into each ply
thoroughly.
(1) Cut each fill-in ply to the same dimensions as the cut-out
area.
(2) Find a short side on each ply and cut two corners to a radius
of 0.25 in. (6,3 mm).
(1) Cut the first repair ply 1.0 in. (25,4 mm) larger all around
(except at the panel edge) than the cut-out repair area.
(2) Cut each subsequent repair ply 0.5 in. (12,7 mm) longer and
0.25 in. (6,3 mm) wider.
(3) Find a long side on each ply and cut two corners
approximately 0.5 in. (12,7 mm) from the end at an angle of
45 degrees.
(1) Cut the fiberglass sanding ply 0.75 in. (19,0 mm) larger all
around (except at the panel edge) than the largest repair
ply.
(2) Find a long side and cut the two corners approximately
1.0 in. (25,4 mm) from the end at an angle of 45 degrees.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Remove any unwanted material from the repair area with a suction
cleaner.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Apply an equal layer of adhesive to the cut-out area and the edges
using a brush (CoMat 02-087).
(1) Remove the parting film from one side of the first fill-in
ply.
(2) Put the first fill-in ply, with the adhesive side down, in
the cut-out area, and align it with the edge of the panel
land.
(3) Remove air and unwanted adhesive with a clean metal spatula.
(4) Remove the remaining parting film from the first fill-in
ply.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) Remove one sheet of non-porous parting film from the first
repair ply.
(2) Put the first repair ply, with the adhesive side down, onto
the repair area and align it with the panel edge, making sure
that it has a 1.0 in. (25,4 mm) overlap around the repair
area.
(3) Use the roller to remove air and unwanted adhesive from the
ply.
(4) Remove the remaining non-porous parting film from the first
repair ply.
(1) Repeat step B above for the remaining repair plies, making
sure each subsequent repair ply has a 0.25 in. (6,3 mm) over-
lap around the previous ply.
(1) Repeat step B above for the fiberglass sanding ply, making
sure that the ply has a 0.75 in. (19,0 mm) overlap around the
top repair ply.
(2) Make sure that the fiberglass ply is adjacent to, but not on,
the teflon tape.
E. Remove unwanted adhesive from the teflon tape with a clean metal
spatula.
A. Get a heat blanket, which must be larger all around than the repair
area.
B. Cut a sheet of porous parting film (CoMat 02-169) making sure that
it is larger than the heat blanket and has an overlap of at least
3.0 in. (76,2 mm) around the fiberglass ply.
C. Cut nine sheets of breather fabric (CoMat 08-057), making sure that
the breather fabric has the same dimensions as the porous parting
film.
D. Put the porous parting film on to the repair area, making sure that
it has an equal overlap around the repair area. Put the layers of
breather fabric on top of the porous parting film.
(2) Make sure that each strand connects the breather fabric with
the area around the silicone rubber sheet.
G. Put the non-porous parting film on to the repair area, making sure
that it has an equal overlap around the repair area. Put the
silicone rubber sheet on top of the non-porous parting film.
H. Put the heat blanket and breather cloth on to the repair area.
(1) Cut two sheets of breather cloth (CoMat 02-166), at least 2.0
in. (50,8 mm) larger on each side than the silicone rubber
sheet.
(2) Put the two sheets of breather cloth on to the repair area.
(3) Put the heat blanket on top of the breather cloth, making
sure that the heat blanket has an overlap all around the
repair area.
(1) Use nylon bagging film (CoMat 02-163) and sealant tape
(CoMat 08-051).
(2) Make sure that the bagging film is approximately four times
larger than the panel.
(4) Install the vacuum hose, from the suction pump, so that it
goes directly on to the breather cloth.
(5) Attach and seal the vacuum bag to the panel with the sealant
tape (CoMat 08-051).
A. Use the vacuum pump to decrease the pressure in the repair area,
making sure it gives an indication of at least 25.0 in. (635,0 mm)
of mercury while the adhesive cures.
D. Start to measure the cure time when the temperature gets to 180 oF
(82oC).
A. When the cure process is completed, remove the layup materials from
the repair area.
CAUTION: DO NOT CAUSE DAMAGE TO THE REPAIR PLIES OR THE GRAPHITE PLIES
OF THE PANEL.
(2) Close the access panel, and make sure that the aerodynamic
contour of the external surface is correct and the hinge area
does not catch.
(1) Use the intake cowl as a template and make a mark for the
fastener hole(s).
(1) Measure approximately 0.35 in. (8,9 mm) from the panel edge
and apply teflon tape (CoMat 02-007).
(2) Radius chamfer the repair plies and the sanding ply.
A. Remove all unwanted material from the repair area with a suction
cleaner.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, SRM 54-01-00 Composite Structure Tap Test, to
confirm that the repair is correctly bonded.
1. General
B. This repair removes the damaged area and installs carbon fibre
fill-in plies and a carbon fibre patch.
C. Only one repair for each access panel interface land is permitted.
2. Referenced Information
A. Standard equipment
C. Repair Parts
--------------------------------------------
PART NO. PART IDENT
--------------------------------------------
NAS1791-C4-1P Captive nut
CCR264CS-3-4 Rivet
ST1729E/20/X Nut plate packer
D. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Air intake cowl Composite structure
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Mask around the repair area with teflon tape (CoMat 02-007).
Calculate the distance that the tape must be from the damage as
follows.
(1) Measure a minimum of 2.25 in. (57.2 mm) each side along the
panel land, making sure that this dimension is between
adjacent captive nuts.
(2) On the internal surface, measure 3.00 in. (76.2 mm) from the
edge of the panel land.
(4) Carefully apply the teflon tape along the marks on the
measured repair area, making sure that the teflon tape (on
the panel land) is between the captive nuts.
(1) Find the center of the damaged area, measure 0.5 in.
(12.7 mm) each side along the panel land and make a mark.
(2) Measure 1.6 in. (40.6 mm) from the panel edge and make a mark
to show the panel land area.
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. DO NOT
USE A LIQUID WITH THE ABRASIVE PAPER.
(1) Find the edges of the cut-out area and measure a minimum of
1.0 in. (25.4 mm) from each side.
(4) Find a long side and cut the two corners 0.5 in. (12.7 mm)
from the end, at an angle of 45 degrees.
A. Use heat lamps to dry the repair area. Keep the temperature at
176oF (80oC) for 6 hours. The repair materials must be applied
immediately at the end of the 6 hours.
10. Prepare the fill-in and repair plies (Ref Fig 201).
(1) Wear lint-free gloves (CoMat 02-097) and cut four pieces of
dry carbon fibre fabric (CoMat 08-059) 1.0 in. (25.4 mm)
larger all around (except at the panel edge) than the cut-out
repair area.
(1) Wear lint-free gloves (CoMat 02-097) and cut one piece of dry
carbon fibre fabric (CoMat 08-059) a minimum of 2.0 in.
(50.8 mm) larger all around (except at the panel edge) than
the cut-out repair area.
(1) Wear lint-free gloves (CoMat 02-097) and cut the three
subsequent repair plies from dry carbon fibre fabric
(CoMat 08-059), each piece 0.25 in. (6.3 mm) larger all
around (except at the panel edge) than the previous piece.
(4) Make sure that the backing plate has a good contour with the
panel land and a good overlap of the cut-out area.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
NOTE: After the plies are soaked, the remaining adhesive (if it is
kept cool) can be used in the installation procedure.
(2) Apply the adhesive to each ply with the brush (CoMat 02-087)
and cover each ply with another sheet of non-porous parting
film.
(3) Use the roller to force the adhesive into each ply
thoroughly.
(1) Cut each fill-in ply to the same dimensions as the cut-out
area.
(2) Find a long side on each ply and cut two corners to a radius
of 0.25 in. (6.3 mm).
(1) Put the template (refer to step 8.) on the first repair
ply, and cut the ply to the template dimensions.
(2) Cut each subsequent repair ply 0.5 in. (12.7 mm) longer and
0.25 in. (6.3 mm) wider than the previous ply.
(3) Find a long side on each ply and cut two corners
approximately 0.5 in. (12.7 mm) from the end at an angle of
45 degrees.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Clean an area 18 in. (457 mm) all around the repair area with
methylethylketone (CoMat 01-076) and lint-free cloth
(CoMat 02-099). Wipe the repair area dry.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Apply an equal layer of adhesive to the cut-out area and the edges
using a brush (CoMat 02-087).
(1) Remove the parting film from one side of the first fill-in
ply.
(2) Put the first fill-in ply, with the adhesive side down, in
the cut-out area, and align it with the edge of the panel
land.
(3) Remove air and unwanted adhesive from the ply with a clean
metal spatula.
(4) Remove the remaining parting film from the first fill-in
ply.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) Remove one sheet of non-porous parting film from the first
repair ply.
(2) Put the first repair ply, with the adhesive side down, onto
the repair area and align it with the edge of the inner
surface, making sure that the edge of the repair ply is
approximately halfway between the adjacent captive nuts.
(3) Use the roller to remove air and unwanted adhesive from the
ply.
(4) Remove the remaining non-porous parting film from the first
repair ply.
(1) Repeat step B above for the remaining repair plies, making
sure each subsequent repair ply has an equal 0.25 in.
(12.7 mm) overlap around the previous one.
(2) Make sure that the fourth repair ply is adjacent to, but not
on, the teflon tape.
D. Remove unwanted adhesive from the teflon tape with a clean metal
spatula.
A. Get a heat blanket, which must be larger all around than the repair
area.
D. Put the porous parting film on to the repair area, making sure
that it has an equal overlap around the repair area. Put the
layers of breather fabric on top of the porous parting film.
(2) Make sure that each strand connects the breather fabric with
the area around the silicone rubber sheet.
G. Put the non-porous parting film on to the repair area, making sure
that it has an equal overlap around the repair area. Put the
silicone rubber sheet on top of the non-porous parting film.
H. Put the heat blanket and breather cloth on to the repair area.
(2) Put the two sheets of breather cloth on to the repair area.
(3) Put the heat blanket on top of the breather cloth, making
sure that the heat blanket has an overlap all around the
repair area.
(1) Use nylon bagging film (CoMat 02-163) and sealant tape
(CoMat 08-051).
(3) Install the vacuum hose, from the suction pump, so that it
goes directly on to the breather cloth.
(4) Attach and seal the vacuum bag to the panel with the sealant
tape.
A. Use the vacuum pump to decrease the pressure in the repair area,
making sure it gives an indication of at least 20.0 in (508 mm) of
mercury while the adhesive cures.
B. Use the heat blanket to keep the temperature of the repair area at
194o - 200oF (90o - 93oC) for 220 minutes.
D. Start to measure the cure time when the temperature reaches 194 oF
(90oC).
CAUTION: DO NOT CAUSE DAMAGE TO THE REPAIR PLIES OR THE GRAPHITE PLIES
OF THE PANEL.
(2) Temporarily install the access panel, and make sure that the
aerodynamic contour on the external surface is correct.
(1) Use the access panel as a template and make a mark for the
fastener hole(s).
(1) Use a captive nut as a template and make a mark for the
fastener hole(s).
A. Remove all unwanted material from the repair area with a suction
cleaner.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Make a visual inspection to make sure that the repair has been
done in accordance with these procedures.
CANCELLATION NOTICE
1. General.
B. This repair fills the damaged area with resin and installs carbon
fibre repair plies and a fiberglass sanding ply.
C. The damage must not go beyond the stiffener area and must be a
minimum of 2D from a fastener. The damage must not go through all
the composite plies and into the stiffener. The damage must be more
than (4 repair plies + 1 sanding ply) 4.75 in. (120,7 mm) from the
edge of the panel and no more than 24.5 in. (622,3 mm) around the
circumference. The damage can be nearer to the edge if less than
four plies are damaged. Refer to Fig. 201 and 202. There must be a
minimum of 10 in. (254,0 mm) between damaged areas.
D. The orientation of the carbon fibre repair plies must follow the
sequence (±45)/(0-90)/( ±45) for a 3-ply region,
(±45)/0-90)/(0-90)/(±45) for a 4-ply region. Refer to Fig. 201.
2. Referenced Information.
A. Standard equipment
B. Special Tools
D. Repair parts
None.
E. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Air intake cowl Composite structure
A. Referring to Fig. 201 and 202 examine the repair area to assess the
amount of damage and, using the standard workshop tools, measure
the depth of the damage. Do this in several places where the extent
of the damage permits. From this information the number of repair
plies should be calculated as follows:
Where doubt can arise over the exact magnitude of the damage
penetration, i.e. deciding between 0.045in. (1,14 mm) and 0.046in.
(1,17 mm), assume the larger figure as the criteria for selecting
the number of repair plies to use. That is, 4 plies rather than 3,
for this example. If on examination it is found that the damage has
fully penetrated the panel and is into the stiffener, repair is
beyond the scope of this document. In this event reference must be
made to alternative repair procedures.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. With reference to Fig. 201 and 202 calculate the distance for
positioning the strip of teflon tape (CoMat 02-007) from the edge
of the damage as follows: from the edge of the damaged area measure
1.0 in. (25,4 mm) for each damaged ply of the cowl, i.e., if 4 plies
are damaged then measure 4.0 in. (101,6 mm) from the edge of the
damaged area. Add 0.75 in. (19,05 mm) for an outer layer of
fiberglass fabric (CoMat 02-167). Apply the teflon tape so that it
goes around the repair area in a 2.0 in. (50,8 mm) wide strip. Make
the corners at an angle of approximately 45 degrees and
approximately 1.0 in. (25,4 mm) length of side.
B. Remove the sharp edges of the damage using the abrasive paper
(CoMat 05-021) and, with a fresh piece of the abrasive paper, make
the surface of the repair area rough.
A. Cut the first repair ply so that it has a 2.0 in. (50,8 mm) overlap
around the damage. Use carbon fabric (CoMat 08-059) and lint free
gloves (CoMat 02-097). To prevent fraying, the plies may be cut to
the finished dimensions after soaking in adhesive (Ref. steps 1.D.
and 9.C.).
B. Cut the remaining repair plies if they are required. Use the carbon
fabric (CoMat 08-059) and lint free gloves. Cut each subsequent
repair ply 2.0in. (50,8 mm) longer and 2.0in. (50,8 mm) wider. Cut
the last ply (sanding ply) from fiberglass fabric to give a 1.0in.
(25,4 mm) overlap beyond the teflon tape. There must be a repair
ply for each ply of the panel which is damaged. To prevent fraying,
the plies may be cut to the finished dimensions after soaking in
adhesive (Ref steps 1.D. and 9.C.).
A. Dry the repair area. Use the heat lamp to keep the repair area of
the panel at 176oF (80oC) for six hours. The repair materials must
be applied at the end of the six hours.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
C. Cut approximately 1.0 in. (25,4 mm) off each edge of the plies.
Make sure the first ply has a 1.0 in. (25,4 mm) overlap around the
damage. The overlap for each subsequent ply must be 1.0 in.
(25,4 mm). Cut the corners of the repair plies to an angle of
approximately 45 degrees with a length of approximately 0.5 in.
(12,7 mm).
D. Cut the fiberglass ply to the shape defined by the teflon tape
(CoMat 02-007).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Fill the damage with the adhesive using a clean metal spatula. The
filled damage must be level with the outermost existing carbon ply
of the repair area.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Remove the parting film from one side of the first repair ply and
position the ply over the damage with the adhesive side down. Make
sure the damage is located in the center of the ply and at 45
degrees to the damaged ply. Use the roller to remove air caught in
the adhesive. Remove the remaining parting film.
C. Remove the parting film from one side of the remaining repair plies
(if required) and position it over the repair area with the
adhesive side down. Make sure it has an equal overlap around the
first ply. Use the roller to remove the air caught in the adhesive.
Remove the remaining parting film.
NOTE: Make sure that the ply fibres are ( ±45)/(0-90)/(±45) for a
3-ply region, (±45)/0-90)/(0-90)/( ±45) for a 4-ply region.
NOTE: The fiberglass (sanding) ply must touch the teflon tape
(CoMat 02-007) all around.
E. Remove unwanted adhesive from the teflon tape with a clean metal
spatula.
B. Cut the porous parting film (CoMat 02-169). Make sure that the film
is larger than the heat blanket and overlaps the last (fiberglass)
repair ply by at least 3.0 in. (76,2 mm) all around.
C. Cut the breather fabric (CoMat 08-057) into pieces the same size as
the porous parting film (Ref step B. above). The number of pieces
must equal the number of plies used in the repair.
D. Put the porous parting film on to the repair area so that it has an
equal overlap. Put the breather fabric on top of the porous parting
film. Use one layer of breather fabric for each carbon ply used in
the repair.
F. Put four fiberglass tows onto the repair area using one strand of
the fiberglass fabric (CoMat 02-167) in each of four positions
around the repair. Each of the strands must connect the breather
fabric with the area around the silicone rubber sheet.
NOTE: With the fiberglass tows installed, gasses can not collect
below the silicone rubber sheet when the adhesive cures.
G. Put the non-porous parting film (Ref step E. above) onto the repair
area first. Make sure that it has an equal overlap around the
repair area. Put the silicone rubber sheet on top of the non-porous
parting film.
H. Cut two pieces of breather cloth (CoMat 02-166), at least 2.0 in.
(50,8 mm) larger on each side than the silicone rubber sheet. Put
the two pieces of the breather cloth on to the repair area. Put the
heat blanket on top of the breather cloth. The heat blanket must
have an overlap all around the repair area.
J. Put the nylon bagging film (CoMat 02-163) over the repair area so
that the bag overlaps the breather cloth by 2.0 in. (50,8 mm) all
around. Install the vacuum hose from the suction pump so that it
goes directly on to the breather cloth. Attach and seal the film to
the panel with the sealant tape (CoMat 08-051).
A. Decrease the pressure in the repair area with the vacuum suction
pump. During the cure, the reading must show at least 25.0 in.
(635,0 mm) of mercury.
B. Increase the temperature and keep at 190 o - 210oF (88o - 99oC) for
220 minutes. The rate of increase and subsequent decrease must not
be faster than 5.4oF (3 oC) in each minute. Start to measure the
time for the adhesive to cure when the temperature gets to 190 oF
(88oC).
The nylon bagging film with its seal and the vacuum hose; the
temperature probes; the heat blanket; the breather cloth; the
silicone rubber sheet; the non-porous parting film; the breather
fabric; the fiberglass tows; the porous parting film and the teflon
tape.
A. Make the repair area smooth. The contours of the repair area must
be smooth and there must not be an edge or step, between the repair
area and the outer skin of the panel. Use the abrasive paper (CoMat
05-021).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, SRM 54-01-00 Composite Structure Tap Test, to
confirm that the repair is correctly bonded.
1. General.
B. This repair fills the damaged area with epoxy adhesive and installs
carbon fibre repair plies and a fiberglass sanding ply.
D. The orientation of the carbon fibre repair plies must follow the
sequence:(±45)/(0-90)/(0-90)/(±45) for each repair ply up to a
maximum of 4 repair plies. Applicable to both inner and outer
surfaces. Refer to Fig. 202.
F. If the damage goes through the panel, do REPAIR No. 014 (VRS2846).
If the damage goes to the edge of the panel, do REPAIR No. 009
(VRS2844).
2. Referenced Information.
A. Standard equipment
B. Special Tools
D. Repair parts
None.
E. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Probe access panel Composite structure
Interphone access panel Composite structure
A. Referring to Fig. 201 and 202 examine the repair area to assess the
amount of damage and, using the standard workshop tools, measure
the depth of the damage. Do this in several places where the extent
of the damage permits. From this information the number of repair
plies should be calculated as follows:
Where doubt can arise over the exact magnitude of the damage
penetration, i.e. deciding between 0.045in. (1,14 mm) and 0.046in.
(1,17 mm), assume the larger figure as the criteria for selecting
the number of repair plies to use. That is, 4 plies rather than 3,
for this example. If on examination it is found that the damage has
fully penetrated the panel, repair is beyond the scope of this
document. In this event reference must be made to alternative
repair procedures.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. With reference to Fig. 201 and 202 calculate the distance for
positioning the strip of teflon tape (CoMat 02-007) from the edge
of the damage as follows: from the edge of the damaged area measure
1.0 in. (25,4 mm) for each damaged ply of the cowl, i.e., if 4 plies
damaged then measure 4.0 in. (101,6 mm) from the edge of the
damaged area. Add 0.75 in. (19,05 mm) for an outer layer of
fiberglass fabric (CoMat 02-167). Apply the teflon tape so that it
goes around the repair area in a 2.0 in. (50,8 mm) wide strip. Make
the corners at an angle of approximately 45 degrees and
approximately 1.0 in. (25,4 mm) length of side.
B. Remove the sharp edges of the damage using the abrasive paper
(CoMat 05-021) and, with a fresh piece of the abrasive paper, make
the surface of the repair area rough.
A. Cut the first repair ply so that it has a 2.0 in. (50,8 mm) overlap
around the damage. Use carbon fabric (CoMat 08-059) and lint free
gloves (CoMat 02-097). To prevent fraying, the plies may be cut to
the finished dimensions after soaking in adhesive (Ref. steps 1.D.
and 9.C.).
B. Cut the remaining repair plies if they are required. Use the carbon
fabric and lint free gloves. Cut each subsequent repair ply 2.0in.
(50,8 mm) longer and 2.0in. (50,8 mm) wider. Cut the last ply
(sanding ply) from fiberglass fabric to give a 1.0in. (25,4 mm)
overlap beyond the teflon tape. There must be a repair ply for each
ply of the panel which is damaged. To prevent fraying, the plies
may be cut to the finished dimensions after soaking in adhesive
(Ref steps 1.D. and 9.C).
A. Dry the repair area. Use the heat lamp to keep the repair area of
the panel at 176oF (80oC) for six hours. The repair materials must
be applied at the end of the six hours.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
C. Cut approximately 1.0 in. (25,4 mm) off each edge of the plies.
Make sure the first ply has a 1.0 in. (25,4 mm) overlap around the
damage. The overlap for each subsequent ply must be 1.0 in.
(25,4 mm). Cut the corners of the repair plies to an angle of
approximately 45 degrees with a length of approximately 0.5 in.
(12,7 mm). Cut the fiberglass ply to the shape defined by the
teflon tape (CoMat 02-007).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. The repair area must be cool after the drying procedure. Clean the
repair area with methylethylketone (CoMat 01-076) using lint free
cloth (CoMat 02-099). Wipe the area with a piece of clean lint free
cloth before the fluid dries.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Fill the damage with the adhesive using a clean metal spatula. The
filled damage must be level with the top carbon ply of the panel.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Remove the parting film from one side of the first repair ply and
position the ply over the damage with the adhesive side down. Make
sure the damage is located in the center of the ply and at 45
degrees to the damaged ply. Use the roller to remove air caught in
the adhesive. Remove the remaining parting film.
C. Remove the parting film from one side of the remaining repair plies
(if required) and position it over the repair area with the
adhesive side down. Make sure it has an equal overlap around the
first ply. Use the roller to remove the air caught in the adhesive.
Remove the remaining parting film.
NOTE: Make sure that the ply fibres follow the sequence:
(±45)/(0-90)/(0-90)/(±45).
NOTE: The fiberglass (sanding) ply must touch the teflon tape
(CoMat 02-007) all around.
E. Remove unwanted adhesive from the teflon tape with a clean metal
spatula.
B. Cut the porous parting film (CoMat 02-169). Make sure that the film
is larger than the heat blanket and overlaps the last (fiberglass)
repair ply by at least 3.0 in. (76,2 mm) all around.
C. Cut the breather fabric (CoMat 08-057) into pieces the same size as
the porous parting film (Ref step B. above). The number of pieces
must equal the number of plies used in the repair.
D. Put the porous parting film on to the repair area so that it has an
equal overlap. Put the breather fabric on top of the porous parting
film. Use one layer of breather fabric for each carbon ply used in
the repair.
F. Put four fiberglass tows onto the repair area using one strand of
the fiberglass fabric (CoMat 02-167) in each of four positions
around the repair. Each of the strands must connect the breather
fabric with the area around the silicone rubber sheet.
G. Put the non-porous parting film (Ref step E. above) onto the repair
area first. Make sure that it has an equal overlap around the
repair area. Put the silicone rubber sheet on top of the non-porous
parting film.
H. Cut two pieces of breather cloth (CoMat 02-166), at least 2.0 in.
(50,8 mm) larger on each side than the silicone rubber sheet. Put
the two pieces of the breather cloth on to the repair area. Put the
heat blanket on top of the breather cloth. The heat blanket must
have an overlap all around the repair area.
J. Put the nylon bagging film (CoMat 02-163) over the repair area so
that the bag overlaps the breather cloth by 2.0 in. (50,8 mm) all
around. Install the vacuum hose from the suction pump so that it
goes directly on to the breather cloth. Attach and seal the film to
the bulkhead with the sealant tape (CoMat 08-051).
A. Decrease the pressure in the repair area with the vacuum suction
pump. During the cure, the reading must show at least 25.0 in.
(635,0 mm) of mercury.
B. Increase the temperature and keep at 190o - 210oF (88o - 99oC) for
220 minutes. The rate of increase and subsequent decrease must not
be faster than 5.4oF (3oC) in each minute. Start to measure the
time for the adhesive to cure when the temperature gets to 190oF
(88oC).
The nylon bagging film with its seal and the vacuum hose; the
temperature probes; the heat blanket; the breather cloth; the
silicone rubber sheet; the non-porous parting film; the breather
fabric; the fiberglass tows; the porous parting film and the teflon
tape.
A. If the repair is on the outer side of this panel, make the repair
area smooth with waterproof abrasive paper (CoMat 05-021). The
contours of the repair area must be smooth and there must not be an
edge or step, between the repair area and the outer skin of the
panel.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, SRM 54-01-00 Composite Structure Tap Test, to
confirm that the repair is correctly bonded.
1. General.
A. This procedure may be used to repair damage to the air intake cowl
probe access panel, including a hole, cracks and delamination.
B. This repair removes the damaged area and installs a support plate,
carbon fibre filler plies, a carbon fibre patch and a fiberglass
sanding ply.
F. If the damage goes to the edge of the panel, do REAPIR No. 009
(VRS2844). Where damage is beyond the scope of this repair refer to
Goodrich.
2. Referenced Information.
A. Standard equipment
C. Special Tools
D. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Probe access panel Composite structure
Interphone access panel Composite structure
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Mark around the damage with a pencil, making sure to include cracks
and areas of delamination.
6. Apply teflon tape around the repair area (Ref. Fig. 203).
A. Mask around the repair area with teflon tape (CoMat 02-007).
Calculate the distance that the tape must be from the cut-out as
follows:
(1) Measure 1.0 in. (25,4 mm) from the edge of the damage for
each of the four plies of the panel, and add 0.75 in.
(19,05 mm) for an outer layer of fiberglass fabric (CoMat
02-167).
(2) Carefully apply the teflon tape so that it goes around the
area in a 2.0 in. (50,8 mm) wide strip.
7. Cut out the damaged area of the cowl (Ref. Fig. 202).
A. Use a high-speed rotary cutter, and make sure that the edges of the
cut-out have an angle of approximately 45 degrees.
B. The corners of the cut-out must have a radius of at least 0.5 in.
(12,7 mm).
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. DO NOT
USE A LIQUID WITH THE ABRASIVE PAPER.
D. Make the surface of the repair area rough with waterproof abrasive
paper (CoMat 05-021).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Clean the area around the cut-out, on the inner and outer surfaces
of the panel, with methylethylketone (CoMat 01-076) and lint-free
cloth (CoMat 02-099). Wipe the repair area dry.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(2) Apply the adhesive to each ply with the brush (CoMat 02-087)
and cover each ply with another sheet of non-porous parting
film.
(3) Use the roller to force the adhesive into each ply
thoroughly.
(1) Remove one sheet of non-porous film from two of the plies.
(2) Remove both sheets of non-porous film from the third ply.
(3) Align the three plies and put them on with their adhesive
sides together onto a hard, flat surface.
(4) Use the roller to remove unwanted adhesive and air from the
three fiberglass plies.
(2) Use the heat lamp to cure the adhesive for 220 minutes at
190o - 210oF (88o - 99oC) for 220 minutes.
(4) Start to measure the cure time when the temperature reaches
190oF (88oC).
(1) When the support plate is cool, remove the two remaining
pieces of non-porous film.
(2) Drill two pairs of holes, 0.050 in. (1,27 mm) diameter, a
sufficient distance apart to attach the support plate to a
clamp bar with lockwire (CoMat 02-127).
A. Use the heat lamps to dry the repair area. Keep the temperature at
176oF (80oC) for six hours. The repair materials must be applied
immediately at the end of the six hours.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
C. Put the support plate against the inner surface of the access
panel. Make sure the plate has an equal overlap around the cut-out.
D. Put a clamp bar across the repair area with the ends of the bar on
the teflon tape. Attach the support plate to the clamp bar with the
lockwire (CoMat 02-127). Tighten the lockwire to hold the support
plate in the correct position.
Gradually increase the temperature with the heat lamp; the rate of
the increase must not exceed 5.4 oF (3oC) in each minute. Keep the
temperature at 190o - 210 oF (88o - 99oC) for 1 hour. Start to
measure the curing time when the temperature gets to 190 oF (88oC).
12. Prepare the filler and the repair plies (Ref. Fig. 203).
(1) Wear lint-free gloves (CoMat 02-097) and cut out the filler
plies from the carbon fibre fabric (CoMat 08-059) so that
they have a 1.0 in. (25,4 mm) overlap around the cut-out. Cut
(1) Wear lint-free gloves (CoMat 02-097) and cut one piece of dry
carbon fibre fabric (CoMat 08-059) a minimum of 2.0 in.
(50,8 mm) overlap around the cut-out (Ref. step 1.D.).
(1) Wear lint-free gloves (CoMat 02-097) and cut the three
remaining repair plies from dry carbon fibre fabric (CoMat
08-059), each piece 2.0 in. (50,8 mm) larger all around than
the previous piece. Cut one repair ply for each ply of the
panel (Ref. step 1.D.).
(1) Wear lint-free gloves (CoMat 02-097) and cut one piece of
fiberglass fabric (CoMat 02-167) so it has a 1.0 in.
(25,4 mm) overlap around the area identified by the teflon
tape.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
NOTE: After the plies are soaked, the remaining adhesive (if it is
kept cool) can be used in the installation procedure.
B. Soak the carbon fibre and fiberglass plies with the mixed adhesive.
(2) Apply the adhesive to each ply with the brush (CoMat 02-087)
and cover each ply with another sheet of non-porous parting
film.
(3) Use the roller to force the adhesive into each ply
thoroughly.
(1) Cut the first filler ply so that it is a good fit in the
repair cut-out, making sure it lies flat on the support
plate, is the same shape as the cut-out and its edges do not
overlap on the sides of the cut-out.
(2) Cut each subsequent filler ply so that it lies flat on the
filler ply installed before it, making sure it is the same
shape as the cut-out and its edges do not overlap on the
sides of the cut-out.
D. Cut the repair plies to their finished dimensions (Ref. step 1.C.).
(1) Cut the first repair ply so it has a 1.0 in. (25,4 mm)
overlap on the sides of the cut-out.
(2) Cut each subsequent repair ply to overlap the ply before by
1.0 in. (25,4 mm) all around.
E. Cut the fiberglass sanding ply to the same shape as the area
identified by the teflon tape.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Apply an equal layer of EA9390 adhesive to the cut-out area and the
edges using a brush (CoMat 02-087).
(1) Remove the parting film from one side of the first filler
ply.
(2) Put the first filler ply, with the adhesive side down, into
the cut-out, making sure that the filler ply is flat on the
support plate.
NOTE: Make sure that the orientation of the plies are the
same as the damaged plies.
(3) Remove the remaining parting film from the filler ply, and
using a clean metal spatula, make sure that the filler ply is
flat and in the correct position.
(1) Remove the parting film from one side of the filler ply.
NOTE: Make sure that the orientation of the plies are the
same as the damaged plies.
(2) Put the filler ply, with the adhesive side down, into the
cut-out, making sure that the filler ply is flat.
(3) Remove the remaining parting film from the filler ply, and
using a clean metal spatula, make sure that the filler ply is
flat and in the correct position.
D. Put the remaining filler plies (if they are necessary) into the
cut-out.
16. Install the repair plies and the fiberglass ply (Ref. Fig. 203).
(1) Remove one sheet of non-porous parting film from the first
repair ply.
(2) Put the first repair ply, with the adhesive side down, onto
the repair area, making sure that the repair cut-out is in
the center of the repair ply.
(3) Use the roller to remove air which is caught in the adhesive.
(4) Remove the remaining non-porous parting film from the first
repair ply.
(1) Remove one sheet of non-porous parting film from the second
repair ply.
(2) Put the second repair ply, with the adhesive side down, onto
the repair area, making sure that the second repair ply has
an equal overlap around the first repair ply.
(3) Use the roller to remove air which is caught in the adhesive.
(4) Remove the remaining non-porous parting film from the second
repair ply.
C. Put the remaining plies (if they are necessary) on to the repair
area.
(2) Put the fiberglass ply, with the adhesive side down, onto the
repair area, making sure that the fiberglass ply has an equal
overlap around the last repair ply and touches the teflon
tape.
(3) Use the roller to remove air which is caught in the adhesive
and to make the fiberglass smooth.
(4) Remove unwanted adhesive from the teflon tape with a clean
metal spatula.
A. Get a heat blanket, which must be larger all around than the repair
area.
B. Cut a sheet of porous parting film (CoMat 02-169). Make sure that
the film is larger than the heat blanket and has an overlap of at
least 3.0 in. (76,2 mm) around the fiberglass ply.
C. Cut one sheet of breather fabric (CoMat 08-057) for each carbon and
fiberglass ply on the repair area, excluding the filler plies. Make
sure that the breather fabric has the same dimensions as the porous
parting film.
D. Put the porous parting film on to the repair area. Make sure it has
an equal overlap around the repair area. Put the layers of breather
fabric on top of the porous parting film.
(2) Make sure that each strand connects the breather fabric with
the area around the silicon rubber sheet.
G. Put the non-porous parting film onto the repair area. Make sure
that it has an equal overlap around the repair area. Put the
silicone rubber sheet on top of the non-porous parting film.
H. Put the heat blanket and breather cloth onto the repair area.
(2) Put the two sheets of breather cloth onto the repair area.
(3) Put the heat blanket on top of the breather cloth. Make sure
that the heat blanket has an overlap all around the repair
area.
(1) Use nylon bagging film (CoMat 02-163) and sealant tape
(CoMat 08-051).
(2) Make sure that the vacuum bag has an overlap of approximately
2.0 in. (50,8 mm) around the breather cloth.
(3) Install the vacuum hose, from the suction pump, so that it
goes directly on to the breather cloth.
(4) Attach and seal the film to the cowl with the sealant tape.
A. Use the vacuum suction pump to decrease the pressure in the repair
area making sure it gives an indication of at least 25.0 in.
(635,0 mm) of mercury while the adhesive cures.
B. Use the heat blanket to keep the temperature of the repair area at
190o - 210oF (88o - 99oC) for 220 minutes.
D. Start to measure the cure time when the temperature gets to 190 oF
(88oC).
A. When the cure is completed, remove the lay-up materials from the
repair.
A. Make all contours of the repair area smooth with waterproof silicon
carbide abrasive paper (CoMat 05-021), making sure that there is no
edge between the repair area and the outer skin of the panel.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, (Ref SRM 54-01-00) Composite Structure Tap Test,
to confirm that the repair is correctly bonded.
1. General.
B. This repair fills the damaged area with epoxy paste adhesive mixed
with microballoons and installs a carbon fibre repair ply.
CAUTION: USE PROTECTIVE MATS WHEN YOU WORK IN THE AIR INTAKE COWL TO
PREVENT DAMAGE TO THE ACOUSTIC STRUCTURE.
2. Referenced Information.
A. Standard equipment
C. Special Tools
D. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Air intake cowl Composite structure
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the damaged area with turco 6646 solvent (CoMat 01-438) and
lint-free cloth (CoMat 02-099). Wipe the area dry.
B. Inspect the damaged area using IAE 1N20444 tapping tool and the tap
test method, (Ref. SRM 54-01-00) Composite Structure Tap Test, to
find the outer edge of the disbond.
D. The distance between the no damage permitted area and the edge of
the damage must be a minimum of 0.75 times the damage area
diameter. (Fig 201 Sheet 1, 2 and 3).
B. Mask around the damaged area with teflon tape (CoMat 02-007):
(1) Measure 1.0 in. (25,4 mm) from the edge of the damage.
(2) Carefully apply the teflon tape so that it goes around the
area in a 2.0 in. (50,8 mm) wide strip.
C. Make the surface of the repair area rough with waterproof abrasive
paper (CoMat 05-021), making sure to remove the sharp edges of the
damage. Do not increase the dimensions of the damage.
A. Wear lint-free gloves (CoMat 02-097) and cut one piece of dry
carbon fibre fabric (CoMat 08-059) so that it has a 1.5 in.
(38,1 mm) overlap around the damage.
A. Use heat lamps to dry the repair area. Keep the temperature between
150.8oF-170.6oF (66oC-77 oC) for 8 hours. The repair materials must
be applied immediately at the end of 8 hours.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Mix the epoxy paste adhesive (CoMat 08-050) in accordance with the
manufacturer’s instructions. The weight of epoxy paste adhesive
required will be approximately the same as the weight of the dry
carbon fibre fabric.
NOTE: After the repair ply has soaked, the remaining epoxy paste
adhesive (if it is kept cool) can be used in the installation
procedure.
B. Soak the repair ply with the mixed epoxy paste adhesive.
(2) Apply the epoxy paste adhesive to the two sides of the repair
ply with the brush (CoMat 02-087) and cover the repair ply
with another sheet of non-porous parting film.
(3) Use the roller to force the epoxy paste adhesive into the
repair ply thoroughly.
(1) Let the two pieces of the non-porous parting film stay on the
repair ply until the installation procedure.
(2) Cut the repair ply so that it is the same shape as the area
which the teflon tape identifies.
(3) Keep the repair ply and the epoxy paste adhesive mixture cool
until the installation procedure.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the repair area with turco 6646 solvent (CoMat 01-438) and
lint-free cloth (CoMat 02-099). Wipe the repair area dry.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Mix the epoxy paste adhesive (CoMat 08-050) in accordance with the
manufacturer’s instructions. When fully mixed, add the
microballoons (CoMat 02-164) to the mixture: 5 parts (by weight) of
the microballoons to 100 parts (by weight) of the mixture.
B. Fill the damaged area with the mixture using a clean metal spatula.
Make sure the mixture is level with the outer stainless steel mesh.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) Remove one sheet of non-porous parting film from the repair
ply.
(2) Put the repair ply, with the epoxy paste adhesive side down,
on to the repair area. The repair ply must have an equal
overlap around the repair cut-out and touch the teflon tape.
(3) Use the roller to remove the air which is caught in the epoxy
paste adhesive and to make the repair ply smooth.
(4) Remove the unwanted epoxy paste adhesive from the teflon
tape with a clean metal spatula.
(5) Remove the remaining non-porous film from the repair ply.
B. Use non-porous film and overlap the repair area by 2.0 in. (50,80
mm) to prevent contamination of the repair during the cure.
C. Use the heat lamp to keep the temperature of the repair area
between 194o - 200oF (90 o - 93oC) for 220-235 minutes.
E. Start to measure the time for the epoxy paste adhesive to cure when
the temperature reaches 194 oF (90oC).
15. Make the edges of the repair ply smooth (Ref. Fig. 202).
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE REPAIR AREA OR
THE OUTER SURFACE OF THE ACOUSTIC STRUCTURE. BE CAREFUL AND
ONLY REMOVE MATERIAL FROM THE EDGE OF THE REPAIR PLY. DO NOT
USE A LIQUID WITH THE ABRASIVE PAPER.
A. Remove all unwanted material from the repair area with a suction
cleaner.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Clean the surface with turco 6646 solvent (CoMat 01-438) and a
lint-free cloth (CoMat 02-099). Wipe the surface dry.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, (Ref. SRM 54-01-00) Composite Structure Tap Test,
to confirm that the repair is correctly bonded.
C. Measure the thickness of the cured repair ply at the leading edge.
Make sure the into wind step is less than 0.020 in. (0,51 mm).
REPAIR 016
AIR INTAKE COWL LIPSKIN HAND BLEND AND POLISH PROCEDURE REPAIR
(VRS2867)
1. General
B. This repair hand blends out the damage and polishes the repair
to the necessary surface finish.
2. Referenced Information
A. Standard Tools
C. Component Materials
(1) Remove the high-points, the burrs and radius the bottom of
the damage.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
A. Mark the repair scheme VRS2867 on the air intake cowl, adjacent
to the part number. (Refer to the V2500 SPM TASK 70-09-00-400-
501).
REPAIR 017
AIR INTAKE COWL - LIPSKIN DAMAGE REPAIR
(VRS2821)
1. General
2. Related Repairs
3. Referenced Information
A. Standard Equipment
Suction cleaner
Standard workshop tools and equipment
C. Repair Parts
D. Component Material
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
B. The damage, including cracks, must be more than 5.50 in. (139,7
mm) from the edge of the lipskin at the outer barrel attachment
point and 6.25 in. (158,7 mm) from the edge of the lipskin at
the inner barrel attachment point.
CAUTION: MAKE SURE THAT YOU DO NOT CAUSE DAMAGE TO THE ANTI-ICING
DUCT ANGLES OF THE AIR INTAKE COWL LIPSKIN.
7. Cut Out the Damaged Area of the Lipskin (Ref. Fig. 201)
(1) Make sure you keep hole edge distance for the rivets.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Examine the anti-ice ring at the repair area for the following
types of damage: friction, gouged, cracked, nicked, scratched,
pierced, rubbed, dented and bent.
NOTE: If the depth of the damage is more than 0.060 in. (1,52 mm),
do repair CMM Repair 026 (VRS2738).
(2) The patch must be taken from the same part of the
replacement lipskin as the cut-out in the damaged skin.
(1) The mark must be at least 2.5 in. (63,5 mm) around each
side away from the repair patch identified in step A.
C. Carefully cut out the repair patch and the butt straps from the
lipskin.
(2) Measure the dimensions of the repair cut-out for the flush
patch. Add 2.5 in. (63,5 mm) to each side of the repair
cut-out dimensions for the butt strap dimension.
(5) Cut out the flush patch and the butt straps and contour to
the lipskin.
11. Temporarily Install the Repair Patch and the Butt Straps (Ref Fig.
202 and 203).
(2) Trim the edges to have a minimum edge distance between the
patch and the cut-out of 0.050 in. (1,27 mm).
(3) Align the end butt straps with the centerline on the edge
of the repair cut-out and hold in position with clamps.
(4) Position the side butt straps between the end butt straps
with the centerline on the edge of the repair cut-out.
(5) Trim the side butt straps ends to have a maximum clearance
to the end butt straps of 0.020 in. (0,51 mm).
C. Smooth the edges of the repair patch and butt straps with a
smooth file and waterproof silicon carbide abrasive paper
(CoMat 05-021).
12. Apply Surface Protection to the Bare Edges of the Repair patch and
the but straps.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
13. Prepare the Lipskin Repair Area (Ref Fig. 202 and 203).
A. Use a marking pen (CoMat 06-131) to mark the lipskin for three
rows of rivets for each butt strap.
NOTE: Do not mark for a rivet hole on the apex of the lipskin
leading edge.
14. Drill and Countersink the Rivet holes on the Lipskin and the Butt
Straps (Ref Fig. 202 and 203).
A. Drill the rivet holes in the lipskin and the butt straps.
(3) Set the cutting tool stop to make sure the parts under the
lipskin will not be damaged.
(4) Use a 0.09375 in. (2,382 mm) diameter drill and drill
pilot holes through the lipskin and the butt straps.
(3) Set the countersink tool to make sure that the rivet heads
are flush with the surface.
(1) Remove the butt straps and use waterproof silicon carbide
abrasive paper (CoMat 05-021) to remove burrs.
(1) Air dry for 10 minutes and install the butt straps with
the rivets (CR3522-5-4).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
18. Prepare the Repair Patch (Ref Fig. 202 and 203)
(1) Use the marking pen (CoMat 06-131) to mark for three rows
of rivets for the repair patch.
NOTE: Do not mark for a rivet hole on the apex of the lipskin
leading edge.
19. Drill and Countersink the Rivet holes on the Repair Patch (Ref Fig.
202 and 203).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) Set the cutting tool stop to make sure the parts under the
lipskin will not be damaged.
(2) Set the countersink tool to make sure that the rivet heads
are flush with the surface.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
A. Mark the repair scheme number VRS2821 on the air intake cowl,
adjacent to the part number. (Ref. SPM TASK 70-09-00-400-501).
REPAIR 018
AIR INTAKE COWL - LIPSKIN OUTER BARREL SIDE EDGE PATCH REPAIR
(VRS2851)
1. General
2. Related Repairs
3. Referenced Information
A. Standard Equipment
Suction cleaner
Standard workshop tools and equipment
D. Repair Parts
E. Component Material
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
A. Make a mark around the damaged area with a marking pen (CoMat
06-131). Make sure the area to be removed is rectangular in
shape and parallel to the edge, except where it is necessary to
have hole edge distance for the rivets.
B. Set the cutting tool stop to ensure that parts under the
lipskin are not damaged. Drill the lipskin rivet heads
including the first 12 rivets on each side of the repair cut
lines to remove the lipskin rivets in the repair area. Remove
the drilled rivets with a punch.
CAUTION: MAKE SURE THAT YOU DO NOT CAUSE DAMAGE TO THE ANTI-ICING
DUCT ANGLES OR THE AIR INTAKE COWL LIP SKIN.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(2) The patch must be taken from the same part of the
replacement lipskin as the cut-out in the damaged lipskin.
(2) The mark must be 3.48 in. (88,4mm) on each side of the
repair patch identified in step A.
C. Carefully cut out the repair patch and the butt straps from the
lipskin.
(3) Make the butt straps and the repair patch to the contour
of the initial lipskin which is not damaged.
(2) The clearance between the cut-out and the repair patch
must be between 0.020 to 0.050 in. (0.51 to 1.27 mm).
F. Trim and deburr the butt straps and the packers if used to their
correct size.
(2) The clearance between each butt strap and each attachment
angle must be between 0.020 to 0.050 in. (0,51 to 1,27
mm).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
13. Temporarily Install the Butt Straps and Packers if used Ref Fig. 202,
203, 204 and 205.
A. Use the marking pen (CoMat 06-131) to mark the lipskin for
three rows of rivets for each butt strap. Make a mark for each
row of rivet holes.
B. Make a mark along the center of each butt strap. Use a marking
pen (CoMat 06-131)
C. When you install each butt strap, align the center of the strap
with the edge of the repair cut-out. Use soft faced clamps to
hold the straps in position.
D. If used, align the edge of the packer with the edge of the
lipskin.
E. Drill the rivet holes in the lipskin through the butt straps
and the packers if used.
NOTE: Do not drill the holes in the repair patch at this stage.
(1) Use a 0.09375 in. (2,382 mm) diameter drill and follow the
pattern in Fig 202.
(3) Remove and deburr the butt straps and the packers if used.
Use standard workshop tools.
15. Assemble the Repair Patch (Ref Fig. 204 and 205).
(1) These holes must align with the holes in the attachment
angle in the outer barrel side.
(2) Use a hole finder and 0.09375 in. (2,382 mm) diameter
drill and if necessary a hole finder to drill pilot holes.
D. Drill the rivet holes through the repair patch and the butt
straps.
(1) Use a 0.09375 in. (2,382 mm) diameter drill and follow the
pattern in Fig 202 and 203.
(2) Countersink the hole until the heads of the rivets are in
line with the surface of the lipskin/repair patch.
F. Trim and deburr the edges of the holes in the butt straps,
repair patch and lipskin.
(1) Remove the butt straps, the packers if used and the repair
patch.
(4) Make sure that you keep the correct edge distance.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the repair parts and the inner surface of the lipskin
with methylethylketone (CoMat 01-076) and lint free cloth
(CoMat 02-099). Wipe the area dry.
19. Attach the Repair Parts on to the lipskin (Ref Fig. 204 and 205).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(2) Let the parts dry for 10 minutes before they are
assembled.
B. Attach the butt straps and the packers if used to the inner
surface of the lipskin with the reaction rivets (MS20426DD-5-
6).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Mark the repair scheme number VRS2851 on the air intake cowl,
adjacent to the part number. (Ref. SPM TASK 70-09-00-400-501).
REPAIR 019
AIR INTAKE COWL - LIPSKIN INTAKE SIDE EDGE PATCH REPAIR
(VRS2732)
1. General
2. Related Repairs
3. Referenced Information
A. Standard Equipment
Suction cleaner
Standard workshop tools and equipment
C. Repair Parts
D. Component Material
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Make a mark around the damaged area with a marking pen (CoMat
06-131). Make sure the cut lines are at right angles to the
airflow (except where it is necessary to have hole edge
distances for the rivets).
CAUTION: MAKE SURE THAT YOU DO NOT CAUSE DAMAGE TO THE DISTRIBUTION
RING OF THE ENGINE ANTI-ICING SYSTEM.
CAUTION: MAKE SURE THAT YOU DO NOT CAUSE DAMAGE TO THE ANTI-ICING
DUCT ANGLES OF THE AIR INTAKE COWL LIPSKIN.
E. Carefully put the protection plate between the lipskin and the
attachment angle. Make sure there is no unwanted material
between the interfaces.
7. Cut out the damaged Area of the Lipskin (Ref Fig. 201).
CAUTION: MAKE SURE THAT YOU DO NOT CAUSE DAMAGE TO THE ANTI-ICING
DUCT ANGLES OF THE AIR INTAKE COWL LIPSKIN.
A. Use standard workshop tools to cut out the damaged area of the
lipskin radius.
(1) Make sure you keep hole edge distance for the rivets.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Examine the anti-ice ring at the repair area for the following
types of damage: friction, gouged, cracked, nicked, scratched,
pierced, rubbed, dented or bent.
(1) If the depth of the damage is more than 0.060 in. (1,52
mm), do CMM Repair 026 (VRS2738).
10. Prepare the Repair Patch, the Butt Straps and the Packers (if used)
(Ref Fig. 202).
(2) The patch must be taken from the same part of the
replacement lipskin (740-3004-503) as the cut-out in the
damaged lipskin.
B. Measure at least 3.48 in. (88,4 mm) away from the patch
identified in step A and make a mark on the replacement lipskin
using the marking pen (CoMat 06-131).
C. Carefully cut out the repair patch and the butt straps (Leaving
a trim allowance) using standard workshop tools.
(1) Cut the repair patch from a sheet of aluminium alloy 2219-
T62 (CoMat 02-221) 0.080 to 0.090 in. (2,03 to 2,29 mm)
thick.
(2) Cut the butt straps from a sheet of aluminium alloy 2219-
T62 (CoMat 02-219) 0.064 to 0.074 in. (1,62 to 1,87 mm)
thick.
(4) Make the butt straps, the repair patch and the packers to
the contour of the initial lipskin which is not damaged.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
E. Sulphuric acid anodize the butt straps and the repair patch if
possible. If not, apply the chromate conversion coating (CoMat
07-023) or (CoMat 07-165)(Ref. SPM TASK 70-38-02-300-503).
(2) The clearance between the cut-out and the repair patch
must be between 0.020 to 0.050 in. (0,51 to 1,27 mm).
(2) The clearance between each side butt strap and the
attachment angle must be between 0.020 to 0.050 in. (0,51
to 1,27 mm).
(3) Cut the top butt strap so that it will fit between the two
side butt straps with a clearance between 0.020 to 0.050
in. (0,51 to 1,27 mm) on either side.
(2) The rivet plate must be large enough to cover the 24 rivet
holes on both sides of the cut-out.
(3) Make sure the rivet plate has sufficient clearance all
around with an edge distance for each rivet of at least
0.41 in. (10,41 mm).
12. Drill the Rivet Holes in the Butt Straps, the Rivet Plate and the
Packers (if used) (Ref Fig. 202, 203, 204 and 205).
A. Make a mark along the center of the butt straps using the
marking pen (CoMat 06-131).
B. Use the marking pen (CoMat 06-131) to mark the lipskin for
three rows of rivets for each butt strap. Make a mark for each
row of rivet holes.
C. Put the packers (if used), on the inner side of the lipskin and
align the edge of the packers with the edge of the lipskin.
D. Put the three butt straps on the inner side of the lipskin and
align the center with the edge of the cut-out. Use soft faced
clamps to hold the straps in position.
F. Drill the rivet holes through the lipskin, the butt straps and
the packers (if used).
NOTE: Do not drill the rivet holes in the repair patch at this
stage.
(1) Use a 0.09375 in (2,382 mm) diameter drill and follow the
pattern in Fig. 202.
(2) Use a 0.160 to 0.164 in. (4,06 to 4,17 mm) diameter drill
to finish the rivet holes.
(1) The rivet holes must align with the rivet holes in the
lipskin and the inner barrel.
(2) Use a 0.192 to 0.196 in. (4,88 to 4,98 mm) diameter drill
and if necessary a hole finder.
13. Apply Surface Protection to the Rivet Plate, the Butt Straps and the
Packers (if used).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
14. Drill the Rivet Holes in the Repair Patch (Ref Fig. 202, 203, 204 and
205.
A. Temporarily attach the butt straps and the repair patch in the
correct position for installation.
(1) The three lines of rivet holes must align with the rivet
holes in the attachment angle and the inner barrel.
(2) Use a 0.192 - 0.196 in. (4,88 to 4,98 mm) diameter drill
and if necessary use a hole finder.
C. Drill the rivet holes through the repair patch and the butt
straps.
(1) Use a 0.09375 in. (2,382 mm) diameter drill and follow the
pattern in Fig. 202.
(2) Use a 0.160 to 0.164 in. (4,06 to 4,17 mm) diameter drill
to finish the rivet holes.
E. Trim and deburr the edge of the holes in the butt straps, the
repair patch and the lipskin.
(4) Make sure that you keep the correct edge distance.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the repair parts and the inner surface of the lipskin
with methylethylketone (CoMat 01-076) and lint-free cloth
(CoMat 02-099). Wipe the area dry with a clean piece of lint-
free cloth before the solvent evaporates.
18. Assemble the Repair Parts on to the Lipskin (Ref Fig. 204 and 205).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
C. Attach the butt straps and the packers (if used) to the inner
surface of the lipskin with the solid rivets (MS20426DD-5-6).
D. Attach the repair patch to the butt straps, the inner barrel
(rivet plate) and the attachment angle with the cherrymax
rivets (CR3522-5-4), (CR3522-6-3) and (CR3522-6-4) as
applicable.
A. Mark the repair scheme number VRS2732 on the air intake cowl,
adjacent to the part number. (Ref. SPM TASK 70-09-00-400-501).
REPAIR 020
AIR INTAKE COWL - LIPSKIN SEGMENT REPLACEMENT REPAIR
(VRS2731)
1. General
2. Related Repairs
3. Referenced Information
A. Standard Equipment
Suction cleaner
Standard workshop tools and equipment
C. Repair Parts
D. Component Material
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Make a mark around the damaged area with a marking pen (CoMat
06-131). Make sure the area to be removed is rectangular in
shape and parallel to the edge, except where it is necessary to
have hole edge distance for the rivets.
CAUTION: MAKE SURE THAT YOU DO NOT CAUSE DAMAGE TO THE DISTRIBUTION
RING OF THE ENGINE ANTI-ICING SYSTEM.
B. Remove the lipskin rivets and pins in the repair area and the
rivets and pins outside the cut-line. Use the standard workshop
tools.
CAUTION: MAKE SURE THAT YOU DO NOT CAUSE DAMAGE TO THE ANTI-ICING
DUCT ANGLES OF THE AIR INTAKE COWL LIPSKIN.
C. On the inner and outer surface, lift the lipskin in the repair
area away from the attachment angle. Use the standard workshop
tools.
7. Cut out the damaged area of the lipskin (Ref Fig. 201).
CAUTION: MAKE SURE THAT YOU DO NOT CAUSE DAMAGE TO THE ANTI-ICING
DUCT ANGLES OF THE AIR INTAKE COWL LIPSKIN.
(1) Make sure you keep hole edge distance for the rivets.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Examine the anti-ice ring at the repair area for the following
types of damage: friction, gouged, cracked, nicked, scratched,
pierced, rubbed, dented, bent.
NOTE: If any damage to the anti-ice ring is more than 0.060 in.
(1,52 mm), do CMM Repair 026 (VRS2738).
11. Make the Repair Parts (Ref Fig. 202, 203, 204 and 205).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(2) The segment must be taken from the same part of the
replacement lipskin as the cut-out in the damaged lipskin.
(2) The mark must be at least 3.48 in. (88,4 mm) on each side
of the replacement segment identified in step A.
(2) The rivet plate must be large enough so that all of the
rivet holes are covered. There are 24 of these holes on
each side of the cut-out.
(3) Make sure that the edge distance for each rivet will be
0.41 in. (10,41 mm) minimum and that the rivet plate has
sufficient clearance all around.
D. Carefully cut out the replacement segment and the butt straps
from the lipskin. Cut out the rivet plate from a strip of
aluminium alloy 2219-T62 (CoMat 02-220).
(3) Make the butt straps and the replacement segment to the
contour of the initial lipskin which is not damaged.
G. Trim and deburr the butt straps and the packers, if used, to
their correct size.
(2) The clearance between each butt strap and each attachment
angle must be between 0.020 to 0.050 in. (0,51 to 1,27
mm).
12. Temporarily Install the Butt Straps, the Packers, if used, and the
Rivet Plate (Ref Fig. 202, 203 and 204).
A. Make a mark along the center of each butt strap. Use a marking
pen (CoMat 06-131).
B. Use the marking pen (CoMat 06-131) to mark the lipskin for
three rows of rivets for each butt strap. Make a mark for each
row of rivet holes.
C. When you install each butt strap, align the center of the strap
with the edge of the lipskin. Use soft faced clamps to hold the
straps and the rivet plate in position.
D. If used, align the edge of the packers with the edge of the
lipskin.
E. Drill the holes in the rivet plate to align with the holes in
the lipskin and the inner barrel.
(1) Use a 0.192 to 0.196 in. (4,88 to 4,98 mm) drill and a
hole finder if necessary.
F. Drill the rivet holes in the lipskin through the butt straps
and the packers if used.
(1) Use a 0.09375 in. (2,382 mm) diameter drill and follow the
pattern in Fig. 202 and 203.
(2) Use a 0.160 to 0.164 in. (4,06 to 4,17 mm) diameter drill
to finish the rivet holes.
13. Apply Surface Protection to the Bare Edges of the Butt Straps, the
Packers if used, and the Rivet Plate.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
14. Assemble the replacement segment (Ref Fig. 202, 203, 204 and 205).
(1) These holes must align with the holes in the attachment
angles and the inner barrel.
(2) Use a 0.192 to 0.196 in. (4,88 to 4,98 mm) drill and a
hole finder if necessary at the inner barrel positions.
(3) Use a 0.160 to 0.164 in. (4,06 to 4,17 mm) drill and a
hole finder if necessary at the outer barrel positions.
C. Drill the rivet holes through the replacement segment, the butt
straps and the rivet plate.
(1) Use a 0.09375 in. (2,382 mm) diameter drill and follow the
pattern in Fig. 202 and 203.
(2) Use a 0.160 to 0.164 in. (4,06 to 4,17 mm) drill to finish
the rivet holes.
(2) Countersink the holes until the heads of the rivets are in
line with the surface of the lipskin/replacement segment.
E. Trim and deburr the edges of the holes in the butt straps, the
replacement segment, the packers if used, and in the lipskin.
(4) Make sure that you keep the correct edge distance.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the repair parts and the inner surface of the lip skin
with methylethylketone (CoMat 01-076) and lint free cloth
(CoMat 02-099). Rub the area dry with a clean piece of lint free
cloth (CoMat 02-099) before the fluid dries.
18. Attach the Repair Parts to the Lipskin (Ref Fig. 203, 204, 205 and
206).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(2) Let the parts dry for 10 minutes before they are
assembled.
B. Attach the butt straps, and the packers if used, to the inner
surface of the lipskin with the reaction rivets (MS20426DD-5-
6).
C. Attach the lipskin and the rivet plate to the inner barrel and
the attachment angle.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS) AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
A. Mark the repair scheme number VRS2731 on the air intake cowl,
adjacent to the part number. (Ref. SPM TASK 70-09-00-400-501).
1. General.
B. This repair removes the damaged sealant and installs new sealant.
2. Referenced Information.
A. Standard Equipment
Suction cleaner
Standard workshop tools and equipment
C. Special Tools
D. Repair Parts
None
E. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Air intake cowl Composite structure
WARNING: USE THE CORRECT PROCEDURE AND EQUIPMENT WHEN YOU MOVE THE
COWL. MAKE SURE THE COWL IS HELD CORRECTLY DURING THE REPAIR
PROCEDURE OR INJURY CAN OCCUR.
CAUTION: BE CAREFUL WHEN YOU MOVE THE COWL. DAMAGE TO THE EDGES OR THE
CORNERS OF THE COWL CAN OCCUR.
CAUTION: DO NOT CAUSE DAMAGE TO THE ANODIZED SURFACE OF THE LIP SKIN
OR THE ACOUSTIC STRUCTURE. USE ONLY PLASTIC TOOLS AND PUT
PROTECTIVE MATS ON THE COWL.
B. Put a strip of the teflon tape (CoMat 02-007) on each side of the
repair area.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(2) Rub the repair area with the soaked abrasive pad and fully
remove the sealant and contamination.
(3) Wipe the area with a clean piece of lint free cloth
(CoMat 02-099) before the fluid dries.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(2) Hold the cartridge and pull the dasher rod out approximately
25% of the way up the cartridge.
(3) Push the ramrod into the hollow end of the dasher rod and
inject approximately 33% of the contents of the dasher rod
into the cartridge.
NOTE: Make sure that you do not use too much force or tap the
ramrod if the piston does not move easily.
(4) Inject the remaining contents of the dasher rod into the
cartridge in two equal movements.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(2) Pull out and then push the dasher rod in a clockwise
direction into the cartridge (equals one movement).
NOTE: Make sure that the dasher rod rotates approximately 90o
during each movement.
NOTE: Make sure that after the last movement the dasher rod is
pushed fully into the cartridge.
(4) Hold the cartridge tightly and turn the dasher rod
approximately 3 times in an anti-clockwise direction. Remove
the dasher rod from the cartridge.
9. Apply the aerodynamic sealant (Ref. Fig. 201, 202, 203 and 204).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Fill the repair area with the sealant (CoMat 08-141) or (CoMat 08-
146).
NOTE: Make sure that the sealant is pushed along in front of the
nozzle tip when you use the sealant gun.
NOTE: Make sure that no air gets between the repair area and the
sealant.
(2) The top of the sealant must be level with the surface of the
cowl.
C. When the sealant has cured, remove the teflon tape (CoMat 02-007)
from each side of the repair area.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
(1) If the surface of the repair area is below the surface of the
cowl, do steps 7 thru 9 again.
1. General.
D. There must only be one repair of this type on each air intake cowl.
2. Referenced Information.
A. Standard equipment
Suction cleaner
Standard workshop tools and equipment
C. Repair Materials
D. Repair parts
--------------------------------------------
PART NO. PART IDENT
--------------------------------------------
MBF2113-5 Composilok fastener
CCR264CS-4-3 Cherrylok rivet
A4C4B2-069 Bal-lok receptacle (4 rivet type)
E. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Air Intake Cowl Composite structure
Use an 1N20444 tapping tool and the tap test method, (Ref. SRM 54-01-00)
Composite Structure Tap Test, to check for evidence of disbond damage. No
Disbonds permitted. Contact UTAS if disbond or other damage is found.
(2) Use the center of the correct pin receptacle position as the
datum point.
(3) Mark a circle 1.28 in. (32,51 mm) diameter on the outer skin.
(2) Make sure the diameter of the hole is 1.28 in. (32,51 mm).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the repair parts and the air intake cowl cut-out area with
Turco 6646 (CoMat 01-438) and lint free cloth (CoMat 02-099). Dry
the area with a clean piece of clean lint free cloth before the
solvent evaporates.
B. Perform Tap Test Inspection around cut out hole (Ref. SRM 54-01-
00). If further disbond is found, contact UTAS for further disposi-
tion
A. Make the external doubler from 0.063 in. (1,60 mm) AISI 321 AMS
5510 stainless steel. Refer to Fig 201.
NOTE: Make sure the external doubler is the same contour as the
outer skin.
NOTE: If cracks are found, discard the external doubler and make a
replacement.
C. Wet abrasive blast the repair doubler (Ref SPM Task 70-12-01-120-
501).
10. Drill the Composilok fastener holes in the air intake cowl.
(1) Put the assembly on the outer skin of the air intake cowl
with the bal-lok receptacle in the center of the cut-out and
attach temporarily.
(1) Use a 0.165 in. (4,191 mm) diameter drill to increase the
pilot holes to align with those in the external doubler
plate.
(2) Make sure the diameter of the hole is 1.32 in. (33,5 mm).
C. Perform Tap Test Inspection around cut out hole (Ref. SRM 54-01-
00).
A. Remove all unwanted material from the repair area with a suction
cleaner.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the repair parts and the air intake cowl cut-out area with
Turco 6646 (CoMat 01-438) and lint free cloth (CoMat 02-099). Dry
the area with a clean piece of clean lint free cloth before the
solvent evaporates.
A. Mix the catalyst (CoMat 07-118) and the varnish (CoMat 07-166) in
accordance with the manufacturers instructions.
B. Apply the varnish (CoMat 07-166) with the tymex nylon brush (CoMat
02-088) to the bare edges of the cut-out, to the edges of the holes
and to all exposed carbon fibers.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Remove all unwanted jointing compound from the repair area with a
clean metal spatula.
B. Clean the repair area with Turco 6646 (CoMat 01-438) and lint-free
cloth (CoMat 02-099). Dry the area with a clean piece of lint-free
cloth before the solvent evaporates.
A. Apply aerodynamic sealant to the repair area (Ref. REPAIR No. 021
VRS2725).
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
External Doubler
Fig. 201
REPAIR 023
AIR INTAKE COWL - COOLANT DUCT REPLACEMENT
(VRS2933)
1. General
2. Referenced Information
A. Standard Equipment
C. Repair Parts
D. Component Material
CAUTION: MAKE SURE THAT YOU DO NOT CAUSE DAMAGE TO THE AFT BULKHEAD
OF THE AIR INTAKE COWL.
A. Remove the heads of the rivets which attach the duct to the
bulkhead.
(2) The rivets have a 0.156 in. (3.97 mm) diameter and steel
shanks.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
B. Clean the interfaces between the bulkhead and the duct with
methylethylketone (CoMat 01-076) and lint-free cloth
(CoMat 02-099). Wipe the area dry.
(1) The diameter of the rivet holes must not be larger than
0.164 in. (4.17 mm).
C. Make sure that the washers on the forward face of the bulkhead
are satisfactory.
A. Align the duct with the 1.62 in. (41.1 mm) diameter hole.
(2) Make sure that the rivet edge distance is 0.40 in. (10.2
mm) or smaller if approved by inspection.
(1) Use a 0.063 in. (1.60 mm) diameter drill for the pilot
holes.
(2) Hole sizes for the rivets must be 0.160 to 0.164 in. (4.06
to 4.16 mm) diameter.
D. Use standard workshop tools to remove all burrs from the rivet
holes in the replacement duct.
8. Examine the Rivet Holes In the Cooling Duct and the Aft Bulkhead
A. Make sure that the holes in the duct and the bulkhead are
aligned.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Clean the interfaces of the bulkhead, the repair area and the
replacement duct with methylethylketone (CoMat 01-076) and
lint-free cloth (CoMat 02-099). Wipe the area dry.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
(2) Let the parts dry in the air for 10 minutes before they
are assembled.
B. Align the holes in the rear bulkhead with the holes in the
replacement duct.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Make a visual inspection to make sure that the repair has been
done in accordance with these procedures.
REPAIR 025
AIR INTAKE COWL - LIP SKIN JOINT TO INNER BARREL RIVET REPLACEMENT REPAIR
(VRS2746)
1. General
2. Referenced Information
A. Standard Equipment
Suction cleaner
Standard workshop tools and equipment
Cherrylock rivet gun Type G784 or equivalent
Cherrylock pulling head Type H681-6C
Cherrylock hole gauge Type T172-600
Cherrymax Rivet Gun G747 or equivalent
Cherrymax Pulling Head H701B-456
C. Repair Parts
D. Component Material
CAUTION: MAKE SURE THAT YOU DO NOT CAUSE DAMAGE TO THE DISTRIBUTION
RING OF THE ENGINE ANTI-ICING SYSTEM.
CAUTION: MAKE SURE THAT YOU DO NOT CAUSE DAMAGE TO THE ANTI-ICING
DUCT ANGLES OR THE AIR INTAKE COWL LIP SKIN.
D. Remove the defective rivet tails from the ‘D’ chamber with a
suction cleaner.
NOTE: (1) If the holes are below 0.205 in. (5.21 mm) in diame-
ter, they must be drilled out to the specified size
given in step 7.B.
C. Replace the rivets that were not drilled out in step 6.B. Do
steps 6 through 9.
A. Make sure that the rivet heads are flush with the lipskin.
(1) Remove and replace any rivets which have been incorrectly
installed.
A. Mark the repair scheme VRS2746 on the air intake cowl adjacent
to the part number. (Refer to the V2500 SPM TASK 70-09-00-400-
501).
REPAIR 026
AIR INTAKE COWL - LIPSKIN JOINT TO OUTER BARREL RIVET REPLACEMENT REPAIR
(VRS2770)
1. General
D. Related Repairs:
Reference Designation
PCI-V2500-1IA Overhaul Processes and Consumable Index
V2500 SPM, Procedures to make identification and
Task 70-09-00-400-501 location marks
Reference Information
Table 601
A. Standard Equipment
Pulling head
Hole gauge
Suction cleaner
Consumables
Table 602
E. Repair Parts
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Wipe the repair area clean with a CoMat 02-099 lint-free cloth
made moist with CoMat 01-076 methylethylketone. Wipe the area
dry with a CoMat 02-099 lint-free cloth before the fluid dries.
5. Remove the Anti-Ice Ducts and Access Panels to the Lipskin inside
area
NOTE: Removal of the anti-ice access panel is the same for air
intake cowls with SBN71-0184 or SBN70-0134.
A. Remove the 23 bolts and anti-ice access panels from the air
intake cowl. (See Figure 202).
B. Remove the anti-ice clamp insulation (1) and (2), and the clamp
and seal at the air intake cowl rear bulkhead. (See Figure
206).
C. Remove the 7 bolts from each of the two half locating plates.
Remove the two half locating plates from the air intake cowl
rear bulkhead. (See Figure 203).
D. Put your hand into the air exhaust and hold the inner duct. Pull
the inner and outer duct away from the anti-ice bulkhead
fitting. Keep the two ducts together and remove them through
the anti-ice access panel opening. (See Figure 204).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: WHEN REMOVING RIVETS DO NOT INCREASE THE RIVET HOLE SIZE.
DO NOT DRILL THROUGH THE RIVET. DAMAGE TO THE INTERNAL
PARTS MAY OCCUR. DO NOT REMOVE MORE THAN THREE ADJACENT
RIVETS AT ONE TIME. MISALIGNMENT OF THE PARTS MAY OCCUR.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Wipe the repair area clean with a CoMat 02-099 lint-free cloth
moistened with CoMat 01-076 methylethylketone. Wipe the area
dry with a CoMat 02-099 lint-free cloth before the fluid dries.
B. Use the hole gauge to check the diameter of the holes. Rivet
holes must not be more than 0.164 in. (4,17 mm) for a standard
rivet. If the rivet hole is more than 0.164 in. (4,17 mm) an
oversize rivet must be installed at that location.
NOTE: If the holes are over 0.180 in. (4,57 mm) in diameter,
contact UTAS.
A. Use a depth gauge to measure for the correct rivet length. Put
a thin layer of CoMat 04-005 jointing compound on the rivets
and in the rivet holes. Use the rivet gun, (type with the
pulling head), to install the rivets.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Wipe the repair area clean with a CoMat 02-099 lint-free cloth
made moist with CoMat 01-076 methylethylketone. Wipe the area
dry with a CoMat 02-099 lint-free cloth before the fluid dries.
A. Make sure that the rivet heads are flush with the lipskin.
(1) Remove and replace any rivets which have been incorrectly
installed.
B. Remove the cap from the anti-ice bulkhead fitting. (See Figure
204).
C. Remove the anti-ice inner duct from the outer duct. With Ref.
to CMM Section 71-11-00 Repair No,021 (VRS2782), turn the anti-
ice inner duct end for end and install back in the outer duct.
(The aft end of the inner duct will now become the forward end
of the inner duct). (See Figure 204).
D. Hold the inner and outer anti-ice ducts together. Put them into
the air intake cowl through the anti-ice access panel opening.
align the air exhaust with the anti-ice access panel. Push the
two ducts into the anti-ice bulkhead fitting. (See Figure 204).
NOTE: Make sure the inner duct with the two small D-rings (1)
and (2), and the outer duct with the large D-ring and 3
ring pack are correctly engaged. (See Figure 204).
E. Install the two half locating plates with the 7 bolts each, on
the rear bulkhead. (Make sure the half locating plates are
engaged in the anti-ice outer duct). Torque the seven bolts of
each half locating plate to 40 lbs in. (4,5 Nm). (See Figure
203).
F. Install the anti-ice seal and clamp at the air intake cowl rear
bulkhead. Torque tighten clamp to 45-55 lbs in. (5,0 to 6,2
Nm). Attach the clamp insulation (1) and (2) on the clamp with
CoMat 02-147 Lockwire. (See Figure 206).
G. Install the anti-ice access panel with the 23 bolts. Torque the
23 bolts to 30-35 lbs in. (3,5 to 4,0 Nm). (See Figure 202).
A. Mark the repair scheme VRS2770 on the air intake cowl, adjacent
to the part number. (Refer to the V2500 SPM, Task
70-09-00-400-501).
A. This procedure can be used to repair disbond between the carbon ply
and honeycomb core. Refer to paragraph 5 for damage limitations.
2. Referenced Information.
A. Standard equipment
C. Special Tools
D. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Air intake cowl Composite structure
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the damaged area with turco 6646 solvent (CoMat 01-438) and
lint-free cloth (CoMat 02-099). Wipe the area dry.
(1) A1 only - The damage must not have a diameter more than 4.0
in. (101,6 mm).
(2) A5 only - The damage must not have a diameter more than 8.0
in. (203,2 mm).
B. Inspect the damaged area using IAE 1N20444 tapping tool and the tap
test method, (Ref. SRM 54-01-00) Composite Structure Tap Test, to
find the outer edge of the disbond.
D. The distance between the no damage permitted area and the edge of
the damage must be a minimum of 0.75 times the damage area
diameter. (Fig 201 Sheet 2, 3 and 4).
A. Make a mark around the damaged area with a pencil. Make sure that
all areas of disbond are included.
B. Apply a 2.0 in. (50,8 mm) wide strip of teflon tape approximately
1.0 in. (25,4 mm) away from the mark around the damaged area.
(1) Use a scalpel and cut around the damaged wire mesh.
NOTE: Make sure that you do not fray the edges of the wire
mesh.
NOTE: Make sure that you do not damage the facing sheet when
you cut the wire mesh.
C. Use the heat lamps to dry the repair area. Keep the temperature
between 150.8°F - 170.6°F (66°C - 77°C) for 8 hours. The repair
materials must be applied immediately at the end of the 8 hours.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the repair area with turco 6646 solvent (CoMat 01-438) and
lint-free cloth (CoMat 02-099). Wipe the repair area dry.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Mix the epoxy paste adhesive (CoMat 08-021) in accordance with the
manufacturer’s instructions.
(1) Use a clean plastic spatula and fill the damaged area with
epoxy paste adhesive.
(2) Push the epoxy paste adhesive through the facing sheet until
it is level with the acoustic panel wire mesh.
B. Use heat lamps to cure the epoxy paste adhesive for 1 hour between
190o - 210oF (88o - 99 oC)
C. Start to measure the time for the epoxy paste adhesive to cure when
the temperature reaches 190oF (88oC).
(2) Use lint-free gloves (CoMat 02-097) and cut the repair patch
from a piece of dry carbon fibre fabric (CoMat 08-059).
(3) Make the repair patch 1.5 in. (38,1 mm) larger all around
than the repair cut-out.
NOTE: To make sure the repair patch does not fray, cut the patch to
its necessary dimensions after it has been soaked with the
epoxy paste adhesive.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Mix the epoxy paste adhesive (CoMat 08-050) in accordance with the
manufacturer’s instructions. The weight of epoxy paste adhesive
necessary will be approximately the same of the weight of the dry
carbon fibre fabric.
NOTE: After the repair patch is soaked, the remaining adhesive (if
it is kept cool) can be used in the installation process.
(2) Use the brush (CoMat 02-087) and apply the adhesive to the
repair patch.
D. Use standard workshop tools. Cut the repair patch to the same
dimensions as the area identified by the teflon tape.
E. Keep the repair patch and the adhesive cool until the installation
process.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(2) Put the repair patch, with the adhesive (CoMat 08-050) side
down, on to the repair area in the correct position for
installation.
NOTE: Make sure that the repair patch has an equal overlap
around the repair cut-out and touches the teflon tape.
(4) Remove the other non-porous parting film from the repair
ply.
NOTE: Make sure that the porous parting film is 1.0 in. (25,4
mm) larger all around than the repair patch.
NOTE: Make sure that the bleeder cloth is 2.0 in. (50,8 mm)
larger all around than the non-porous parting film.
NOTE: Make sure that the non-porous parting film is 1.0 in.
(25,4 mm) larger all around than the bleeder cloth.
(4) Put the heat blanket on top of the non-porous parting film
(CoMat 02-367) and keep an equal overlap all around the
repair area.
(6) Put a sheet of breather cloth (CoMat 02-166) on top of, and
with an equal overlap all around, the heat blanket.
(7) Put a caul plate on top of the repair and weigh down with
weights.
A. Use the heat blanket to keep the temperature of the repair area
between 194o - 200oF (90 o - 93oC) for 220 minutes.
B. Start to measure the time for the epoxy paste adhesive to cure when
the temperature reaches 194 oF (90oC).
16. Make the edges of the outer ply smooth (Ref. Fig. 201).
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE REPAIR AREA OR
THE OUTER SURFACE OF THE ACOUSTIC STRUCTURE. BE CAREFUL AND
ONLY REMOVE MATERIAL FROM THE EDGE OF THE OUTER PLY. DO NOT
USE A LIQUID WITH THE ABRASIVE PAPER.
A. Remove all unwanted material from the repair area with a suction
cleaner.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Clean the surface with turco 6646 solvent (CoMat 01-438) and a
lint-free cloth (CoMat 02-099). Wipe the surface dry.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, (Ref. SRM 54-01-00) Composite Structure Tap Test,
to confirm that the repair is correctly bonded.
C. Measure the thickness of the cured repair ply at the leading edge.
Make sure the into wind step is less than 0.020 in. (0,51 mm).
A. Ident the component/log book with the REPAIR no. VRS 2779
(Ref. SPM TASK 70-09-00-400-501).
1. General.
2. Referenced Information.
A. Standard equipment
C. Special Tools
D. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Air intake cowl Composite structure
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the damaged area with turco 6646 solvent (CoMat 01-438) and
lint-free cloth (CoMat 02-099). Use a clean lint-free cloth (CoMat
02-099) to dry the area.
C. The edge distance of the damage must be a minimum of 0.75 times the
damage diameter from the no damage area. (Fig 201 Sheet 2 and 3)
6. Prepare the damaged area for repair (Ref. Fig. 201 Sheet 4).
A. Use a marking pen (CoMat 06-131) to make a mark around the damaged
area. Make sure that all cracks and areas of delamination are
included.
(1) Use hand tools and an applicable rotary cutter to remove all
the wiremesh and carbon ply from the damaged area.
NOTE: Make sure that you do not fray the edges of the mesh.
(2) Use a high speed rotary sander to remove the honeycomb from
the repair area.
NOTE: Make sure that you do not damage the septum layer.
(4) Use the rotary file and remove any sharp edges from the
damaged area.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Clean the damaged area with turco 6646 solvent (CoMat 01-438) and
lint-free cloth (CoMat 02-099). Use a clean lint-free cloth (CoMat
02-099) to dry the area.
A. Visually examine the area to make sure all defects have been
prepared for repair.
A. Use heat lamps to dry the repair area. Keep the temperature
between 149.0oF - 170.6 oF (65oC - 77oC) for 8 hours. The repair
materials must be applied immediately at the end of the 8 hours.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Mix the epoxy paste adhesive (CoMat 08-021) in accordance with the
manufacturer’s instructions.
NOTE: Make sure that you do not mix more than 250 grams of the
epoxy paste adhesive in one container.
B. Use the syringe and apply the epoxy paste adhesive into the hole in
the facing sheet.
12. Seal the epoxy paste adhesive, if necessary (Ref. Fig. 201 Sheet 4).
A. Cut a piece of non-porous parting film (CoMat 02-367) for each hole
in the facing sheet.
B. Put the pieces of non-porous parting film (CoMat 02-367) over each
applicable hole and safety into position with speed tape.
C. Clean all unwanted epoxy paste adhesive away from the repair holes.
A. Use the heat lamps to cure the epoxy paste adhesive for 1 hour at a
temperature of 200.0oF (93 oC).
NOTE: Make sure that the cure temperature does not get higher than
200.0oF (93oC).
NOTE: Make sure that you do not fray the edges of the mesh.
15. Prepare the repaired surface (Ref. Fig. 201 Sheet 4).
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE REPAIR AREA OR
THE OUTER SURFACE OF THE ACOUSTIC STRUCTURE. BE CAREFUL AND
ONLY REMOVE MATERIAL FROM THE EDGE OF THE OUTER PLY. DO NOT
USE A LIQUID WITH THE ABRASIVE PAPER.
A. Use the waterproof abrasive paper (CoMat 05-019) and make the
repair adhesive smooth. The contours of the repair adhesive must be
smooth with the surrounding skin.
A. Remove all unwanted material from the repair area with a suction
cleaner.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Clean the surface with turco 6646 solvent (CoMat 01-438) and a
lint-free cloth (CoMat 02-099). Use a clean lint-free cloth (CoMat
02-099) to dry the area.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, (Ref. SRM 54-01-00) Composite Structure Tap Test,
to confirm that the repair is correctly bonded.
SECTION
B-B
(With damaged area removed)
STRUCTUAL SPEED
NON-POROUS
ADHESIVE TAPE
PARTING FILM
SECTION
B-B
(With repair materials installed)
STRUCTUAL
ADHESIVE
sh000B4485B
SECTION
B-B
(Completed repair)
1. General.
B. The A1 hybrid (serial no. V299 and subsequent) and all standards of
A5 air intake cowls only, have a capping strap. This repair is not
applicable to the panel edge landings on the A1 air intake cowl.
The damage must be only on the capping strap and not on the rub
strip. Refer to Fig. 201.
C. The length of the damage must not be more than 36.31 in. (922,3 mm)
at each side from the 12 o’clock position and 13.71 in. (348,2 mm)
across the bottom. Refer to Fig. 201.
2. Referenced Information.
A. Standard equipment
Drill
G-Clamps
Punch
Countersink tool
Standard workshop tools and equipment
Spray gun (optional)
B. Special Tools
None.
D. Repair parts
--------------------------------------------
PART NO. PART IDENT
--------------------------------------------
HL11VF6-6 Pin/Rivet
HL97V-6 Collar
NAS9314AD5-5 Rivet
NAS9314AD5-6 Rivet
E. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Capping strap Aluminium alloy
A. Using the marking pen (CoMat 06-131), mark around the damaged area.
Make sure that the mark is a minimum of 2D from the first hole on
each side of the undamaged capping strap.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
D. Remove the fasteners that attach the damaged area to the aft angle.
NOTE: Make sure the holes in the aft angle are not damaged during
removal of the fasteners.
(1) Use a 0.160 in. (4,0 mm) diameter drill to remove the heads
of the rivets.
(3) Put an Allen key into the pin to hold it stable. Keep the
pins and discard the collars.
E. Cut out and remove the damaged area of the capping strap. Make sure
there is a minimum of 2D edge distance on adjacent fasteners. Do
not remove the part of the capping strap under the outer skin.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Make repair sections from al-clad sheet (CoMat 02-357). Use the
removed sections as a template.
B. Put marks, for hole locations, through the aft angle onto the
capping strap section using a marking pen (CoMat 06-131).
C. Drill the rivet or pin holes in the aft side of the capping strap
section.
Where rivets are used, drill the holes in the capping strap between
0.160 and 0.164 in. (4,06 and 4,17 mm).
Where pins are used, drill the holes in the capping strap between
0.190 and 0.193 in. (4,82 and 4,90 mm).
NOTE: Make sure that the holes in the capping strap align with the
holes in the aft angle.
NOTE: Make sure the rivet head will be flush with the surface.
A. Mask around the repair area with the masking tape (CoMat 02-178) to
prevent overspray.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
C. Apply the primer to the replacement sections and repair area within
the masking tape with either the spray equipment or a brush.
CAUTION: ALLOW THE PAINT TO DRY FOR 15 MINUTES BEFORE THE HEAT IS
APPLIED.
D. Cure the primer for one hour at 180 o - 200oF (82o - 93oC) with an
explosion proof heat lamp.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
A. Mark the repair scheme number (VRS 2792) on the air intake cowl,
adjacent to the part number (Ref. IAE V2500 SPM,
TASK 70-09-00-400-501).
Repair Worn Capping Strap on the Aft Edge of Air Intake Cowl
Fig. 201 (Sheet 1)
Repair Worn Capping Strap on the Aft Edge of Air Intake Cowl
Fig. 201 (Sheet 2)
Repair Worn Capping Strap on the Aft Edge of Air Intake Cowl
Fig. 201 (Sheet 3)
1. General.
Abrasion
Scratch
Nick
Gouge
E. Damage must be a minimum of 6.5 in. (165,1 mm) between the edge of
one repair to the edge of the next repair.
H. The removed damage must have a minimum run-out to blend depth ratio
20:1.
I. Only one repair for each web bay (between each stiffener) is
permitted.
2. Referenced Information.
A. Standard equipment
Suction cleaner
Standard workshop tools and equipment
B. Special tools
None
D. Expendable parts
None
E. Repair parts
None
F. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Aft bulkhead Titanium
A. Examine the repair area of the cowl. Make a note of the depth of
damage. If the damage goes through the panel, do 54-10-00
REPAIR No. 032 (VRS2793). If the damage does not go fully through
the panel but is greater than 0.005 in. (0,13 mm) it is possible to
do 54-10-00 REPAIR No. 032 (VRS2793) or REPAIR No. 033 (VRS2794).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the damage and repair area of the bulkhead with the
methylethylketone (CoMat 01-076) and lint-free cloth
(CoMat 02-099). Wipe the repair area dry.
CAUTION: YOU MUST USE SILICON CARBIDE TYPE WHEELS, STONES AND ABRA-
SIVE PAPERS TO DRESS, MAKE SMOOTH AND POLISH TITANIUM COMPO-
NENTS. YOU MUST NOT USE ALUMINIUM OXIDE TYPES.
(1) Remove the high-points, the burrs and radius the bottom of
the damage.
A. When the repair is completed, remove the repair materials from the
repair area.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
1. General.
B. This repair removes the damaged area and installs a doubler plate.
C. The area of damage must not be more than 1.0 in. (25,4 mm) in
diameter when the damage is cleaned up. The damage can only be
repaired on the web where the web area is sufficiently large to
permit a doubler plate to be installed. If the damage is more do
REPAIR No. 033 (VRS2794).
D. Only one repair for each web segment is permitted, and three
repairs for each bulkhead. Refer to Fig. 201.
2. Referenced Information.
A. Standard equipment
Suction cleaner
Standard workshop tools and equipment
B. Special tools
None
D. Expendable parts
None
E. Repair parts
--------------------------------------------
PART NO. PART IDENT
--------------------------------------------
NAS9307M-5 Monel blind rivet
F. Component material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Aft bulkhead Titanium
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the damage and repair area of the bulkhead with the
methylethylketone (CoMat 01-076) and lint-free cloth
(CoMat 02-099). Wipe the repair area dry.
A. Mark around the repair area using marking pen (CoMat 06-131). Make
sure the area is a regular shape.
CAUTION: YOU MUST USE SILICON CARBIDE TYPE WHEELS, STONES AND
ABRASIVE PAPERS TO DRESS, MAKE SMOOTH AND POLISH TITANIUM
COMPONENTS. YOU MUST NOT USE ALUMINIUM OXIDE TYPES.
C. Remove the sharp edges from the damage with the abrasive paper
(CoMat 05-021).
CAUTION: YOU MUST USE SILICON CARBIDE TYPE WHEELS, STONES AND
ABRASIVE PAPERS TO DRESS, MAKE SMOOTH AND POLISH TITANIUM
COMPONENTS. YOU MUST NOT USE ALUMINIUM OXIDE TYPES.
B. Make a mark of the two rows of rivet holes on the doubler plate. The
edge distance must be a 2D minimum and the pitch of the rivet holes
as follows. Refer to Fig. 202.
(1) Draw a square around the damaged clean-up area 2D larger than
the damage. Mark a rivet hole at each corner and a rivet hole
centrally between each corner, a total of 8 rivet holes.
(2) Draw an outer square 3D larger than the inner square. Mark a
rivet hole at each corner. Position the pitch of two rivet
holes equally between the pitch of the inner row, a total of
12 rivet holes.
C. Put the doubler plate in position on the damaged web. Make sure
that the damaged area is in the center of the doubler plate.
E. Drill two 0.094 in. (2,38 mm) diameter pilot holes through the
doubler plate and the web. Ref. step B.
G. Drill all the pilot holes in the repair pattern, 0.094 in.
(2,38 mm) diameter.
I. Drill the holes to their final size, 0.160 in. (4,06 mm).
K. Remove the burrs and sharp edges using the abrasive paper
(CoMat 05-021).
A. Do a visual check of the repair area and the drilled holes to make
sure there is no more damage.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Let the sealant dry for 10 minutes before assembly of the parts.
C. Put the doubler plate into position. Make sure the holes are
aligned. Use temporary fasteners to hold the plate in position.
B. Do a visual inspection to make sure that the repair has been done
in accordance with this procedure.
Repair Doubler
Fig. 202
1. General.
C. Only one repair for each web segment is permitted, and three
repairs for each bulkhead. The damage should not extend more than
two stiffeners. The maximum web section permitted to be removed is
one full section and the two adjacent half sections. Refer to
Fig. 201.
2. Referenced Information.
A. Standard equipment
Suction cleaner
Standard workshop tools and equipment
B. Special tools
None
D. Expendable parts
None
E. Repair parts
--------------------------------------------
PART NO. PART IDENT
--------------------------------------------
MS20615-5 Rivet
NAS9307M-5 Monel blind rivet
745-3440-501 Titanium aft bulkhead web section
F. Component material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Aft bulkhead Titanium
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Use a marking pen (CoMat 06-131) to make a mark around the repair
area. Identify the middle of the web bay each side of the damaged
area, and make a mark for the cut-lines. Refer to Fig. 202.
CAUTION: YOU MUST USE SILICON CARBIDE TYPE WHEELS, STONES AND ABRASIVE
PAPERS TO DRESS, MAKE SMOOTH AND POLISH TITANIUM COMPONENTS.
YOU MUST NOT USE ALUMINIUM OXIDE TYPES.
A. Put a protective plate between the web and the engine ring to
prevent damage to the engine ring when the web is cut.
B. Use a high speed rotary cutter to cut along the marked lines to
remove the damaged area.
C. Remove the sharp edges from the web cut-out with the abrasive paper
(CoMat 05-021).
CAUTION: YOU MUST USE SILICON CARBIDE TYPE WHEELS, STONES AND ABRA-
SIVE PAPERS TO DRESS, MAKE SMOOTH AND POLISH TITANIUM COMPO-
NENTS. YOU MUST NOT USE ALUMINIUM OXIDE TYPES.
C. Remove the sharp edges from the repair piece with the abrasive
paper (CoMat 05-021).
E. Pilot drill all the rivet holes from the template to the repair
piece. Use a 0.1719 in. (4,366 mm) drill to open the holes to their
final size.
F. Disassemble the template and the repair piece and remove the burrs
and sharp edges with abrasive paper (CoMat 05-021).
I. Pilot drill the rivet holes to from the zed stiffener to the repair
piece. Use a 0.1719 in. (4,366 mm) drill to open the holes to their
final size.
J. Disassemble the zed stiffener and the repair piece and remove the
burrs with abrasive paper (CoMat 05-021).
CAUTION: YOU MUST USE SILICON CARBIDE TYPE WHEELS, STONES AND ABRASIVE
PAPERS TO DRESS, MAKE SMOOTH AND POLISH TITANIUM COMPONENTS.
YOU MUST NOT USE ALUMINIUM OXIDE TYPES.
A. Make the doubler plates from titanium sheet (AMS 4901), 0.05 in.
(1,27 mm) (CoMat 02-255). Make sure the doubler plates have
sufficient area to rivet to the web.
B. Use a marking pen (CoMat 06-131) to make a mark along the center of
the doubler plates.
F. Pilot drill the rivet holes from the doubler plates to the repair
piece. Use a 0.1719 in. (4,366 mm) drill to open the holes to their
final size.
G. Disassemble the doubler plates and the repair piece and remove the
burrs with abrasive paper (CoMat 05-021).
I. Pilot drill the rivet holes from the doubler plates to the web
segment. Use a 0.1719 in. (4,366 mm) drill to open the holes to
their final size.
J. Disassemble the doubler plates and the web segment and remove the
burrs with abrasive paper (CoMat 05-021).
A. Remove all unwanted material from the repair area and the inner
surfaces of the air inlet cowl with a suction cleaner.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Clean the damage and repair area of the bulkhead with the
methylethylketone (CoMat 01-076) and lint-free cloth
(CoMat 02-099). Wipe the repair area dry.
10. Make an inspection of the repair area and the repair parts.
A. Do a visual check of the repair area and the drilled holes to make
sure there is no more damage.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Inspect the doubler plate, the web sections (adjacent to the repair
area) and the replacement web sections using applicable fluorescent
penetrant examination, Standard Practices Manual (SPM) 70-23-01-
200-501. Make sure there are no cracks.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Let the sealant dry for 10 minutes before assembly of the parts.
F. Put the repair piece assembly in position and align the holes in
the doubler plates with the web segment.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
Repair Area
Fig. 202
Repair Doubler
Fig. 203
1. General.
A. This procedure may be used to repair damage to the air intake cowl
(including cracks and delamination). The damage must be more than
2.5 in. (63,5 mm) from the forward edge and 7.0 in. (177,8 mm) from
the aft edge of the acoustic panel. On the 3-piece acoustic liner
the damage must be more than 2.5 in. (63,5 mm) from the axial edges
of the acoustic panel. On the 2-piece acoustic liner the damage
must be more than 3.5 in. (88,9 mm) from the axial edges of the
acoustic panel. Damage is not permitted in the 6 in. (152,4 mm)
area along I.R. 230o (ref. figs. 204 and 205). The cleaned up
damage must be confined to a maximum area of 0.5 in. (12,7 mm)
diameter of the backing tray (internal skin) and 2.0 in. (50,8 mm)
diameter of the facing sheet (carbon ply) (ref. Fig. 202). There
must be a minimum of 10.0 in. (254,0 mm) between damaged areas.
B. This repair removes the damaged area and installs a repair plate.
The repair area is filled with potting compound or structural
adhesive and then an outer ply is installed on top.
2. Referenced Information
A. Standard equipment
B. Special Tools
D. Repair Parts
None.
E. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Air intake cowl Composite structure
4. Prepare the damaged area for repair (Ref. Fig. 201 and 202).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Inspect the damgeded area using IAE 1N20444 tapping tool and the
tap test method, SRM 54-01-00 Composite Structure Tap Test, to find
any areas of delamination.
C. Mark around the damage with a pencil, making sure to include cracks
and areas of delamination.
D. Put the teflon tape (CoMat 02-007) in 2.0 in. (50,8 mm) wide strips
approximately 1.0 in. (25,4 mm) away from the mark around the
damage.
NOTE: Make sure that the corners of the tape have a minimum radius
of 0.5 in. (12,7 m).
E. Use a high-speed rotary cutter and remove all the damage (including
cracks) from the carbon ply. Make sure the maximum diameter is not
more than 2.0 in. (50,8 mm).
CAUTION: DO NOT DAMAGE THE INTERNAL SKIN AND ADJACENT STRUCTURE WHEN
YOU REMOVE THE HONEYCOMB. IF YOU DAMAGE THE INNER SKIN AND
ADJACENT STRUCTURE YOU MAY HAVE TO DO A DIFFERNET REPAIR.
F. Use a high-speed rotary sander and remove the honeycomb from the
repair area.
G. Use a high-speed rotary cutter and remove all the damage (including
cracks) from the internal skin. Make sure the maximum diameter is
not more than 0.5 in. (12,7 mm) and there is a minimum overlap of
0.75 in. (19,1 mm) on the internal skin to support the repair
plate.
NOTE: Make sure that the internal skin is not damaged when the
honeycomb is removed.
J. Let the repair area dry for 6 hours at 176 oF (80oC) with a heat
lamp. The repair materials must be applied immediately after the 6
hours.
A. Wear lint-free gloves (CoMat 02-097) and cut three pieces of dry
carbon fibre fabric (Comat 08-059) 1.0 in. (25,4 mm) larger all
around than the cut-out.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(2) Apply the adhesive to each ply with the brush (CoMat 02-087)
and cover each ply with another sheet of non-porous parting
film.
(3) Use the roller to force the adhesive into each ply
thoroughly.
(1) Align the three plies and put them on with their adhesive
sides together onto a hard, flat surface.
(2) Use the heat lamp to cure the adhesive for 220 minutes at
190o - 210oF (88o - 99oC) for 220 minutes.
(4) Start to measure the cure time when the temperature reaches
190oF (88oC).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(2) Put the repair plate in the correct on the internal skin
position and install.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(2) Make sure the honeycomb cells that can be seen are filled
with potting compound/structural adhesive.
E. When the repair is cool, remove the weight, the cawl plate and the
non-porous parting film.
A. Cut a piece of dry carbon fibre fabric (CoMat 08-059) 1.0 in.
(25.4 mm) larger all around than the area identified by the teflon
tape.
NOTE: Make sure that the outer ply is not cut to its correct
dimension until it has been soaked with adhesive.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(2) Apply the adhesive to the ply with the brush (CoMat 02-087)
and put a second sheet of non-porous parting film on top.
(3) Use the roller to force the adhesive into the ply thoroughly.
Make sure the ply is soaked with the adhesive.
D. Cut the ply so that it is the same shape as the area identified by
the teflon tape.
NOTE: Make sure that the two pieces of non-porous parting film stay
on the ply until the installation procedure.
E. Keep the outer ply and the resin cool until the installation
procedure.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Use the brush (CoMat 02-087) and apply an equal layer of adhesive
to the area identified by the teflon tape.
(1) Remove one sheet of the non-porous parting film from the
outer ply.
(2) Put the outer ply, with the adhesive side down, on to the
repair area in the correct position for installation. Make
sure the outer ply has an equal overlap around the repair
cut-out and touches the teflon tape.
(3) Use the roller and smooth the surface of the outer ply until
all air bubbles are removed.
(2) Use the heat lamp to keep the temperature of the repair area
between 190o - 210oF (88 o - 99oC) for 220 minutes.
(4) Start to measure the cure time when the temperature reaches
190oF (88oC).
D. When the repair area is cool, remove the lamp, temperature probes,
weight, cawl plate, teflon tape and non-porous parting film.
11. Make the edges of the outer ply smooth (Ref. Fig. 203)
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. ONLY
REMOVE MATERIAL FROM THE EDGE OF THE OUTER PLY. DO NOT USE A
LIQUID WITH THE ABRASIVE PAPER.
A. Rub the edges of the outer ply, with waterproof abrasive paper
(CoMat 05-021), until smooth with the adjacent surface.
A. Remove all unwanted material with a suction cleaner. Make sure that
no particles of the materials stay in the acoustic panel.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Make a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, (Ref. SRM 54-01-00) Composite Structure Tap Test,
to confirm that the repair is correctly bonded.
A. Ident the component/log book with the REPAIR no. VRS 7504
(Ref. SPM TASK 70-09-00-400-501).
REPAIR NO 035.
AIR INTAKE COWL ACOUSTIC LINER SURFACE DAMAGE REPAIR
VRS7539
1. General.
B. This repair fills the damaged area with epoxy paste adhesive mixed
with microballoons and installs a carbon fiber repair ply.
CAUTION: USE PROTECTIVE MATS WHEN YOU WORK IN THE AIR INTAKE COWL TO
PREVENT DAMAGE TO THE ACOUSTIC STRUCTURE.
2. Referenced Information.
A. Standard equipment
C. Special Tools
D. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Air intake cowl Composite structure
B. If the damage goes through the outer stainless steel mesh and into
the carbon ply, do REPAIR No. 015 (VRS2815).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the damaged area with Turco 6646 (CoMat 01-438) and lint-free
cloth (CoMat 02-099). Wipe the area dry.
A. Mask around the damaged area with teflon tape (CoMat 02-007):
(1) Measure 1.0 in. (25,4 mm) from the edge of the damage.
NOTE: If the damaged area is less than 1.0 in. (25.4 mm) from the
forward edge of the acoustic panel, insert the patch into the
joint between the acoustic panel and the lipskin.
(2) Carefully apply the teflon tape so that it goes around the
area in a 2.0 in. (50,8 mm) wide strip.
B. Make the surface of the repair area rough with waterproof abrasive
paper (CoMat 05-021), making sure to remove the sharp edges of the
damage. Do not increase the dimensions of the damage.
A. Wear lint-free gloves (CoMat 02-097) and cut one piece of dry
carbon fiber fabric (CoMat 08-059) so that it has a 1.5 in.
(38,1 mm) overlap around the damage.
A. Use heat lamps to dry the repair area. Keep the temperature between
149.0º- 170.6oF (65 oC - 77ºC) for 8 hours. The repair materials must
be applied at the end of 8 hours.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Mix the epoxy paste adhesive (CoMat 08-050) in accordance with the
manufacturer’s instructions. The weight of epoxy paste adhesive
required will be approximately the same as the weight of the dry
carbon fiber fabric.
NOTE: After the ply has soaked, the remaining epoxy paste adhesive
(if it is kept cool) can be used in the installation
procedure.
C. Soak the repair ply with the mixed epoxy paste adhesive.
(2) Apply the epoxy paste adhesive to the two sides of the repair
ply with the brush (CoMat 02-087) and cover the ply with
another sheet of non-porous parting film.
(3) Use the roller to force the epoxy paste adhesive into the
repair ply thoroughly.
(1) Let the two pieces of the non-porous parting film stay on the
repair ply until the installation procedure.
(2) Cut the repair ply so that it is the same shape as the area
which the teflon tape identifies.
(3) Keep the repair ply and the epoxy paste adhesive mixture cool
until the installation procedure.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the repair area with Turco 6646 (CoMat 01-438) and lint-free
cloth (CoMat 02-099). Wipe the repair area dry.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Mix the epoxy paste adhesive (CoMat 08-050) in accordance with the
manufacturer’s instructions. When fully mixed, add the
microballoons (CoMat 02-164) to the mixture: 5 parts (by weight) of
the microballoons to 100 parts (by weight) of the mixture.
B. Fill the damaged area with the mixture using a clean metal spatula.
Make sure the mixture is level with the outer stainless steel mesh.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) Remove one sheet of non-porous parting film from the repair
ply.
(2) Put the repair ply, with the epoxy paste adhesive side down,
on to the repair area. The outer ply must have an equal
overlap around the repair cut-out and touch the teflon tape.
(3) Use the roller to remove the air which is caught in the epoxy
paste adhesive and to make the repair ply smooth.
(4) Remove the unwanted epoxy paste adhesive from the teflon
tape with a clean metal spatula.
(5) Remove the remaining non-porous film from the repair ply.
B. Use the heat lamp to keep the temperature of the repair area
between 194o - 200oF (90 o - 93oC) for 220 minutes.
D. Start to measure the time for the epoxy paste adhesive to cure when
the temperature reaches 194 oF (90oC).
17. Make the edges of the repair ply smooth (Ref. Fig. 202).
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE REPAIR AREA OR
THE OUTER SURFACE OF THE ACOUSTIC STRUCTURE. BE CAREFUL AND
ONLY REMOVE MATERIAL FROM THE EDGE OF THE OUTER PLY. DO NOT
USE A LIQUID WITH THE ABRASIVE PAPER.
A. If the repair ply has been inserted into the acoustic panel/lipskin
joint, replace the aerodynamic sealant (Ref. SRM Repair 021
VRS2725).
A. Remove all unwanted material from the repair area with a suction
cleaner.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Clean the surface with Turco 6646 solvent (CoMat 01-438) and a
lint-free cloth (CoMat 02-099). Wipe the surface dry.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, (Ref. SRM 54-01-00) Composite Structure Tap Test,
to confirm that the repair is correctly bonded.
C. Measure the thickness of the cured repair ply at the leading edge.
Make sure the into wind step is less than 0.020 in. (0,51 mm).
1. General.
A. The fan cowl is made up of two doors that enclose the fan section
of the engine. The doors form an aerodynamic faring from the aft
end of the inlet cowl to the forward end of the thrust reverser.
B. The fan cowl doors are made of bonded aluminum honeycomb structures
approximately 0.90 in. (22,9 mm) thick. The structure uses
composite lamintaed skins of graphite fiber, graphite tape, and
honeycomb core bonded together with epoxy paste adhesive under
pressure and elavated temperatures.
C. The doors are hinged from the engine pylon and fastened at the
lower bifurcation splitline by tension latches. The doors are
interchangeable from engine to engine.
2. Structure Description.
A. The materials used in the construction of the fan cowl doors are
graphite composites, machined CRES bar, aluminum alloy castings,
molded silicon rubber sections, and various fittings made from
formed CRES sheet and forged steel alloys.
3. Structure Identification.
The purpose of the tables is to help you to easily locate and identify
components which may be damaged. This is then used to help you to:
12 --
1. Introduction
This section contains the allowable damage limits for both sheet metal
and bonded panel structural components of the V2500 fan cowl doors. Any
damage which is found to be more than the allowable damage limits should
be repaired in accordance with the procedures found in 54-20-00, Repairs,
Page Block 201.
2. Zones
Each of the individual components is divided into zones. The zones which
are affected by the different types of allowable damage are identified in
the figures and tables which follow.
3. Section Organization
A. General
(3) Damage - All damage limits assume that exposed edges do not
extend above the skin contour. Any damage should be reworked
to remove or feather the extensions. Holes and cracks in the
pressure boundaries must be sealed with applicable tape
material. Allowable damage is classified as either unlimited
usage or time limited.
B. Fan Cowl Door Structure - Allowable Damage (See Figure 101, Figure
102 and Table 101).
The allowable damage zones for the fan cowl door structure are:
A - Hinge area, Figure 101 (Sheets 1 & 5) and Figure 102 (Sheets
1 & 5).
B - Latch area, Figure 101 (Sheets 1 & 5) and Figure 102 (Sheets
1 & 5).
C - Main panel body, Figure 101 (Sheets 3 & 7) and Figure 102
(Sheets 3 & 7).
D - Access panel area, Figure 101 (Sheets 2 & 6) and Figure 102
(Sheets 2 & 6).
Left Fan Cowl Door Zones - Laminate Skin Only (No Honeycomb)
Figure 101 (Sheet 9)
Right Fan Cowl Door Zones - Laminate Skin Only (No Honeycomb)
Figure 102 (Sheet 9)
Right Fan Cowl Door Zones - Laminate Skin Only (No Honeycomb)
Figure 102 (Sheet 10)
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Nick A, B, C, No nearer than 4.00 in. Max. depth of 6000 FH
D, E, F (101.6 mm) to other 0.010 in. (0.254 4500 FC
G, H, K damage. mm) by max. length 20 Months
Protect with sealing tape of 1.00 in. (25.4
(CoMat 02-006). If length mm).
is more than limit, then Unlimited use.
consider as a gouge. No
nicks permitted in Zone
K1.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Disbond C (upper Any disbond must be Max. area less 750 FH
region within the main panel than or equal to
ONLY - body as indicated in Figs 576 sq. in. (3716
inner 101 Sheet 3 and Sheet 7 sq. cm).
and and 102 Sheet 3 and Sheet 7500 FH
outer 7.
skin) The total disbond area
should include the dis-
crepant area from both
the inner and outer
skins. Any overlapping
areas of disbond should
only be counted once.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Disbond C (lower Any disbond must be Max. area greater 750 FH
region within the main panel than 186 sq. in.
ONLY - body as indicated in Figs (1200 sq. cm), but
inner 101 Sheet 3 and Sheet 7 less than
and and 102 Sheet 3 and Sheet 400sq.in. (2581
outer 7. sq. cm).
skin) The total disbond area 7500 FH
should include the dis-
crepant area from both
the inner and outer
skins. Any overlapping
areas of disbond should
only be counted once.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Hole A, B, D, No nearer than 6.00 in. Max. diameter of Fly on limit
F, G, H (152.4 mm) to other 3.0 in. (76.2 mm) only.
damage. in inner skin or Inspect tape
Protect with sealing tape outer skin only at each
(CoMat 02-006). Maximum (not through flight
of three holes on each both). (outer skin
door. Repair no later Time Limited. only).
than next 600 FH, 750 FC
or 100 Days.
Crack C No nearer than 6.00 in. Max. length of 1.0 Fly on limit
(152.4 mm) to other in. (25.4 mm) in only.
damage. inner skin only. Inspect tape
Protect with sealing tape Time Limited. at each
(CoMat 02-006). Maximum flight.
of three cracks on each
door. Repair no later
than next 600 FH, 750 FC
or 100 Days.
Crack A, B, D, No nearer than 6.00 in. Max. length of 3.0 Fly on limit
F, G, H (152.4 mm) to other in. (76.2 mm) in only.
damage. inner skin or Inspect tape
Protect with sealing tape outer skin only at each
(CoMat 02-006). Maximum (not through flight
of three cracks on each both). (outer skin
door. Repair no later Time Limited. only).
than next 600 FH, 750 FC
or 100 Days.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Dent C (outer The center of the damage Diameter up to 1.2 6000 FH
skin must be separated by at in. (30.48 mm) or 4500 FC
only) least five times the diameter between 20 Months
largest damage diameter 3.0 in (76.2 mm)
from adjacent damage or and 4.5 in (114.3
to change in laminate mm) and by max.
construction. depth of 0.03 in.
Maximum of three dents on (0.76 mm)
each door. No Unlimited use.
delamination/disbond
permitted on dent.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Dent A, B No nearer than 6.00 in. Diameter of 6000 FH
(outer (152.4 mm) to other between 1.2 in 4500 FC
skin damage or to change in (30.48 mm) and 3.0 20 Months
only) laminate construction. in. (76.2 mm) in
Maximum of three dents on outer skin only by
each door. No max. depth of 0.09
delamination/disbond in. (2.28 mm).
permitted on dent. Unlimited use.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Dent F No nearer than 6.00 in. Max. diameter of 6000 FH
(152.4 mm) to other 3.0 in. (76.2 mm) 4500 FC
damage or to change in by max. depth of 20 Months
laminate construction. 0.10 in. (2.54
Maximum of three dents on mm).
each door. No Unlimited use.
delamination/disbond
permitted on dent.
C. Fan Cowl Door Corner Plates - Allowable Damage (See Figure 103 and
Table 102).
The Allowable damage zones for the fan cowl door corner plates are:
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Wear on L Min. thickness 6000 FH
the M 0.040 in. (1.0 mm) 4500 FC
corner N remaining and min. 20 Months
plate length 0.120 in.
(3.0 mm)
remaining.
Unlimited use.
Missing L Protect with sealing/ Missing corner 500 FC Fly
or M speed tape (CoMat 02- plate, or on limit
damaged N 006). remaining only.
corner Make sure 2.0 in. (50,8 thickness less Inspect at
plates mm) overlap where than 0.040 in. 10 FC
possible. (1,0 mm) or intervals.
Replace no later than 500 remaining length
FC. less than 0.20 in
(3,0 mm).
Time Limited.
GENERAL REPAIR
1. General
Repairs given in this section are for structural damage exceeding the
limits shown in the Allowable Damage section. The repairs are written
to restore a part to it’s original strength and configuration as when
it was manufactured. Procedures to refinish a repaired area are also
given.
2. Adhesive Preparation
Some repairs call for the use of certain adhesives. The following are
the procedures to use in the preparation of the adhesives.
A. EA956/L3 Adhesive
B. EA956 Adhesive
C. EA934NA Adhesive
D. Both the original skin and the repair material must be clean
and dry before the repair can be started. Water on the surface
or in the materials will make the repair weak. All water must be
removed before the repair can be done. Use heat lamps at 230ºF-
250ºF (115ºC-127ºC) for one hour.
010 LEFT FAN COWL ACCESS PANELS MAIN AREA SURFACE DAM-
(VRS2869) AGE REPAIR
(REF 71-13-00 LEFT FAN COWL ACCES PANELS)
011 TO BE SUPPLIED
012 FAN COWL EDGE DELAMINATION REPAIR
(VRS2834) (REF 71-13-00 LEFT FAN COWL)
(VRS2877) (REF 71-13-00 RIGHT FAN COWL)
013 FAN COWL EDGE DELAMINATION REPAIR
(VRS2829) (REF 71-13-00 LEFT FAN COWL)
(VRS2874) (REF 71-13-00 RIGHT FAN COWL)
014 FAN COWL LANDS SURFACE DAMAGE REPAIR
(VRS2830) (REF 71-13-00 LEFT FAN COWL)
(VRS2876) (REF 71-13-00 RIGHT FAN COWL)
015 FAN COWL ACCESS PANEL LANDS SURFACE DAMAGE REPAIR
(VRS2832) (REF 71-13-00 LEFT FAN COWL ACCESS PANELS)
(VRS2945) (REF 71-13-00 RIGHT FAN COWL ACCESS PANELS)
016
(VRS2835) CANCELLED
017
(VRS2831) CANCELLED
(VRS2878)
018 FAN COWL AFT DOOR LANDS REPAIR
(VRS2833) (REF 71-13-00 LEFT FAN COWL)
(VRS2875) (REF 71-13-00 RIGHT FAN COWL)
019
(VRS2843) CANCELLED
020 FAN COWL PART PENETRATION REPAIR
(VRS2712) (REF 71-13-00 LEFT FAN COWL)
(VRS2713) (REF 71-13-00 RIGHT FAN COWL)
021 FAN COWL - EXTERNAL PAINT DAMAGE REPAIR
(VRS2743) (REF 71-13-00 LEFT FAN COWL)
(VRS2744) (REF 71-13-00 RIGHT FAN COWL)
037 LEFT FAN COWL LAMINATE OIL FILLER ACCESS DOOR LANDS
(VRS7502) SURFACE DAMAGE REPAIR
(REF 71-13-00 LEFT FAN COWL)
038 FAN COWL MAIN AREA DISBOND REPAIR
(VRS7500) (REF 71-13-00 LEFT FAN COWL)
039 FAN COWL - REPLACE THE CORNER PLATES
(VRS2790) DELETED - REFER TO CMM 71-13-00 REPAIR NO. 024
055 FAN COWL MAIN AREA FILLER PLATE REPAIR
(VRS7505) (REF 71-13-00 LEFT FAN COWL)
(REF 71-13-00 RIGHT FAN COWL)
057 FAN COWL HINGE FITTING LUG OVERSIZE HOLE REPAIR
(VRS7511) (REF 71-13-00 LEFT FAN COWL)
(REF 71-13-00 RIGHT FAN COWL)
058 FAN COWL HINGE FITTING LUG OVERSIZE HOLE BUSH
(VRS7530) REPAIR
(REF 71-13-00 LEFT FAN COWL)
(REF 71-13-00 RIGHT FAN COWL)
REPAIR 001
FAN COWL EDGE EROSION DAMAGE REPAIR
(VRS2728/2729)
1. General
B. The edge erosion must be confined to an area 1.0 in. (25.4 mm)
long and 0.02 in. (0.51 mm) deep.
2. Referenced Information
A. Standard Tools
C. Component Materials
A. Cut the loose fibers from the repair area. Use the waterproof
abrasive paper (CoMat 05-021) to remove the surface protection.
Make the repair area even with the adjacent surface.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Smooth the repair surface even with the adjacent surface with
waterproof abrasive paper (CoMat 05-021).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Make a visual inspection to make sure that the repair has been
done in accordance with these procedures.
1. General.
A. This procedure may be used to repair damage to the fan cowl door
sandwich (Ref. Fig. 201 for applicable regions) (including cracks)
which must be more than 0.5 in. (12,7 mm) from the fittings,
brackets, hinges and flanges. The damage must be confined to an
area of 1.0 in. (25,4 mm) diameter or less in the main panel area.
The damage in all other applicable areas must be confined to
2.0 in. (50,8 mm) diameter or less. If the damage is beyond these
limits or above the horizontal center-line, refer to Goodrich.
D. This repair can only be done in the areas indicated, Ref. Fig. 201.
E. The orientation of the carbon fibre repair plies must follow the
sequence as follows:
Zone B - Latch area (0-90)/(0-90)/( ±45)/(±45)/(0-90)/(±45)
Zone C - Main panel body (0-90)/(0-90)
Zone D - Access panel area (0-90)/(0-90)/( ±45)/(±45)/(0-90).
Ply orientation is given from the outer most ply to the inner.
2. Referenced Information.
A. Standard equipment
C. Special Tools
D. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Fan cowl Composite structure
A. Mark around the damage with a pencil, making sure to include cracks
and areas of delamination.
B. Mask around the repair area with 2.0 in (50,8 mm) wide strips of
teflon tape (CoMat 02-007). Calculate the distance that the tape
must be from the area identified in step A as follows:
(1) Measure 1.0 in. (25,4 mm) from the edge of the damage for
each of the outer plies.
(2) Add 0.75 in. (19,05 mm) for an outer layer of fiberglass
fabric (CoMat 02-167).
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. ONLY
REMOVE MATERIAL FROM THE EDGE OF THE OUTER PLY. DO NOT USE A
LIQUID WITH THE ABRASIVE PAPER.
C. Make the surface of the repair area rough with waterproof abrasive
paper (CoMat 05-021).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(2) Apply the adhesive to each ply with the brush (CoMat 02-087)
and cover each ply with another sheet of non-porous parting
film.
(3) Use the roller to force the adhesive into each ply
thoroughly.
(1) Remove one sheet of non-porous film from two of the plies.
(2) Remove both sheets of non-porous film from the third ply.
(3) Align the three plies and put them on with their adhesive
sides together onto a hard, flat surface.
(4) Use the roller to remove unwanted adhesive and air from the
three fiberglass plies.
(2) Use the heat lamp to cure the adhesive for 220 minutes at
190o - 210oF (88o - 99oC) for 220 minutes.
(4) Start to measure the cure time when the temperature reaches
190oF (88oC).
(1) When the support plate is cool, remove the two remaining
pieces of non-porous film.
(2) Drill two pairs of holes, 0.050 in. (1,27 mm) diameter, a
sufficient distance apart to attach the support plate to a
clamp bar with lockwire (CoMat 02-127).
A. Use the heat lamps to dry the repair area. Keep the temperature at
176oF (80oC) for six hours. The repair materials must be applied
immediately at the end of the six hours.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
C. Apply an equal layer of adhesive to the support plate and the cowl
using the brush (CoMat 02-087).
(1) Put the support plate against the inner surface of the cowl,
making sure that the support plate has an equal overlap
around the repair area.
(3) Put lockwire (CoMat 02-127) around the clamp bar and twist
the ends together to hold the support plate in the correct
position.
Gradually increase the temperature with the heat lamp; the rate of
the increase must not exceed 5.4 oF (3oC) in each minute. Keep the
temperature at 190o - 210 oF (88o - 99oC) for 1 hour. Start to
measure the curing time when the temperature gets to 190 oF (88oC).
10. Prepare the filler plies, the repair plies, and the honeycomb
(Ref. Fig. 202 and 203).
A. Wear lint-free gloves (CoMat 02-097) and cut the lower filler plies
(Ref. step 1.E.):
The lower filler plies and fiberglass cap ply must overlap the cut-
out in the cowl inner skin by 1.0 in. (25,4 mm) all around.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.E.
Wear lint free gloves (CoMat 02-097) and cut the upper filler plies
(Ref. step 1.E.):
The upper filler plies and fiberglass cap ply must overlap the cut-
out in the cowl outer skin by 1.0 in. (25,4 mm) all around.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.E.
Wear lint free gloves (CoMat 02-097) and cut the repair plies:
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.E.
B. Cut the repair plug from the honeycomb (CoMat 08-063, 08-065,
08-066) to be a good fit in the repair hole. Use lint-free gloves
(CoMat 02-097).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
12. Install the lower filler plies (Ref. Fig. 202 and 203).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Put each filler ply onto a sheet of non-porous parting film (CoMat
02-168). Use the brush (CoMat 02-087) to apply the adhesive to the
two sides of each ply. Put another layer of parting film on these
plies and roll the adhesive into the plies so that they are fully
soaked. Do not remove the parting film until the installation
procedure.
C. Cut each lower filler ply to be a good fit in the cut-out. They
must be flat on the support plate and have the same shape as the
cut-out. The edges of the plies must not overlap on the sides of
the cut-out (Ref. step 1.E.).
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.E.
D. Remove the non-porous parting film from one side of the first
carbon filler ply. Put the ply into the cut-out, adhesive side
down. The ply must be located correctly and flat against the
support plate. Remove the remaining non-porous parting film and use
a clean metal spatula to keep the ply flat on the support plate.
Repeat this step for each subsequent carbon filler ply and
fiberglass cap ply. Make sure that the plies are flat and located
correctly.
Gradually increase the temperature with the heat lamp; the rate of
increase must not exceed 5.4 oF (3oC) in each minute. Keep the
temperature at 190o - 210 oF (88o - 99oC) for 220 minutes. Start to
measure the curing time when the temperature gets to 190 oF (88oC).
When the adhesive has cured, remove the non-porous parting film.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Fill the open cells of the honeycomb in the cowl and the repair
plug with potting compound. Use a clean metal spatula and make sure
all of the cells are filled.
C. Install the honeycomb plug into the hole and make sure it is flat
against the inner plies. Use a clean metal spatula to remove
unwanted potting compound and make the surface smooth.
Gradually increase the temperature with the heat lamp; the rate of
increase must not exceed 5.4 oF (3oC) in each minute. Keep the
temperature at 113o - 131 oF (45o - 55oC) for between one and two
hours. Start to measure the curing time when the temperature gets
to 113oF (45oC).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
15. Install the upper filler plies and the repair plies (Ref. Fig. 205).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Put each filler ply onto a sheet of non-porous parting film (CoMat
02-168). Use the brush (CoMat 02-087) to apply the adhesive to the
two sides of each ply. Put another layer of parting film on the
plies and roll the adhesive into the carbon plies so that they are
fully soaked. Do not remove the parting film until the installation
procedure.
C. Cut each upper filler ply and the fiberglass cap ply to be a good
fit in the cut-out of the outer skin. They must be flat on the
honeycomb plug and have the same shape as the cut-out. The edges of
the plies must not overlap on the edges of the cut-out.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.E.
D. Cut the first carbon repair ply to its finished dimensions so that
it overlaps the cut-out in the outer skin by 1.0 in. (25,4 mm) all
around. Cut each subsequent carbon ply to overlap the previous by
1.0 in (25,4 mm). Cut the fiberglass repair ply so that it has the
same shape as the area defined by the teflon tape.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.E.
F. Remove the non-porous parting film from one side of the fiberglass
cap ply. Put the ply into the cut-out resin side down. The ply must
be located correctly and flat against the honeycomb plug. Remove
the remaining non-porous parting film and use a clean metal spatula
to keep the ply flat on the plug. Repeat this step for the first and
any subsequent carbon filler plies. Make sure that the plies are
flat and located correctly.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.E.
G. Remove the parting film from one side of the first carbon repair
ply and position it over the damage with the adhesive side down.
Make sure that the damage is located in the centre of the ply. Use
the roller to remove air caught in the adhesive. Remove the
remaining parting film.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.E.
H. Remove the parting film from one side of the second carbon repair
ply and position it over the repair area with the resin side down.
Make sure it has an equal overlap around the first ply. Use the
roller to remove air caught in the resin. Remove the remaining
parting film.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.E.
I. Remove the parting film from one side of the fiberglass repair ply
and position it over the repair area with the adhesive side down.
Make sure it has an equal overlap around the last ply.
NOTE: The fiberglass repair ply must touch the teflon tape.
J. Use the roller to remove air caught in the adhesive. Remove the
remaining parting film. Remove unwanted adhesive from the teflon
tape with a clean metal spatula.
A. Get a heat blanket, which must be larger all around than the repair
area.
B. Cut a sheet of porous parting film (CoMat 02-169). Make sure that
the film is larger than the heat blanket and has an overlap of at
least 3.0 in. (76,2 mm) around the fiberglass ply.
C. Cut one sheet of breather fabric (CoMat 08-057) for each carbon and
fiberglass ply on the repair area, excluding the filler plies. Make
sure that the breather fabric has the same dimensions as the porous
parting film.
D. Put the porous parting film on to the repair area. Make sure it has
an equal overlap around the repair area. Put the layers of breather
fabric on top of the porous parting film.
(2) Make sure that each strand connects the breather fabric with
the area around the silicon rubber sheet.
G. Put the non-porous parting film onto the repair area. Make sure
that it has an equal overlap around the repair area. Put the
silicone rubber sheet on top of the non-porous parting film.
H. Put the heat blanket and breather cloth onto the repair area.
(2) Put the two sheets of breather cloth onto the repair area.
(3) Put the heat blanket on top of the breather cloth. Make sure
that the heat blanket has an overlap all around the repair
area.
(1) Use nylon bagging film (CoMat 02-163) and sealant tape
(CoMat 08-051).
(2) Make sure that the vacuum bag has an overlap of approximately
2.0 in. (50,8 mm) around the breather cloth.
(3) Install the vacuum hose, from the suction pump, so that it
goes directly on to the breather cloth.
(4) Attach and seal the film to the cowl with the sealant tape.
A. Use the vacuum suction pump to decrease the pressure in the repair
area making sure it gives an indication of at least 25.0 in.
(635,0 mm) of mercury while the adhesive cures.
B. Use the heat blanket to keep the temperature of the repair area at
190o - 210oF (88o - 99oC) for 220 minutes.
D. Start to measure the cure time when the temperature gets to 190 oF
(88oC).
A. When the cure is completed, remove the lay-up materials from the
repair.
A. Make all contours of the repair area smooth with waterproof silicon
carbide abrasive paper (CoMat 05-021), making sure that there is no
edge between the repair area and the outer skin of the panel.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, (Ref. SRM 54-01-00) Composite Structure Tap Test,
to confirm that the repair is correctly bonded.
1. General.
C. The damage must be a sufficient distance from the edge of the fan
cowl to install all the repair plies and sanding ply. Refer to
Para. 4A and Fig. 201 and 202. The repair should be at least 10 in.
(254,0 mm) from any other damage in 2-ply skin region, 15 in.
(381,0 mm) elsewhere.
D. This repair can only be done in the areas indicated, ref. Fig. 201.
This repair should not be done on the inner surface.
E. The orientation of the carbon fibre repair plies must follow the
sequence as follows:
Zone A - Hinge area (0-90)/(0-90)/( ±45)/(±45)/(0-90)/(±45)
Zone B - Latch area (0-90)/(0-90)/( ±45)/(±45)/(0-90)/(±45)
Zone C - Main panel body (0-90)/(0-90)
Zone D - Access panel area (0-90)/(0-90)/( ±45)/(±45)/(0-90)
Zone K - Forward/Aft edge sandwich area (0-90)/(0-90)/( ±45)/(±45).
Ply orientation is given from the outer most ply to the inner.
2. Referenced Information.
A. Standard equipment
B. Special Tools
D. Repair parts
None.
E. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Fan cowl door Composite structure
A. Referring to Fig. 202 examine the repair area to assess the amount
of damage and, using the standard workshop tools, measure the depth
of the damage. Do this in several places where the extent of the
damage permits. From this information the number of repair plies
should be calculated as follows:
Where doubt can arise over the exact magnitude of the damage
penetration, i.e. deciding between 0.065 in. (1,65 mm) and
0.066 in. (1,68 mm), assume the larger figure as the criteria for
selecting the number of repair plies to use. That is, 6 plies
rather than 5, for this example.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Apply the teflon tape (CoMat 02-007) to the repair area. Fig. 202
shows the dimensions of the area to be covered with the tape
(repair of 2 ply damage shown).
B. Make the surface of the repair area rough and remove the sharp
edges from the damage with the abrasive paper (CoMat 05-021). Do
not damage the carbon plies of the cowl.
A. Cut the first repair ply so that it has a 2.0in. (50,8 mm) overlap
around the damage. Use carbon fabric (CoMat 08-059) and lint free
gloves (CoMat 02-097). To prevent fraying, the plies may be cut to
the finished dimensions after soaking in adhesive (Ref. steps 1.E
and 9.C).
B. Cut the remaining repair plies if they are required using the
carbon fabric and lint free gloves. Cut each subsequent repair ply
2.0in. (50,8 mm) longer and 2.0in. (50,8 mm) wider. There must be a
repair ply for each ply of the area which is damaged and these must
be covered by a sanding ply (CoMat 02-167). To prevent fraying, the
plies may be cut to the finished dimensions after soaking in
adhesive (Ref. steps 1.E and 9.C).
A. Dry the repair area. Use the heat lamp to keep the repair area of
the cowl at 176oF (80oC) for six hours. The repair materials must
be applied at the end of the six hours.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
C. Cut approximately 1.0 in. (25,4 mm) off each edge of the plies.
Make sure the first ply has a 1.0 in. (25,4 mm) overlap around the
damage. The overlap for each subsequent ply must be 1.0 in.
(25,4 mm). Cut the corners of the repair plies to an angle of
approximately 45 degrees with a length of approximately 0.5 in.
(12,7 mm). Cut the last (fiberglass) ply to the shape defined by
the teflon tape (CoMat 02-007).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. The repair area must be cool after the drying procedure. Clean the
repair area with methylethylketone (CoMat 01-076) using lint free
cloth (CoMat 02-099). Wipe the area with a piece of clean lint free
cloth before the fluid dries.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Fill the damage with the mixture using a clean metal spatula. The
filled damage must be level with the existing carbon plies of the
repair area.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Remove the parting film from one side of the first repair ply and
position the ply over the damage with the adhesive side down. Make
sure the damage is located in the center of the ply. Use the roller
to remove air caught in the adhesive. Remove the remaining parting
film.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.E.
C. Remove the parting film from one side of the second repair ply (if
it is required) and position it over the repair area with the
adhesive side down. Make sure it has an equal overlap around the
first ply. Use the roller to remove the air caught in the adhesive.
Remove the remaining parting film.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.E.
NOTE: The last repair (sanding) ply must touch the teflon tape
(CoMat 02-007) all around.
E. Remove unwanted adhesive from the teflon tape with a clean metal
spatula.
B. Cut the porous parting film (CoMat 02-169). Make sure that the film
is larger than the heat blanket and overlaps the last (fiberglass)
repair ply by at least 3.0 in. (76,2 mm) all around.
C. Cut the breather fabric (CoMat 08-057) into pieces the same size as
the porous parting film (Ref. step B. above). The number of pieces
must equal the number of plies used in the repair.
D. Put the porous parting film on to the repair area so that it has an
equal overlap. Put the breather fabric on top of the porous parting
film. Use one layer of breather fabric for each repair ply used.
F. Put four fiberglass tows onto the repair area using one strand of
the fiberglass fabric (CoMat 02-167) in each of four positions
around the repair. Each of the strands must connect the breather
fabric with the area around the silicone rubber sheet.
NOTE: With the fiberglass tows installed, gasses can not collect
below the silicone rubber sheet when the adhesive cures.
G. Put the non-porous parting film (Ref. step E. above) onto the
repair area first. Make sure that it has an equal overlap around
the repair area. Put the silicone rubber sheet on top of the non-
porous parting film.
H. Cut two pieces of breather cloth (CoMat 02-166), at least 2.0 in.
(50,8 mm) larger on each side than the silicone rubber sheet. Put
the two pieces of the breather cloth on to the repair area. Put the
heat blanket on top of the breather cloth. The heat blanket must
have an overlap all around the repair area.
J. Put the nylon bagging film (CoMat 02-163) over the repair area so
that the bag overlaps the breather cloth by 2.0 in. (50,8 mm) all
around. Install the vacuum hose from the suction pump so that it
goes directly on to the breather cloth. Attach and seal the film to
the bulkhead with the sealant tape (CoMat 08-051).
A. Decrease the pressure in the repair area with the vacuum suction
pump. During the cure, the reading must show at least 25.0 in.
(635,0 mm) of mercury.
B. Increase the temperature and keep at 190 o - 210oF (88o - 99oC) for
220 minutes. The rate of increase and subsequent decrease must not
be faster than 5.4oF (3 oC) in each minute. Start to measure the time
for the adhesive to cure when the temperature gets to 190 oF (88oC).
the nylon bagging film with its seal and the vacuum hose;
the temperature probes; the heat blanket; the breather cloth;
the silicone rubber sheet; the non-porous parting film;
the breather fabric; the fiberglass tows; the porous parting film
and the teflon tape.
A. Make the repair area smooth. The contours of the repair area must
be smooth and there must not be an edge or step, between the repair
area and the outer skin of the bulkhead. Use the abrasive paper
(CoMat 05-021).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, SRM 54-01-00 Composite Structure Tap Test, to
confirm that the repair is correctly bonded.
1. General.
B. This is a cosmetic repair and does not add strength to the fan
cowl.
2. Referenced Information.
A. Standard equipment
C. Repair Parts
--------------------------------------------
PART NO. PART IDENT
--------------------------------------------
Left Fan Cowl Composite structure
Right Fan Cowl Composite structure
CAUTION: BE CAREFUL WHEN YOU MAKE THE SURFACE OF THE REPAIR AREA
ROUGH. DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL.
DO NOT USE A LIQUID WITH THE ABRASIVE PAPER.
A. Lightly roughen the outer skin of the repair area with abrasive
paper (CoMat 05-021) to remove all the surface protection.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: DO NOT TOUCH THE CLEANED SURFACE OF THE REPAIR AREA. IF THE
SURFACE IS NOT FULLY CLEANED THE COMPOUND CAN NOT BOND
SATISFACTORILY.
B. Apply the potting compound mix to fill the damaged area of the cowl
and using a clean plastic spatula make the contours of the repair
area the same as the contours of the adjacent area of the cowl.
D. Smooth the repair area level with the adjacent surface with
abrasive paper (CoMat 05-021).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
CAUTION: DO NOT HEAT CURE MORE THAN 3.66 CUBIC INCHES (60 CUBIC
CENTIMETERS) OF THE ADHESIVE. MORE THAN 3.66 CUBIC INCHES
(60 CUBIC CENTIMETERS) OF THE ADHESIVE WILL INCREASE IN
VOLUME IF IT IS HEAT CURED.
B. Apply the adhesive mix to fill the damaged area of the cowl and
using a clean plastic spatula make the contours of the repair area
the same as the contours of the adjacent area of the cowl.
D. Smooth the repair area level with the adjacent surface with
abrasive paper (CoMat 05-021).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
A. Make a mark VRS2726 (left fan cowl) and VRS2727 (right fan cowl)
adjacent to the assembly number. Use a CoMat 06-131 marking pen of
a colour that contrasts.
CANCELLATION NOTICE
1. General.
2. Referenced Information.
A. Standard equipment
C. Repair Parts
--------------------------------------------
PART NO. PART IDENT
--------------------------------------------
Left Fan Cowl Composite structure
Right Fan Cowl Composite structure
Air Start Door Composite structure
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Let the repair area dry for a maximum of 6 hours at 176 oF (80oC)
using heat lamps.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Apply the adhesive mix to fill the damaged area using a clean metal
spatula.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Cure the adhesive for 220 minutes at 194 o to 200oF (90o to 93oC)
with an explosion proof heat lamp. Temperature increase up to cure
temperature or subsequent decrease must not be more than 5.4 oF
(3oC) in each minute. Start the cure time when the temperature gets
to 194oF (90oC).
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
A. Make a mark VRS2836 (left fan cowl), VRS2920 (right fan cowl) and
VRS2842 (right fan cowl access panels) adjacent to the assembly
number. Use a CoMat 06-131 marking pen of a colour that contrasts.
1. General.
B. This repair fills the damaged area with epoxy adhesive mixed with
microballoons and installs carbon fibre repair plies and a
fiberglass sanding ply.
C. There must be enough distance to install all the repair plies and
sanding ply and not be within the interface area of the land, refer
to Para. 4A and 6A and Fig. 202. The damage must not go through
more than 5 plies on the outer skin and 4 plies on the inner skin.
Only one repair for each access panel opening land is permitted.
There must be a minimum of 10.0 in. (254,0 mm) between damaged
areas.
D. The orientation of the carbon fibre repair plies must follow the
sequence as follows:
2. Referenced Information.
A. Standard equipment
B. Special Tools
D. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Fan cowl Composite structure
A. Referring to Fig 202 examine the repair area to assess the amount
of damage and, using the standard workshop tools, measure the depth
of the damage. Do this in several places where the extent of the
damage permits. From this information the number of repair plies
should be calculated as follows:
Where doubt can arise over the exact magnitude of the damage
penetration, i.e. deciding between 0.060 in. (1,52 mm) and
0.061 in. (1,55 mm), assume the larger figure as the criteria for
selecting the number of repair plies to use. That is, 5 plies
rather than 4, for this example. If the damage is on the interface
of the land or it goes to the edge of the cowl, do REPAIR No. 009
(VRS2837/VRS2924).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the repair area with the methylethylketone (CoMat 01-076) and
lint free cloth (CoMat 02-099). Wipe the dry.
A. Mask around the repair area with teflon tape (CoMat 02-007).
Calculate the distance that the tape must be from the damage as
follows:
(1) Measure 1.0 in. (25,4 mm) from the edge of the damage for
each damaged ply of the cowl (ref. step 4.), and add 0.75 in.
(19,05 mm) for an outer layer of fiberglass fabric
(CoMat 02-167).
(2) Carefully apply the teflon tape so that it goes around the
area in a 2.0 in. (50,8 mm) wide strip.
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. DO NOT
USE A LIQUID WITH THE ABRASIVE PAPER.
B. Make the surface of the repair area rough with the abrasive paper
(CoMat 05-021) making sure to remove the sharp edges of the damage.
(1) Wear lint-free gloves (CoMat 02-097) and cut one piece of dry
carbon fabric (CoMat 08-059) so that it has a 2.0 in.
(50,8 mm) overlap around the damage.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.D.
(1) Wear lint-free gloves (CoMat 02-097) and use dry carbon
fabric, and cut each subsequent repair ply 2.0 in. (50,8 mm)
longer and 2.0 in. (50,8 mm) wider. There must be one repair
ply for each ply of the cowl which is damaged.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.D.
(1) Wear lint-free gloves (CoMat 02-097) and cut one piece of
fiberglass fabric (CoMat 02-167) so that it has a 1.0 in.
(25,4 mm) overlap around the area identified by the teflon
tape.
A. Use heat lamps to dry the repair area. Keep the temperature at 176 oF
(80oC) for six hours. The repair materials must be applied
immediately at the end of the six hours.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
NOTE: After the plies are soaked, the remaining adhesive (if it is
kept cool) can be used in the installation process.
B. Soak the carbon fibre and fiberglass plies with the mixed adhesive.
(2) Apply the adhesive to each ply with the brush (CoMat 02-087)
and cover each ply with another sheet of non-porous parting
film.
(3) Use the roller force the adhesive into each ply thoroughly.
(1) Cut approximately 1.0 in. (25,4 mm) off each edge of the
plies.
(2) Make sure the first ply has a 1.0 in. (25,4 mm) overlap
around the damage.
(3) Make sure that each subsequent ply extends 1.0 in. (25,4 mm)
more around the damage.
(5) Cut the fiberglass ply so that it is the same shape as the
area defined by the teflon tape.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Fill the damaged area of the panel with the mixture using a clean
metal spatula. Make sure the mixture is level with the top carbon
ply of the cowl.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) Remove one sheet of non-porous parting film from the first
repair ply.
(2) Put the first repair ply, with the adhesive side down, onto
the repair area, making sure that the damage is located in
the center of the ply.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.D.
(3) Use a roller to remove air and unwanted adhesive from the
ply.
(4) Remove the remaining non-porous parting film from the first
repair ply.
(1) Remove one sheet of non-porous parting film from the second
repair ply.
(2) Put the second repair ply, with the adhesive side down, onto
the repair area, making sure that it has an equal overlap
around the first repair ply.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.D.
(3) Use a roller to remove air and unwanted adhesive from the
ply.
(4) Remove the remaining non-porous parting film from the second
repair ply.
(1) Repeat step C. above for the fiberglass sanding ply, making
sure that it has an equal overlap around the last carbon
fibre repair ply, and is touching the teflon tape.
F. Remove unwanted adhesive from the teflon tape with a clean metal
spatula.
A. Get a heat blanket, which must be larger all around than the repair
area.
B. Cut the a sheet of porous parting film (CoMat 02-169) making sure
that it is larger than the heat blanket and has an overlap of at
least 3.0 in. (76,2 mm) around the fiberglass ply.
C. Cut the breather fabric (CoMat 08-057) into sheets the same size as
the porous parting film. The number of pieces must equal the number
of plies used in the repair.
D. Put the porous parting film on to the repair area, making sure that
it has an equal overlap around the repair area. Put the layers
breather fabric on top of the porous parting film.
(2) Make sure that each strand connects the breather fabric with
the area around the silicone rubber sheet.
NOTE: With the fiberglass tows installed, gasses can not collect
below the silicone rubber sheet when the adhesive cures.
G. Put the non-porous parting film on to the repair area, making sure
that it has an equal overlap around the repair area. Put the
silicone rubber sheet on top of the non-porous parting film.
H. Put the heat blanket and breather cloth on to the repair area.
(2) Put the two pieces of the breather cloth on to the repair
area.
(3) Put the heat blanket on top of the breather cloth, making
sure that the heat blanket has an overlap all around the
repair area.
(1) Use nylon bagging film (CoMat 02-163) and sealant tape
(CoMat 08-051).
(2) Make sure that the vacuum bag has an overlap of approximately
2.0 in. (50,8 mm) around the breather cloth.
(3) Install the vacuum hose, from the suction pump, so that it
goes directly on to the breather cloth.
(4) Attach and seal the vacuum bag to the panel with the sealant
tape.
A. Use the vacuum pump to decrease the pressure in the repair area,
making sure it gives an indication of at least 25.0 in. (635,0 mm)
of mercury while the adhesive cures.
B. Use the heat blanket to keep the temperature of the repair area at
190o - 210oF (88o - 99oC) for 220 minutes.
D. Start to measure the cure time when the temperature gets to 190 oF
(88oC).
A. When the cure process is completed, remove the layup materials from
the repair area.
A. Remove all unwanted material from the repair area with a suction
cleaner.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, SRM 54-01-00 Composite Structure Tap Test, to
confirm that the repair is correctly bonded.
1. General.
B. This repair removes the damaged area and installs carbon fibre
filler plies, a carbon fibre patch and a fiberglass sanding ply.
C. This repair can only be done in the areas indicated, and must not
be more than 1.0 in. (25,4 mm) wide and 1.6 in. (40,6 mm) long. The
damage must be a sufficient distance from the fittings, brackets,
hinges and flanges to install all the repair plies and the sanding
ply on the outer surface. Only one repair for each land is
permitted. Refer to Figures 201 and 202.
2. Referenced Information.
A. Standard equipment
B. Special Tools
D. Repair parts
None
E. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Oil filler panel Composite sandwich structure
Chip detector panel Composite structure
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Mask around the repair area with 2.0 in. (50,8 mm) wide strips of
teflon tape (CoMat 02-007). Calculate the distance that the tape
must be from the damage as follows:
(1) Measure a minimum of 3.75 in. (95,3 mm) each side along the
door land.
(2) On the external surface, measure 4.85 in. (123,2 mm) from the
door edge.
(4) Carefully apply the teflon tape along the marks on the
measured repair area.
CAUTION: BE CAREFUL WHEN YOU MAKE THE SURFACE OF THE REPAIR AREA
ROUGH. DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL.
DO NOT USE A LIQUID WITH THE ABRASIVE PAPER.
C. Remove the surface protective treatment from the repair area with
waterproof abrasive paper (CoMat 05-021). Make the edges of the
area smooth.
(1) Find the centre of the damaged area, measure 0.5 in.
(12,7 mm) each side along the door land and make a mark.
(2) Measure 1.6 in. (40,6 mm) from the door edge and make a mark
to show the door land area.
A. Let the repair area dry for 6 hours at 176 oF (80oC) using heat
lamps.
(1) Wear lint-free gloves (CoMat 02-097) and cut eight pieces of
dry carbon fibre fabric (CoMat 08-059) 1.0 in. (25,4 mm)
larger all around (except at the door edge) than the cut-out
repair area.
(1) Wear lint-free gloves (CoMat 02-097) and cut one piece of dry
carbon fibre fabric (CoMat 08-059) a minimum of 2.0 in.
(50,8 mm) larger all around (except at the door edge) than
the cut-out repair area.
(1) Wear lint-free gloves (CoMat 02-097) and cut seven pieces of
dry carbon fibre fabric (CoMat 08-059), each piece 0.25 in.
(6,3 mm) larger all around (except at the door edge) than the
previous piece.
(1) Wear lint-free gloves (CoMat 02-097) and cut one piece of
fiberglass fabric (CoMat 02-167) so it is 0.75 in. (19,0 mm)
larger all around (except at the door edge) than the largest
ply.
(4) Make sure that the backing plate has a good contour with the
door land and a good overlap of the cut-out area.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Soak the fiberglass and the carbon plies with the adhesive.
(2) Apply the adhesive to the two sides of each ply with the
brush (CoMat 02-087) and put a second sheet of non-porous
parting film on each ply.
(3) Use the roller to force the adhesive into each ply
thoroughly.
(1) Cut each filler ply to the same dimensions as the cut-out
area.
(2) Find a long side on each ply and cut two corners to a radius
of 0.25 in. (6,3 mm).
(1) Cut the first repair ply 1.0 in. (25,4 mm) larger all around
(except at the door edge) than the cut-out repair area.
(2) Cut each subsequent repair ply 0.5 in. (12,7 mm) longer and
0.25 in. (6,3 mm) wider.
(3) Find a long side on each ply and cut two corners
approximately 0.5 in. (12,7 mm) from the end at an angle of
45 degrees.
(1) Cut the fiberglass sanding ply 0.75 in. (19,0 mm) larger all
around (except at the door edge) than the last repair ply.
(2) Find a long side and cut two corners approximately 1.0 in.
(25,4 mm) from the end at an angle of 45 degrees.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Apply an equal level of the adhesive mix to the cut-out area and
the edges using a brush (CoMat 02-087).
(1) Remove the parting film from one side of the first filler
ply.
(2) Put the first filler ply, with the adhesive side down, in the
cut-out area, and align it with the edge of the door land.
(3) Remove air and unwanted adhesive from the ply with a clean
metal spatula.
(4) Remove the remaining parting film from the first filler ply.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) Remove the non-porous parting film (CoMat 02-367) from one
side of the first repair ply.
(2) Put the first repair ply, with the adhesive side down, onto
the repair area and align it with the door edge, making sure
that it has an equal 1.0 in. (25,4 mm) overlap around the
repair area.
(4) Remove the remaining non-porous parting film from the first
repair ply.
C. Put the seven subsequent carbon repair plies on to the repair area.
(1) Repeat step B. above for the remaining repair plies, making
sure each subsequent repair ply has an equal 0.25 in.
(6,3 mm) overlap around the previous one.
(1) Repeat step B. above for the fiberglass ply, making sure that
the ply has an equal overlap of 0.75 in. (19,0 mm) around the
top repair ply.
(2) Make sure that the fiberglass ply is adjacent to, but not on,
the teflon tape.
E. Remove the unwanted adhesive from the teflon tape with a clean
metal spatula.
A. Get a heat blanket, which must be larger all around than the repair
area.
B. Cut a sheet of porous parting film (CoMat 02-169) making sure that
it is larger than the heat blanket and has an overlap of at least
3.0 in. (76.2 m) around the fiberglass ply.
C. Cut one sheet of breather fabric (CoMat 08-057) for each carbon and
fiberglass ply on the repair area. Make sure that the breather
fabric has the same dimensions as the porous parting film.
D. Put the porous parting film on to the repair area, making sure that
it has an equal overlap around the repair area. Put the layers of
breather fabric on top of the porous parting film.
(2) Make sure that each strand connects the breather fabric with
the area around the silicon rubber sheet.
G. Put the non-porous parting film on to the repair area, making sure
that it has an equal overlap around the repair area. Put the
silicone rubber sheet on top of the non-porous parting film.
H. Put the heat blanket and breather cloth on to the repair area.
(2) Put the two sheets of breather cloth on to the repair area.
(3) Put the heat blanket on top of the breather cloth, making
sure that the heat blanket has an overlap all around the
repair area.
(1) Use nylon bagging film (CoMat 02-163) and sealant tape
(CoMat 08-051).
(2) Make sure that the bagging film is approximately four times
larger than the door.
(3) Make sure that the vacuum bag has an overlap of approximately
2.00 in. (50.8 mm) around the breather cloth.
(4) Install the vacuum hose, from the suction pump, so that it
goes directly on to the breather cloth.
(5) Attach and seal the bagging film to the cowl with the sealant
tape (CoMat 08-051).
A. Use the vacuum suction pump to decrease the pressure in the repair
area, making sure it gives an indication of at least 25.0 in.
(635.0 mm) of mercury while the adhesive cures.
B. Use the heat blanket to keep the temperature of the repair area at
190o - 210oF (88o - 99oC) for 220 minutes.
D. Start to measure the cure time when the temperature reaches 190 oF
(88oC).
(1) Measure between 0.12 - 0.16 in. (3,0 - 4,0 mm) from the
internal surface and make a mark.
(2) Chamfer the hinge area along the edge of the internal surface
at an angle of 45 degrees.
(1) Use the latch as a template and make a mark for the fastener
hole(s).
(1) Use the latch as a template and make a mark for the latch
opening.
(1) Measure approximately 0.35 in. (8,9 mm) from the door edge
and apply teflon tape (CoMat 02-007).
(2) Radius chamfer the repair plies and the sanding ply.
(2) Close the access door, and make sure that the aerodynamic
contour on the external surface is correct and the hinge area
does not catch.
A. Use a brush (CoMat 02-087) and apply epoxy varnish (CoMat 07-085)
to the cut and chamfered edges, and let the varnish dry.
NOTE: Use longer fasteners if necessary, and make sure that they
are properly secured.
A. Remove all unwanted material from the repair area with a suction
cleaner.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Make a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, SRM 54-01-00 Composite Structure Tap Test, to
confirm that the repair is correctly bonded.
1. General
B. This repair removes the damaged area and installs carbon fibre
fill-in and repair plies.
2. Referenced Information
A. Standard equipment
A. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Fan Cowl Composite structure
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMI-
CALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY
INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES INSTRUCTIONS ON
HOW YOU MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY USE,
KEEP AND DISCARD CHEMICALS.
B. Mask around the repair area with teflon tape (CoMat 02-007).
Calculate the distance that the tape must be from the damage as
follows:
(1) Measure a minimum of 2.25 in. (57.2 mm) each side along the
panel land.
(2) On the inner surface, measure 2.4 in. (60.9 mm) from the edge
of the panel land.
(3) Measure along the skin contour, and make the two corners of
the marked area to an angle of 45 degrees and a length of
approximately 1.5 in. (38.1 mm).
(4) Use the marking pen (CoMat 06-131) to apply temporary marks
to the measured repair area.
(5) Carefully apply the teflon tape along the marks on the
measured repair area.
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. DO NOT
USE A LIQUID WITH THE ABRASIVE PAPER.
C. Remove the surface protective treatment from the repair area with
waterproof abrasive paper (CoMat 05-021). Make the edges of the
area smooth, and also rub the external surface side of the panel
land.
(1) Find the center of the damaged area, measure 0.5 in.
(12.7 mm) each side along the panel land and make a mark in
line with the edge of the external surface.
A. Use heat lamps to dry the repair area. Keep the temperature at 80 oC
(176oF) for 6 hours. The repair materials must be applied
immediately at the end of the 6 hours.
(1) Wear lint-free gloves (CoMat 02-097) and cut four pieces of
dry carbon fibre fabric (CoMat 08-059) 1.0 in. (25.4 mm)
larger all around (except at the panel edge) than the cut-out
repair area.
(1) Wear lint-free gloves (CoMat 02-097) and cut one piece of dry
carbon fibre fabric (CoMat 08-059) a minimum of 2.0 in.
(50.8 mm) larger all around (except at the panel edge) than
the cut-out repair area.
(2) Wear lint-free gloves (CoMat 02-097) and cut three pieces of
dry carbon fibre fabric (CoMat 08-059), each piece 0.25 in.
(6.3 mm) larger all around (except at the panel edge) than
the previous piece.
(4) Make sure that the backing plate has a good contour with the
panel land and a good overlap of the cut-out area.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
NOTE: After the plies are soaked, the remaining adhesive (if it is
kept cool) can be used in the installation procedure.
(2) Apply adhesive to each ply with the brush (CoMat 02-087) and
cover each ply with another sheet of non-porous parting
film.
(3) Use the roller to force the adhesive into each ply thor-
oughly.
(1) Cut each fill-in ply to the same dimensions as the cut-out
area.
(2) Find a long side on each fill-in ply and cut two corners to a
radius of 0.25 in. (6.3 mm).
(3) Cut the first repair ply so that it extends 1.0 in. (25.4 mm)
from the three edges of the cut-out area.
(4) Find a long side and cut two corners approximately 0.5 in.
(12.7 m) from the end at an angle of 45 degrees.
(5) Cut each subsequent repair ply 0.5 in. (12.7 mm) longer and
0.25 in. (6.3 mm) wider.
(6) Find a long side on each ply and cut two corners
approximately 0.5 in. (12.7 mm) from the end at an angle of
45 degrees.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMI-
CALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY
INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES INSTRUCTIONS ON
HOW YOU MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY USE,
KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMI-
CALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY
INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES INSTRUCTIONS ON
HOW YOU MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY USE,
KEEP AND DISCARD CHEMICALS.
A. Apply an equal layer of adhesive to the cut-out area and the edges
using a brush (CoMat 02-087).
(1) Remove the parting film from one side of the first fill-in
ply.
(2) Put the first fill-in, with the adhesive side down, in the
cut-out area, and align it with the inner skin edge.
(3) Remove air and unwanted adhesive from the ply with a clean
metal spatula.
(4) Remove the remaining parting film from the first fill-in
ply.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMI-
CALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY
INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES INSTRUCTIONS ON
HOW YOU MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY USE,
KEEP AND DISCARD CHEMICALS.
(1) Remove one sheet of non-porous parting film from the first
repair ply.
(2) Put the first repair ply, with the adhesive side down, onto
the repair area and align it with the inner skin edge, making
sure that it has an equal overlap around the repair cut-out.
(3) Use the roller to remove air and unwanted adhesive from the
ply.
(4) Remove the remaining non-porous parting film from the first
repair ply.
(1) Repeat step B above for the remaining repair plies. Make sure
that the fourth (top) repair ply is adjacent to, but not on,
the teflon tape.
D. Remove unwanted adhesive from the teflon tape with a clean metal
spatula.
A. Get a heat blanket, which must be a minimum of 3.0 in. (76 m) larger
all around than the repair area.
B. Cut a sheet of porous parting film (CoMat 02-169) making sure that
it is larger than the heat blanket and has an overlap of at least
3.0 in. (76.2 m) around the top repair ply.
C. Cut four sheets of breather fabric (CoMat 08-057), making sure that
the breather fabric has the same dimensions as the porous parting
film.
D. Put the porous parting film on to the repair area, making sure that
it has an equal overlap around the repair area. Put the layers of
breather fabric on top of the porous parting film.
(2) Make sure that each strand connects the breather fabric with
the area around the silicon rubber sheet.
G. Put the non-porous parting film on to the repair area, making sure
that it has an equal overlap around the repair area. Put the
silicone rubber sheet on top of the non-porous parting film.
H. Put the heat blanket and breather cloth on to the repair area.
(1) Cut two sheets of breather cloth (CoMat 02-166), at least 2.0
in. (50.8 mm) larger on each side than the silicone rubber
sheet.
(2) Put the two sheets of breather cloth on to the repair area.
(3) Put the heat blanket on top of the breather cloth, making
sure that the heat blanket has an overlap all around the
repair area.
(1) Use nylon bagging film (CoMat 02-163) and sealant tape
(CoMat 08-051).
(2) Make sure that the vacuum bag has an overlap of approximately
2.0 in. (50.8 mm) around the breather cloth.
(3) Install the vacuum hose, from the suction pump, so that it
goes directly on to the breather cloth.
(4) Attach and seal the vacuum bag to the panel with the sealant
tape.
A. Use the vacuum pump to decrease the pressure in the repair area,
making sure it gives an indication of at least 25.0 in. (635.0 mm)
of mercury while the adhesive cures.
B. Use the heat blanket to keep the temperature of the repair area at
194o - 200oF (90o - 93 oC) for 220 minutes.
D. Start to measure the cure time when the temperature reaches 194 oF
(90oC).
A. When the cure process is completed, remove the layup materials from
the repair.
CAUTION: DO NOT CAUSE DAMAGE TO THE REPAIR PLIES OR THE GRAPHITE PLIES
OF THE COWL.
(2) Close the access panel, and make sure that the aerodynamic
contour is correct.
A. Remove all unwanted material from the repair area with a suction
cleaner.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Make a visual inspection to make sure that the repair has been done
in accordance with these procedures.
1. General.
B. This repair fills the damaged area with epoxy adhesive mixed with
microballoons and installs carbon fibre repair plies and a
fiberglass sanding ply.
C. The damage must be a sufficient distance from the edge of the panel
to install all the repair plies and sanding ply. Refer to Para. 6A
and Fig. 201 and 202. The damage can be nearer to the edge if less
plies are damaged. There must be a minimum of 10.0 in. (254,0 mm)
between damaged areas. The damage on the Chip Detector door must
not go through more than 4 composite plies. The damage on the Oil
Filler door must not go through 2 plies on the outer surface or 4
plies on the inner surface.
2. Referenced Information.
A. Standard equipment
B. Special Tools
D. Repair parts
None
E. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Left fan cowl Composite structure
chip detector door
Left fan cowl Composite sandwich structure
oil filler door
A. Referring to Fig. 202 examine the repair area to assess the amount
of damage and, using the standard workshop tools, measure the depth
of the damage. Do this in several places where the extent of the
damage permits. From this information the number of repair plies
should be calculated as follows:
Where doubt can arise over the exact magnitude of the damage
penetration, i.e. deciding between 0.045in. (1,14 mm) and 0.046in.
(1,17 mm), assume the larger figure as the criteria for selecting
the number of repair plies to use. That is, 4 plies rather than 3,
for this example. If the damage goes through the panel, or goes
into the honeycomb of the panel, refer to manufacturer.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the repair area with the methylethylketone (CoMat 01-076) and
lint free cloth (CoMat 02-099). Wipe the area with a clean piece of
lint free cloth before the fluid dries.
A. Mask around the repair area with teflon tape (CoMat 02-007).
Calculate the distance that the tape must be from the damage as
follows:
(1) Measure 1.0 in. (25,4 mm) from the edge of the damage for
each ply of the panel (ref. step 4.), and add 0.75 in.
(19,05 mm) for an outer layer of fiberglass fabric
(CoMat 02-167).
(2) Carefully apply the teflon tape so that it goes around the
area in a 2.0 in. (50,8 mm) wide strip.
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. DO NOT
USE A LIQUID WITH THE ABRASIVE PAPER.
B. Make the surface of the repair area rough and remove the sharp
edges from the damage with the abrasive paper (CoMat 05-021).
A. Cut the first repair ply so that it has a 2.0in. (50,8 mm) overlap
around the damage. Use carbon fabric (CoMat 08-059) and lint free
gloves (CoMat 02-097). To prevent fraying, the plies may be cut to
the finished dimensions after soaking in adhesive (Ref. steps 1.D
and 9.C).
B. Cut the remaining repair plies if they are required using the
carbon fabric and lint free gloves. Cut each subsequent repair ply
2.0in. (50,8 mm) longer and 2.0in. (50,8 mm) wider. There must be a
repair ply for each ply of the panel which is damaged and these
must be covered by a single fiberglass ply (CoMat 02-167). To
prevent fraying, the plies may be cut to the finished dimensions
after soaking in adhesive (Ref. steps 1.D and 9.C).
A. Use heat lamps to dry the repair area. Keep the temperature at
176oF (80oC) for six hours. The repair materials must be applied
immediately at the end of the six hours.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
NOTE: After the plies are soaked, the remaining adhesive is used on
the repair area (Ref. step 12.).
C. Cut approximately 1.0 in. (25,4 mm) off each edge of the plies.
Make sure the first ply has a 1.0 in. (25,4 mm) overlap around the
damage. The overlap for each subsequent ply must be 1.0 in.
(25,4 mm). Cut the corners of the repair plies to an angle of
approximately 45 degrees with a length of approximately 0.5 in.
(12,7 mm). Cut the fiberglass ply to the shape defined by the
teflon tape (CoMat 02-007).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Fill the damaged area of the panel with the mixture using a clean
metal spatula. The filled damage must be level with the top carbon
fibre ply of the panel.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Remove the parting film from one side of the first repair ply and
position the ply over the damage with the adhesive side down. Make
sure the damage is located in the center of the ply. Use the roller
to remove air caught in the adhesive. Remove the remaining parting
film.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.D.
C. Remove the parting film from one side of the second repair ply (if
it is required) and position it over the repair area with the
adhesive side down. Make sure it has an equal overlap around the
first ply. Use the roller to remove the air caught in the adhesive.
Remove the remaining parting film.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.D.
NOTE: The fiberglass (sanding) ply must touch the teflon tape
(CoMat 02-007) all around.
E. Remove unwanted adhesive from the teflon tape with a clean metal
spatula.
B. Cut the porous parting film (CoMat 02-169). Make sure that the film
is larger than the heat blanket and overlaps the last (fiberglass)
repair ply by at least 3.0 in. (76,2 mm) all around.
C. Cut the breather fabric (CoMat 08-057) into pieces the same size as
the porous parting film (Ref step B. above). The number of pieces
must equal the number of plies used in the repair.
D. Put the porous parting film on to the repair area so that it has an
equal overlap. Put the breather fabric on top of the porous parting
film. Use one layer of breather fabric for each repair ply used.
F. Put four fiberglass tows onto the repair area using one strand of
the fiberglass fabric (CoMat 02-167) in each of four positions
around the repair. Each of the strands must connect the breather
fabric with the area around the silicone rubber sheet.
NOTE: With the fiberglass tows installed, gasses can not collect
below the silicone rubber sheet when the adhesive cures.
G. Put the non-porous parting film (Ref step E. above) onto the repair
area first. Make sure that it has an equal overlap around the
repair area. Put the silicone rubber sheet on top of the non-porous
parting film.
H. Cut two pieces of breather cloth (CoMat 02-166), at least 2.0 in.
(50,8 mm) larger on each side than the silicone rubber sheet. Put
the two pieces of the breather cloth on to the repair area. Put the
heat blanket on top of the breather cloth. The heat blanket must
have an overlap all around the repair area.
J. Put the nylon bagging film (CoMat 02-163) over the repair area so
that the bag overlaps the breather cloth by 2.0 in. (50,8 mm) all
around. Install the vacuum hose from the suction pump so that it
goes directly on to the breather cloth. Attach and seal the film to
the bulkhead with the sealant tape (CoMat 08-051).
A. Decrease the pressure in the repair area with the vacuum suction
pump. During the cure, the reading must show at least 25.0 in.
(635,0 mm) of mercury.
B. Increase the temperature and keep at 190 o - 210oF (88o - 99oC) for
220 minutes. The rate of increase and subsequent decrease must not
be faster than 5.4oF (3 oC) in each minute. Start to measure the time
for the adhesive to cure when the temperature gets to 190 oF (88oC).
A. When the cure process is completed, remove the layup materials from
the repair area.
A. Make the repair area smooth. The contours of the repair area must
be smooth and there must not be an edge or step, between the repair
area and the outer skin of the bulkhead. Use the abrasive paper
(CoMat 05-021).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, SRM 54-01-00 Composite Structure Tap Test, to
confirm that the repair is correctly bonded.
1. General.
B. The damage must not be in the 12.0 in. (304,8 mm) overheat zone on
the forward edge. The damage must not be more than 0.50 in.
(12,7 mm) in the forward and aft direction by maximum length of
1.25 in. (31,8 mm) circumferentially. There must be a minimum of
10.0 in. (254,0 mm) between damaged areas. Refer to Fig. 201.
2. Referenced Information.
A. Standard equipment
C. Special Tools
D. Repair parts
None.
E. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Left Fan Cowl Composite structure
Right Fan Cowl Composite structure
WARNING: USE THE CORRECT PROCEDURE AND EQUIPMENT WHEN YOU MOVE THE
COWL. MAKE SURE THE COWL IS HELD CORRECTLY DURING THE REPAIR
PROCEDURE.
CAUTION: BE CAREFUL NOT TO DAMAGE THE EDGES AND CORNERS OF THE COWL.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Dry the repair area. Use the heat lamp to keep the repair area of
the outer skin at 176oF (80oC) for six hours. The repair materials
must be applied at the end of the six hours.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. After removing the heatlamps used previously for drying the repair
area, fill a suitable disposable syringe (CoMat 02-162) with the
adhesive.
C. Slowly inject the adhesive with the syringe into the delaminated
area until the adhesive begins to flow out from the edges of the
plies.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Using the sonic test equipment (1N20444) and the tap test method,
SRM 54-01-00 Composite Structure Tap Test, examine the repair for
any signs of incomplete filling and or delamination.
1. General.
C. This repair can only be done in the areas indicated, Ref. Fig. 201.
2. Referenced Information.
A. Standard equipment
C. Special Tools
D. Repair parts
None.
E. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Left Fan Cowl Composite structure
Right Fan Cowl Composite structure
WARNING: USE THE CORRECT PROCEDURE AND EQUIPMENT WHEN YOU MOVE THE
COWL. MAKE SURE THE COWL IS HELD CORRECTLY DURING THE REPAIR
PROCEDURE.
CAUTION: BE CAREFUL NOT TO DAMAGE THE EDGES AND CORNERS OF THE COWL.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. At the two farthest points make a mark for drilling. Use a marking
pen (CoMat 06-131).
A. Use a hand drill with a 0.062 in. (1,58 mm) drill to drill two
holes to the depth of delamination.
A. Dry the repair area. Use the heat lamp to keep the repair area of
the outer skin at 176oF (80oC) for six hours. The repair materials
must be applied at the end of the six hours.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. After removing the heatlamps used previously for drying the repair
area, fill a suitable disposable syringe (CoMat 02-162) with the
adhesive.
C. Put the syringe into one of the drilled holes and slowly inject the
adhesive until it starts to come through the other drilled hole.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Using the sonic test equipment (1N20444) and the tap test method,
SRM 54-01-00 Composite Structure Tap Test, examine the repair for
any signs of incomplete filling and or delamination.
1. General.
B. This repair fills the damaged area with epoxy adhesive mixed with
microballoons and installs carbon fibre repair plies and a
fiberglass sanding ply.
C. There must be enough distance to install all the repair plies and
sanding ply and not be within the interface area of the land, refer
to Para. 4A and 6A and Fig. 202. The damage must not go through all
the composite plies.
D. The orientation of the carbon fibre repair plies must follow the
sequence as follows:
(0-90)/(0-90)/(±45)/(±45)/(0-90)/(0-90)/(0-90)/(0-90).
2. Referenced Information.
A. Standard equipment
B. Special Tools
D. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Left fan cowl Composite structure
Right fan cowl Composite structure
A. Examine the damaged area to assess the amount of damage and, using
the standard workshop tools, measure the depth of the damage. Do
this in several places where the extent of the damage permits. From
this information the number of repair plies should be calculated as
follows:
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the repair area with the methylethylketone (CoMat 01-076) and
lint free cloth (CoMat 02-099). Wipe the repair area dry.
A. Mask around the repair area with 2.0 in. (50,8 mm) wide strips of
teflon tape (CoMat 02-007). Calculate the distance that the tape
must be from the damage as follows:
(1) Measure 1.0 in. (25,4 mm) from the edge of the damage for
each damaged ply of the cowl (ref. step 4.).
(2) Add 0.75 in. (19,05 mm) for an outer layer of fiberglass
fabric (CoMat 02-167).
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. DO NOT
USE A LIQUID WITH THE ABRASIVE PAPER.
B. Remove the sharp edges from the damage and make the surface of the
repair area rough with the abrasive paper (CoMat 05-021).
A. Wear lint-free gloves (CoMat 02-097) and cut one piece of dry
carbon fabric (CoMat 08-059) so that it has a 2.0 in. (50,8 mm)
overlap around the damage.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.D.
B. Wear lint-free gloves (CoMat 02-097) and cut each subsequent repair
ply from dry carbon fabric (CoMat 08-059) 2.0 in. (50,8 mm) larger
all around than the previous piece. Cut one repair ply for each ply
of the cowl which is damaged.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.D.
A. Use heat lamps to dry the repair area. Keep the temperature at 176 oF
(80oC) for six hours. The repair materials must be applied
immediately at the end of the six hours.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
NOTE: After the plies are soaked, the remaining adhesive (if it is
kept cool) can be used in the installation process.
B. Soak the carbon fibre and fiberglass plies with the mixed adhesive.
(2) Apply the adhesive to each ply with the brush (CoMat 02-087)
and put a second sheet of non-porous parting film on each
ply.
(3) Use the roller force the adhesive into each ply thoroughly.
(1) Cut approximately 1.0 in. (25,4 mm) off each edge of the
plies.
(2) Make sure the first ply has a 1.0 in. (25,4 mm) overlap
around the damage.
(3) Make sure that each subsequent ply extends 1.0 in. (25,4 mm)
more around the damage.
(5) Cut the fiberglass ply so that it is the same shape as the
area defined by the teflon tape.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Fill the damaged area of the panel with the mixture using a clean
metal spatula. Make sure the mixture is level with the top carbon
ply of the cowl.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) Remove the non-porous parting (CoMat 02-168) film from one
side of the first repair ply.
(2) Put the first repair ply, with the adhesive side down, onto
the repair area, making sure that the damage is located in
the center of the ply.
NOTE: Make sure that the ply fibres follow the orientation as
given in step 1.D.
(3) Use a roller to remove air and unwanted adhesive from the
ply.
(4) Remove the remaining non-porous parting film from the first
repair ply.
(1) Remove one sheet of non-porous parting film from the second
repair ply.
(2) Put the second repair ply, with the adhesive side down, onto
the repair area, making sure that it has an equal overlap
around the first repair ply.
NOTE: Make sure that the ply fibres follow the orientation
as given in step 1.D.
(3) Use a roller to remove air and unwanted adhesive from the
ply.
(4) Remove the remaining non-porous parting film from the second
repair ply.
(1) Repeat step C. above for the fiberglass sanding ply, making
sure that it has an equal overlap around the last carbon
fibre repair ply, and is touching the teflon tape.
F. Remove unwanted adhesive from the teflon tape with a clean metal
spatula.
A. Get a heat blanket, which must be larger all around than the repair
area.
B. Cut the a sheet of porous parting film (CoMat 02-169) making sure
that it is larger than the heat blanket and has an overlap of at
least 3.0 in. (76,2 mm) around the fiberglass ply.
C. Cut the breather fabric (CoMat 08-057) into sheets the same size as
the porous parting film. The number of pieces must equal the number
of plies used in the repair.
D. Put the porous parting film on to the repair area, making sure that
it has an equal overlap around the repair area. Put the layers
breather fabric on top of the porous parting film.
(2) Make sure that each strand connects the breather fabric with
the area around the silicone rubber sheet.
G. Put the non-porous parting film on to the repair area, making sure
that it has an equal overlap around the repair area. Put the
silicone rubber sheet on top of the non-porous parting film.
H. Put the heat blanket and breather cloth on to the repair area.
(2) Put the two pieces of the breather cloth on to the repair
area.
(3) Put the heat blanket on top of the breather cloth, making
sure that the heat blanket has an overlap all around the
repair area.
(1) Use nylon bagging film (CoMat 02-163) and sealant tape
(CoMat 08-051).
(2) Make sure that the vacuum bag has an overlap of approximately
2.0 in. (50,8 mm) around the breather cloth.
(3) Install the vacuum hose, from the suction pump, so that it
goes directly on to the breather cloth.
(4) Attach and seal the vacuum bag to the panel with the sealant
tape (CoMat 08-051).
A. Use the vacuum pump to decrease the pressure in the repair area,
making sure it gives an indication of at least 25.0 in. (635,0 mm)
of mercury while the adhesive cures.
B. Use the heat blanket to keep the temperature of the repair area at
190o - 210oF (88o - 99oC) for 220 minutes.
D. Start to measure the cure time when the temperature gets to 190 oF
(88oC).
A. When the cure process is completed, remove the layup materials from
the repair area.
A. Remove all unwanted material from the repair area with a suction
cleaner.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, SRM 54-01-00 Composite Structure Tap Test, to
confirm that the repair is correctly bonded.
1. General.
NOTE: For applicable repair area refer to Figures 203, 204 and 205.
2. Referenced Information.
A. Standard equipment
B. Special Tools
D. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Oil filler door Composite sandwich structure
Chip detector door Composite structure
Air starter door Composite structure
A. Examine the damaged area to assess the amount of damage and, using
the standard workshop tools, measure the depth of the damage. Do
this in several places where the extent of the damage permits.
From this information the number of repair plies should be
calculated as follows:
-------------------------------------------------------------
DEPTH OF DAMAGE NO. OF PLIES
-------------------------------------------------------------
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Mask around the repair area with 2.0 in. (50,8 mm) wide strips of
teflon tape (CoMat 02-007). Calculate the distance that the tape
must be from the damage as follows:
(1) Measure 1.0 in. (25,4 mm) from the edge of the damage for
each ply of the cowl which is damaged.
(2) Add 0.75 in. (19,05 mm) for an outer layer of fiberglass
fabric (CoMat 02-167).
CAUTION: BE CAREFUL WHEN YOU MAKE THE SURFACE OF THE REPAIR AREA
ROUGH. DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL.
DO NOT USE A LIQUID WITH THE ABRASIVE PAPER.
B. Remove the sharp edges from the damage and make the surface of the
repair area rough with waterproof abrasive paper (CoMat 05-021).
A. Wear lint-free gloves (CoMat 02-097) and cut one piece of dry
carbon fibre fabric (CoMat 08-059) so that it has a 2.0 in.
(50,8 mm) overlap around the damaged area.
A. Let the repair area dry for 6 hours at 176 oF (80oC) using heat
lamps.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Soak the fiberglass and the carbon plies with the adhesive.
(2) Apply the adhesive to the two sides of each ply with the
brush (CoMat 02-087) and put a second sheet of non-porous
parting film on each ply.
(3) Use the roller to force the adhesive into each ply
thoroughly.
(1) Cut approximately 1.0 in. (25,4 mm) off each edge of the
repair plies. Make sure that the first repair ply has a
1.0 in. (25,4 mm) overlap around the damage, and each
subsequent repair ply has a 1.0 in. (25,4 mm) overlap around
the repair ply below it. Trim the corners of the repair plies
to 45 degrees by 0.5 in. (12,7 m). Cut the fiberglass ply so
that it is the same shape as the area identified by the
teflon tape (CoMat 02-007).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Apply the adhesive mix to the damaged area of the cowl with a clean
metal spatula. Make sure the adhesive is level with the top carbon
ply of the cowl.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) Remove the non-porous parting film (CoMat 02-367) from one
side of the first repair ply.
(2) Put the first repair ply, with the adhesive side down, onto
the repair area, making sure that the damaged area is in the
center of the repair ply.
(4) Remove the remaining non-porous parting film from the repair
ply.
(1) Remove the non-porous parting film from one side of the
repair ply.
(2) Put the first repair ply, with the adhesive side down, on to
the repair area, making sure that the second repair ply has
and equal overlap around the first repair ply.
(4) Remove the remaining non-porous parting film from the repair
ply.
D. Put the remaining carbon repair plies on to the repair area, repeat
step C above.
(1) Remove the non-porous parting film from one side of the
fiberglass ply.
(2) Put the fiberglass ply, with the adhesive side down, on to
the repair area making sure that fiberglass ply has an equal
overlap around the last carbon repair ply to the teflon mask
area.
(3) Use the roller to remove air which is trapped in the adhesive
and to make the fiberglass ply smooth.
(4) Remove the unwanted adhesive from the teflon tape with a
clean metal spatula.
A. Get a heat blanket, which must be larger all around than the repair
area.
B. Cut a sheet of porous parting film (CoMat 02-169) making sure that
it is larger than the heat blanket and has an overlap of at least
3.0 in. (76,2 m) around the fiberglass ply.
C. Cut one sheet of breather fabric (CoMat 08-057) for each carbon and
fiberglass ply on the repair area. Make sure that the breather
fabric has the same dimensions as the porous parting film.
D. Put the porous parting film on to the repair area, making sure that
it has an equal overlap around the repair area. Put the layers of
breather fabric on top of the porous parting film.
(2) Make sure that each strand connects the breather fabric with
the area around the silicon rubber sheet.
G. Put the non-porous parting film on to the repair area, making sure
that it has an equal overlap around the repair area. Put the
silicone rubber sheet on top of the non-porous parting film.
H. Put the heat blanket and breather cloth on to the repair area.
(2) Put the two sheets of breather cloth on to the repair area.
(3) Put the heat blanket on top of the breather cloth, making
sure that the heat blanket has an overlap all around the
repair area.
(1) Cover the repair area with the nylon bagging film
(CoMat 02-163) that must have a minimum overlap of 2.00 in.
(50,8 mm) around the breather cloth.
(2) Install the vacuum hose, from the suction pump, so that it
goes directly on to the breather cloth.
(3) Attach and seal the bagging film to the cowl with the sealant
tape (CoMat 08-051).
A. Use the vacuum suction pump to decrease the pressure in the repair
area, making sure it gives an indication of at least 25.0 in.
(635,0 mm) of mercury while the adhesive cures.
B. Use the heat blanket to keep the temperature of the repair area at
194o - 200oF (90o - 93oC) for 220 minutes.
D. Start to measure the cure time when the temperature reaches 194 oF
(90oC).
A. When the cure process is completed, remove the layup materials from
the repair.
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. ONLY
REMOVE MATERIAL FROM THE EDGE OF THE OUTER PLY. DO NOT USE A
LIQUID WITH THE ABRASIVE PAPER.
A. Remove all unwanted material from the repair area with a suction
cleaner.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Make a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, SRM 54-01-00 Composite Structure Tap Test, to
confirm that the repair is correctly bonded.
CANCELLATION NOTICE
CANCELLATION NOTICE
1. General.
A. This procedure may be used to repair damage to the aft door lands
on the left and right fan cowls.
B. This repair removes the damaged area and installs carbon fiber
fill-in and repair plies, a fiberglass sanding ply, and replaces
the door rubbing strip.
C. This repair is to be done on door lands which have damage less than
1.0 in. (25,4 mm) long. If the damage exceeds this limit, refer to
Goodrich.
2. Referenced Information.
A. Standard equipment
B. Special Tools
D. Repair Parts
--------------------------------------------
PART NO. PART IDENT
--------------------------------------------
CSR904B-4-5 Rivet
CSR904B-4-6 Rivet
740-4001-015 Nylon strip (left fan cowl - top)
740-4001-017 Nylon strip (left fan cowl - bottom)
740-4002-015 Nylon strip (right fan cowl - top)
740-4002-017 Nylon strip (left fan cowl - bottom)
E. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Fan cowl Composite structure
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the repair area with Solvent Turco 6646 (CoMat 01-438) and
lint free cloth (CoMat 02-099). Wipe the area dry.
6. Remove the rubbing strip from the door land. (Ref. Fig. 201).
A. Make a 90 degree cut 0.31 in. (7,88 mm) from a rivet and a minimum
of 5.0 in. (127 mm) from each side of the damaged area.
B. Drill out the rivets that attach the part of the rubbing strip to
be removed, and make a note of the position of the rivet holes.
C. Use a thin-bladed knife to break the bond between the rubbing strip
and the door land.
A. Apply teflon tape (CoMat 02-161) to the outer skin, 2.5 in.
(63,5 mm) from and all around the damaged area.
B. Remove the surface protective treatment from the repair area with
waterproof abrasive paper (CoMat 05-021). Lightly abrade the
exposed graphite fiber surface of the outer skin top ply.
C. Remove the rubbing strip adhesive from the inner surface of the
door land with waterproof adhesive paper (CoMat 05-021).
(1) Make a backing plate from 0.032 in. (0,81 mm) thick aluminum,
and bend it to the same contour as the door land.
(3) Attach the backing plate to the door land with clamps or
adhesive tape.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the outer skin surfaces and the door land of the repair area
with Solvent Turco 6646 (CoMat 01-438) and lint free cloth (CoMat
02-099). Wipe the area dry.
A. Dry the repair area. Use the heat lamp to keep the repair area of
the cowl at 176oF (80oC) for six hours. The repair materials must
be applied immediately at the end of the six hours.
11. Prepare the fill-in and repair and sanding plies (Ref. Fig. 202).
(1) Wear lint-free gloves (CoMat 02-097) and cut the fill-in
plies from dry carbon fiber fabric (CoMat 08-059), a minimum
of 1.0 in. (25,4 mm) larger all around than the damaged area.
(1) Wear lint-free gloves (CoMat 02-097) and cut one piece of dry
carbon fiber fabric (CoMat 08-059) a minimum of 2.0 in. (50,8
mm) larger all around the damaged area.
(1) Wear lint-free gloves (CoMat 02-097) and cut three pieces of
dry carbon fiber fabric (CoMat 08-059), each piece 0.25 in.
(6,3 mm) larger all around than the previous piece.
(1) Wear lint-free gloves (CoMat 02-097) and cut one piece of
fiberglass fabric (CoMat 02-167) 0.75 in. (19,0 mm) larger
all around than the largest repair ply.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
NOTE: After the plies are soaked, the remaining adhesive (if it is
kept cool) can be used in the installation process.
B. Soak the carbon fiber and fiberglass plies with the mixed adhesive.
(2) Apply adhesive to each ply with the brush (CoMat 02-087) and
cover each ply with another sheet of non-porous parting
film.
(3) Use a roller to force the adhesive into each ply thoroughly.
(1) Cut each fill-in ply to the same dimensions as the as the
cut-out area.
(2) Cut 1.0 in. (25,4 mm) from the edge of each repair ply
(2.0 in. (50,8 mm) at the door edge).
(3) Cut the corners of each repair ply approximately 0.5 in.
(12,7 mm) from the end at an angle of 45 degrees.
(4) Cut 1.0 in. (25,4 mm) from the edge of the fiberglass sanding
ply (2.0 in. (50,8 mm) at the door edge).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the repair area with Solvent Turco 6646 (CoMat 01-438) and
lint free cloth (CoMat 02-099). Wipe the repair area dry.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) Remove the parting film from one side of the first fill-in
ply.
(2) Put the first fill-in ply, with the adhesive side down, in
the damaged area.
(3) Remove any creases and air from the ply with a steel roller.
(4) Remove the remaining parting film from the first fill-in ply.
15. Install the repair plies and fiberglass sanding ply (Ref. Fig. 202).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) Remove one sheet of non-porous parting film from the first
repair ply.
(2) Put the first repair ply, with the adhesive side down, onto
the repair area and align it with the door edge, making sure
that it has a 1.0 in. (25,4 mm) overlap around the cut-out.
(3) Use the roller to remove any creases and air from the ply.
(4) Remove the remaining non-porous parting film from the first
repair ply.
(2) Put the fiberglass sanding ply, with the adhesive side down,
on the repair area and align it with the door edge, making
sure that it has a 0.75 in. (19,0 mm) overlap around the last
carbon repair ply.
(3) Use the roller to remove any creases and air from the ply.
E. Remove any unwanted adhesive from the teflon tape with a clean
metal spatula.
A. Get a heat blanket, which must be a minimum of 3.0 in. (76,2 mm)
larger all around than the repair area.
B. Cut a sheet of porous parting film (CoMat 02-169), making sure that
it is larger than the heat blanket and has an overlap of at least
3.0 in. (76,2 mm) around the top repair area.
C. Cut five sheets of breather fabric (CoMat 08-057), making sure that
the breather fabric has the same size dimensions as the porous
parting film.
D. Put the porous parting film on to the repair area, making sure that
it has an equal overlap around the repair area. Put the layers of
breather fabric on top of the porous parting film.
(2) Make sure that each strand connects the breather fabric with
the area around the silicone rubber sheet.
G. Put the non-porous parting film onto the repair area, making sure
that it has an equal overlap around the repair area. Put the
silicone rubber sheet on top of the non-porous parting film.
H. Put the heat blanket and breather cloth on to the repair area.
(1) Cut two sheets of breather cloth (CoMat 02-166), at least 2.0
in. (50,8 mm) larger on each side than the silicone rubber
sheet.
(2) Put the two sheets of the breather cloth on to the repair
area.
(3) Put the heat blanket on top of the breather cloth, making
sure that the heat blanket has an overlap all around the
repair area.
(1) Use nylon bagging film (CoMat 02-163) and sealant tape
(CoMat 08-051).
(2) Make sure that the vacuum bag has an overlap of approximately
2.0 in. (50,8 mm) around the breather cloth.
(3) Install the vacuum hose, from the suction pump, so that it
goes directly on to the breather cloth.
(4) Attach and seal the vacuum bag with the sealant tape.
A. Decrease the pressure in the repair area with the vacuum suction
pump. During the cure, the reading must show at least 25.0 in.
(635,0 mm) of mercury.
B. Increase the temperature and keep at 190o - 210oF (88o - 99oC) for
220 minutes. The rate of increase and subsequent decrease must not
be faster than 5.4oF (3oC) in each minute. Start to measure the
time for the adhesive to cure when the temperature gets to 190oF
(88oC).
A. When the cure process is completed, remove the layup materials from
the repair.
(2) The maximum width of the chamfer should equal to four times
the depth of the chamfer.
C. Remove all unwanted material from the area with a suction cleaner.
D. Use a brush (CoMat 02-087) and apply epoxy varnish (CoMat 07-085)
to the cut and chamfered edges, and let the varnish dry.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
E. Clean the repair area with Solvent Turco 6646 (CoMat 01-438) and
lint-free cloth (CoMat 02-099). Wipe the area dry.
21. Prepare the door land and the replacement rubbing strip (Ref. Fig. 201).
(1) Cut a length from the applicable nylon strip (Ref. 3.D. -
Repair parts) to give a maximum gap of 0.032 in. (0,81 mm) at
each end.
B. Drill the rivet holes (Ref. step 6.B.) in the door land using a
0.128 in. (3,25 mm) diameter drill.
C. Abrade the door land and nylon rubbing strip mating surfaces using
waterproof abrasive paper (CoMat 05-021).
D. Remove all unwanted material from the area with a suction cleaner.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
E. Clean the mating surfaces with Solvent Turco 6646 (CoMat 01-438)
and a lint-free cloth (CoMat 02-099). Wipe the surface dry.
22. Bond the replacement nylon rubbing strip to the door land.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(2) Position the rubbing strip on the door land, making sure that
the edges are aligned, and the centerline of the rubbing
strip is aligned with the center of the rivet holes.
(4) Temporarily attach the rubbing strip to the door land with
clamps.
(1) Use the heat blanket and a temperature probe to keep the
temperature of the repair area at 140oF (60oC) for 180
minutes, or 212oF (100oC) for 20 minutes.
23. Rivet the rubbing strip to the door land (Ref. Fig. 201).
(1) Drill through the holes in the door land, along the
centerline of the rubbing strip, using a 0.128 in. (3,25 mm)
diameter drill.
(2) Drill one hole 0.31 in (8,8 mm) from each end and a second
hole 0.50 in. (12,7 mm) from the first.
(2) Drill one hole 0.50 in. (12,7 mm) from the rivet at each end
of the remaining rubbing strip.
C. Countersink the rivet holes in the rubbing strip and the outer skin
using a 100 degree countersink bit.
E. Grind the rivet heads level with the rubbing strip using a
applicable grinder.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) Use a heat lamp to keep the temperature of the door land area
at 113oF (45oC) for 270 minutes.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, (Ref. SRM 54-01-00) Composite Structure Tap Test,
to confirm that the repair is correctly bonded.
CANCELLATION NOTICE
1. General.
A. This procedure may be used to repair damage to the fan cowl door
sandwich (Ref. Fig. 201 for applicable regions) (including cracks)
which must be more than 0.5 in. (12,7 mm) from the fittings,
brackets, hinges and flanges. The damage must be confined to an
area of 2.0 in. (50,8 mm) diameter or less. If the damage is beyond
these limits refer to Goodrich.
D. This repair can only be done in the areas indicated, Ref. Fig. 201.
E. The orientation of the carbon fibre repair plies must follow the
sequence as follows:
Ply orientation is given from the outer most ply to the inner.
2. Referenced Information.
A. Standard equipment
C. Special Tools
D. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Fan cowl Composite structure
A. The damage (which includes cracks) must be more than 0.5 in.
(12,7 mm) from the fittings, brackets, hinges and flanges. It must
be confined to an area of 2.0 in. (50,8 mm) diameter or less.
A. Mark around the damage with a marking pen (CoMat 06-131), making
sure to include cracks and areas of delamination.
B. Mask around the repair area with 2.0 in (50,8 mm) wide strips of
teflon tape (CoMat 02-007). Calculate the distance that the tape
must be from the area identified in step A as follows:
(1) Measure 1.0 in. (25,4 mm) from the edge of the damage for
each of the outer plies.
(2) Add 0.75 in. (19,05 mm) for an outer layer of fiberglass
fabric (CoMat 02-167).
(3) Make sure the corners of the strip of tape have a radius of
at least 0.5 in. (12,7 mm).
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. ONLY
REMOVE MATERIAL FROM THE EDGE OF THE OUTER PLY. DO NOT USE A
LIQUID WITH THE ABRASIVE PAPER.
C. Make the surface of the repair area rough with waterproof abrasive
paper (CoMat 05-021).
(3) Make the surface of the inner plies smooth so that the
surface is continuous.
(4) Do not penetrate the adhesive that bonds the honeycomb to the
inner plies.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) Wear lint-free gloves (CoMat 02-097) and cut the aluminium
honeycomb core (CoMat 08-066) so that it is a good fit in the
repair hole.
(2) Make sure that the ribbons of the honeycomb plug are in the
same direction as that of the undamaged honeycomb.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Mix the potting compound (CoMat 08-072) for the honeycomb plug in
accordance with the manufacturer’s instructions.
(1) Install the honeycomb plug into the hole, making sure that it
is flat on the inner plies of the cowl.
(3) Fill with the potting compound until it is level with the
honeycomb plug.
(1) USe heat lamps to cure the potting compound for 1 to 2 hours
between 113o - 131oF (45 o - 55oC).
(2) The heat-up rate must not be greater than 5.5 oF (3oC) in each
minute.
10. Prepare the cap ply, the fiberglass ply, the filler plies and
the repair plies (Ref. Fig. 202 and 203).
A. Wear lint-free gloves (CoMat 02-097) and cut the filler plies
(Ref. step 1.E.).
(1) There must be a filler ply for each of the plies in the
related outer skin.
(2) Cut the dry carbon fibre fabric (CoMat 08-059) until it has
an 1.0 in. (25,4 mm) overlap around the repair cut-out.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.E.
C. Wear lint-free gloves (CoMat 02-097) and cut the first repair ply.
(1) Cut one piece of dry carbon fibre fabric (CoMat 08-059) until
it has an 2.0 in. (50,8 mm) overlap around the honeycomb
plug.
NOTE: Make sure that the ply fibres follow the orientation
as given in step 1.E.
D. Wear lint-free gloves (CoMat 02-097) and cut the remaining repair
plies.
(1) There must be a repair ply for each of the outer cowl plies.
(2) Cut one piece of dry carbon fibre fabric (CoMat 08-059) for
each subsequent repair ply until it has an 2.0 in. (50,8 mm)
overlap around the repair ply below.
NOTE: Make sure that the ply fibres follow the orientation
as given in step 1.E.
E. Wear lint-free gloves (CoMat 02-097) and cut the fiberglass ply.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
G. Soak the fiberglass and the dry carbon fibre fabric plies with
EA9390 adhesive (CoMat 08-050).
(2) Apply the adhesive to the two sides of each ply with the
brush (CoMat 02-087) and cover with a second sheet of non-
porous parting film.
(3) Use the roller to force the adhesive into each ply
thoroughly. Make sure that each ply is fully soaked.
H. Cut the cap ply and the filler plies to their finished dimensions.
(1) Let the two pieces of the non-porous parting film stay on
each ply until the installation procedure.
(2) Cut each filler ply and the cap ply until it does not have an
overlap on the sides of the repair cut-out.
(1) Let the two pieces of the non-porous parting film stay on
each ply until the installation procedure.
(2) Cut approximately 1.0 in. (25,4 mm) off each edge of the
repair plies.
(3) Make sure the first repair ply has an 1.0 in. (25,4 mm)
overlap around the honeycomb plug. Each subsequent repair ply
must have a 1.0 in. (25,4 mm) overlap around the repair ply
below it.
J. Cut the fiberglass ply until it is the same shape as the area
identified by the teflon tape.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
12. Install the cap ply, the filler plies and the repair plies
(Ref. Fig. 203).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Put the cap ply and the first filler ply into the repair cut-out.
(2) Remove the non-porous parting film (CoMat 02-168) from one
side of the first filler ply.
(3) Put the first filler ply, with the adhesive side down, into
the repair cut-out, making sure that the filler ply is flat.
(5) Remove the remaining non-porous parting film from the filler
ply and, using a clean metal spatula, make sure the filler
ply is flat and in the correct position.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.E.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.E.
(1) Remove the non-porous parting film (CoMat 02-168) from one
side of the repair ply.
(2) Put the repair ply, with the adhesive side down, on to the
repair area, making sure that the repair cut-out is in the
center of the repair ply.
(4) Remove the remaining non-porous parting film from the repair
ply.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.E.
(1) Remove the non-porous parting film (CoMat 02-168) from one
side of the repair ply.
(2) Put the repair ply, with the adhesive side down, on to the
repair area, making sure that the second repair ply has an
equal overlap around the first repair ply.
(4) Remove the remaining non-porous parting film from the repair
ply.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.E.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.E.
(1) Remove the non-porous parting film (CoMat 02-168) from one
side of the fiberglass ply.
(2) Put the fiberglass ply, with the adhesive side down, on to
the repair area, making sure that the fiberglass ply has an
equal overlap around the first repair ply and touches the
teflon tape.
(3) Use a roller to remove air that is caught in the adhesive and
to make the fiberglass ply smooth.
(4) Remove unwanted adhesive from the teflon tape with a clean
metal spatula.
A. Get a heat blanket, which must be larger all around than the repair
area.
B. Cut a sheet of porous parting film (CoMat 02-169). Making sure that
it is larger than the heat blanket and has an overlap of at least
3.0 in. (76,2 mm) around the fiberglass ply.
C. Cut one sheet of breather fabric (CoMat 08-057) for each carbon and
fiberglass ply on the repair area, excluding the filler plies. Make
sure that the breather fabric has the same dimensions as the porous
parting film.
D. Put the porous parting film on to the repair area, making sure that
it has an equal overlap around the repair area. Put the layers of
breather fabric on top of the porous parting film.
(2) Make sure that each strand connects the breather fabric with
the area around the silicon rubber sheet.
G. Put the non-porous parting film onto the repair area, making sure
that it has an equal overlap around the repair area. Put the
silicone rubber sheet on top of the non-porous parting film.
H. Put the heat blanket and breather cloth onto the repair area.
(2) Put the two sheets of breather cloth onto the repair area.
(3) Put the heat blanket on top of the breather cloth, making
sure that the heat blanket has an overlap all around the
repair area.
(1) Use nylon bagging film (CoMat 02-163) and sealant tape
(CoMat 08-051).
(2) Make sure that the vacuum bag has an overlap of approximately
2.0 in. (50,8 mm) around the breather cloth.
(3) Install the vacuum hose, from the suction pump, so that it
goes directly on to the breather cloth.
(4) Attach and seal the film to the cowl with the sealant tape.
D. Start to measure the cure time when the temperature gets to 190 oF
(88oC).
A. When the cure is completed, remove the lay-up materials from the
repair.
A. Make all contours of the repair area smooth with waterproof silicon
carbide abrasive paper (CoMat 05-021), making sure that there is no
edge between the repair area and the outer skin of the panel.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, (Ref. SRM 54-01-00) Composite Structure Tap Test,
to confirm that the repair is correctly bonded.
REPAIR 021
FAN COWL EXTERNAL PAINT DAMAGE REPAIR
(VRS2743/2744)
1. General
A. Standard Tools
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
B. Mix the primer base (CoMat 07-156), the primer converter (CoMat
07-157), and the thinner (CoMat 07-158) in accordance with the
manufacturers instructions. Let the mixture set for 30 minutes
before you use it.
C. Apply the primer to the damaged area within the masking tape
with either the spray equipment or a brush.
CAUTION: ALLOW THE PAINT TO DRY FOR 15 MINUTES BEFORE THE HEAT IS
APPLIED.
D. Cure the primer for one hour at 180º - 200ºF (82º - 93ºC) with
an explosion proof heat lamp.
A. Apply a 1.0 in. (25.4 mm) wide strip of (CoMat 02-178) masking
tape to the primed surface. Pull the tape from the primed
surface in one abrupt motion. If any of the primer is removed by
the tape, reject the primer coat and do step 4 followed by 6 and
7 again.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
D. When the paint is cured, remove the masking tape from around
the repair area.
A. Apply a 1.0 in. (25,4 mm) wide strip of masking tape to the
painted surface. Pull the tape from the painted surface in one
abrupt motion. If any of the paint is removed by the tape,
reject the paint coat and do step 4, followed by steps 6 through
9 again.
REPAIR 022
FAN COWL DRAINS MAST WALL DAMAGE REPAIR
(VRS2957)
1. General
B. This repair blends out the damaged area until it is smooth with
the rest of the drains mast.
2. Referenced Information
A. Standard Tools
C. Component Material
A. Repair the damage area in accordance with hand polish and blend
procedure (Ref. SPM Task 70-35-03-300-501).
B. Make sure that the maximum depth of the repair is not greater
than the maximum depth of the damage.
C. Make sure that the depth of the repair is zero at the edge of
the marked area.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
REPAIR 023
LEFT FAN COWL LATCH BEARING PLATE REPLACE
(VRS2740)
1. General
A. This repair may be used to replace the latch plate on the left
fan cowl oil filler and chip detector access panel.
2. Referenced Information
A. Standard Tools
C. Repair Parts
D. Component Material
(3) Put an Allen key into the pin to hold it stationary and
remove the collar with pliers.
(4) Make sure the holes in the fan cowl doors are not damaged.
(1) Make sure that the Hi-Lok pins and the washers are not
damaged or put out of shape.
(2) Keep the Hi-Lok pins and the washers. Discard the Hi-Lok
collars.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
B. Clean the new bearing plate and the repair area with
methylethylketone (CoMat 01-076) and lint-free cloth
(CoMat 02-099). Wipe the area with a clean piece of lint-free
cloth before the fluid dries.
(2) If the diameter of the holes are not within the limits
given, or if the holes are damaged, oversize fasteners
must be used.
A. Move the new bearing plate into position making sure that the
laminated shim is between the plate and the fan cowl door.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Examine the repair area to make sure that the bearing plate and
the fasteners are correctly installed. If the repair is
unsatisfactory, repeat the repair.
1. General.
A. This repair may be used to repair damage to the closing land on the
air start blow off door.
B. This repair removes the damaged area and installs carbon fibre
fill-in and repair plies.
2. Referenced Information.
A. Standard equipment
C. Special Tools
D. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Air-start/blow-off door Composite structure
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Mask round the repair area with teflon tape (CoMat 02-007).
Calculate the distance that the tape must be from the damage as
follows:
(1) Measure a minimum of 4.0 in. (101,6 mm) each side along the
panel land.
(2) On the inner surface, measure 4.2 in. (106,7 mm) from the
edge of the panel land.
(3) Measure along the outer skin contour, and make the two
corners of the marked area to an angle of 45 degrees and a
length of approximately 1.5 in. (38,1 mm).
(4) Use the marking pen (CoMat 06-131) to apply temporary marks
to the measured repair area.
(5) Carefully apply the teflon tape along the marks on the
measured repair area.
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE PANEL. DO NOT
USE A LIQUID WITH THE ABRASIVE PAPER.
C. Remove the surface protection treatment from the repair area with
waterproof abrasive paper (CoMat 05-021). Make the edges of the
repair area smooth, and also rub the external surface side of the
panel land.
(1) Find the center of the damaged area, measure 0.5 in.
(12,7 mm) each side along the panel land and make a mark.
(2) Measure 0.7 in. (17,8 mm) from the panel edge and make a mark
to show the panel land area.
B. Make the area smooth with waterproof abrasive paper (CoMat 05-021).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Dry the repair area. Use the heat lamp to keep the repair area of
the cowl at 176oF (80oC) for six hours. The repair materials must
be applied at the end of the six hours.
10. Prepare the fill-in and repair plies (Ref. Fig. 201).
(1) Wear lint-free gloves (CoMat 02-097) and cut eight pieces of
dry carbon fibre fabric (CoMat 08-058) 1.0 in. (25,4 mm)
larger all around (except at the panel edge) than the cut-out
repair area.
(1) Wear lint-free gloves (CoMat 02-097) and cut one piece of dry
carbon fibre fabric (CoMat 08-058) a minimum of 2.0 in.
(50,8 mm) larger all around (except at the panel edge) than
the cut-out repair area.
(1) Wear lint-free gloves (CoMat 02-097) and cut seven pieces of
dry carbon fibre fabric (CoMat 08-058), each piece 0.25 in.
(6,3 mm) larger all around (except at the panel edge) than
the previous piece.
(1) Wear lint-free gloves (CoMat 02-097) and cut one piece of
fiberglass fabric (CoMat 02-167) 0.75 in. (19,0 mm) larger
all around (except at the panel edge) than the largest repair
ply.
(4) Make sure that the backing plate has a good contour with the
panel land and a good overlap of the cut-out area.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
NOTE: After the plies are soaked, the remaining adhesive (if it is
kept cool) can be used in the installation process.
B. Soak the fiberglass and carbon fibre plies with the mixed adhesive.
(2) Apply adhesive to the two sides of each ply with the brush
(CoMat 02-087) and cover each ply with another sheet of non-
porous parting film.
(3) Use a roller to force the adhesive into each ply thoroughly.
C. Cut the fill-in ply and repair plies to their finished dimensions.
(1) Cut each fill-in ply to the same dimensions as the as the
cut-out area.
(2) Find a long side on each fill-in ply and cut two corners to a
radius of 0.25 in. (6,3 mm).
(3) Cut the first repair ply so that it extends 1.0 in. (25,4 mm)
from the three edges of the cut-out area.
(4) Find a long side and cut two corners approximately 0.5 in.
(12,7 mm) from the end at an angle of 45 degrees.
(5) Cut each subsequent repair ply 0.5 in. (12,7 mm) longer and
0.25 in. (6,3 mm) wider.
(6) Find a long side on each ply and cut two corners
approximately 0.5 in. (12,7 mm) from the end at an angle of
45 degrees.
(7) Cut the fiberglass sanding ply so that it extends 0.75 in.
(19,0 mm) from the three edges of the largest repair ply.
(8) Find a long side and cut two corners approximately 1.0 in.
(25,4 mm) from the end at an angle of 45 degrees.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Apply an equal layer of adhesive to the cut-out area and the edges
using a brush (CoMat 02-087)
(1) Remove the parting film from one side of the first fill-in
ply.
(2) Put the first fill-in ply, with the adhesive side down, in
the cut-out area. Align it with the edge of the panel land.
(3) Remove any unwanted adhesive and air from the ply with a
metal spatula.
(4) Remove the remaining parting film from the first fill-in
ply.
15. Install the repair plies and fiberglass sanding ply (Ref. Fig. 201).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) Remove one sheet of non-porous parting film from the first
repair ply.
(2) Put the first repair ply, with the adhesive side down, on the
repair area and align it with the panel edge, making sure
that it has a 1.0 in. (25,4 mm) overlap around the cut-out.
(3) Use the roller to remove air and unwanted adhesive from the
ply.
(4) Remove the remaining non-porous parting film from the first
repair ply.
(2) Put the fiberglass sanding ply, with the adhesive side down,
on the repair area and align it with the panel edge, making
sure that it has a 0.75 in. (19,0 mm) overlap around the last
carbon repair ply and adjacent to, but not on, the teflon
tape.
(3) Use the roller to remove air which is trapped in the adhesive
and to make the fiberglass ply smooth.
(4) Remove any unwanted adhesive from the teflon tape with a
clean metal spatula.
A. Get a heat blanket, which must be a minimum of 3.0 in. (76,2 mm)
larger all around than the repair area.
B. Cut the porous parting film (CoMat 02-169). Make sure that the film
is larger than the heat blanket and overlaps the last (fiberglass)
repair ply by at least 3.0 in. (76,2 mm) all around.
C. Cut nine sheets of the breather fabric (CoMat 08-057) into pieces
the same size as the porous parting film (Ref step B. above).
D. Put the porous parting film on to the repair area, making sure it
has an equal overlap around the repair area. Put the breather
fabric on top of the porous parting film.
F. Put four fiberglass tows onto the repair area using one strand of
the fiberglass fabric (CoMat 02-167) in each of four positions
around the repair. Each of the strands must connect the breather
fabric with the area around the silicone rubber sheet.
NOTE: With the fiberglass tows installed, gasses can not collect
below the silicone rubber sheet when the adhesive cures.
G. Put the non-porous parting film (Ref step E. above) onto the repair
area first. Make sure that it has an equal overlap around the
repair area. Put the silicone rubber sheet on top of the non-porous
parting film.
H. Cut two pieces of breather cloth (CoMat 02-166), at least 2.0 in.
(50,8 mm) larger on each side than the silicone rubber sheet. Put
the two pieces of the breather cloth on to the repair area. Put the
heat blanket on top of the breather cloth. The heat blanket must
have an overlap all around the repair area.
J. Put the nylon bagging film (CoMat 02-163) over the repair area so
that the bag overlaps the breather cloth by 2.0 in. (50,8 mm) all
around. Install the vacuum hose from the suction pump so that it
goes directly on to the breather cloth. Attach and seal the film to
the cowl with the sealant tape (CoMat 08-051).
A. Decrease the pressure in the repair area with the vacuum suction
pump. During the cure, the reading must show at least 25.0 in.
(635,0 mm) of mercury.
B. Increase the temperature and keep at 190 o - 210oF (88o - 99oC) for
220 minutes. The rate of increase and subsequent decrease must not
be faster than 5.4oF (3 oC) in each minute. Start to measure the
time for the adhesive to cure when the temperature gets to 190 oF
(88oC).
A. When the cure process is completed, remove the layup materials from
the repair.
(1) Measure between 0.12 - 0.16 in. (3,0 - 4,1 mm) from the
internal surface and make a mark.
(2) Chamfer along the edge of the internal surface, in the hinge
area, at an angle of 45 degrees.
(1) Use the latch as a template and make a mark for each fastener
hole.
(2) Temporarily close the access panel, and make sure that the
aerodynamic contour on the external surface is correct and
that the hinge area does not catch.
F. Remove all unwanted material from the area with a suction cleaner.
G. Use a brush (CoMat 02-087) and apply epoxy varnish (CoMat 07-085)
to the cut and chamfered edges, and let the varnish dry.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, SRM 54-01-00 Composite Structure Tap Test, to
confirm that the repair is correctly bonded.
1. General.
A. This repair may be used to repair surface damage to the main area
of the access panels of the right fan cowl.
B. This repair fills the damaged area with epoxy adhesive mixed with
microballoons and installs carbon fibre repair plies and a
fiberglass sanding ply.
C. The damage must be a sufficient distance from the edge of the panel
to install all the repair plies and sanding ply. Refer to Para. 6A
and Fig. 201 and 202. The damage can be nearer to the edge if less
plies are damaged. There must be a minimum of 10.0 in. (254,0 mm)
between damaged areas. The damage must not go through more than 5
composite plies.
D. The orientation of the carbon fibre repair plies must follow the
sequence:
(0-90)/(±45)/(±45)/(0-90)/(0-90)/( ±45)/
(±45)/(0-90)/(0-90)/(±45)/(±45)/(0-90).
2. Referenced Information.
A. Standard equipment
B. Special Tools
D. Repair parts
None.
E. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Right fan cowl
access panels Composite structure
B. Make a note of the depth of the damage, and calculate the number of
plies necessary to repair the damage as follows:
If in doubt on the depth of the damage, install one more repair ply
(for example - if you are not sure if the depth is 0.030 in.
(0,76 mm) or 0.031 in. (0,79 mm), use three repair plies).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Mask around the repair area with teflon tape (CoMat 02-007).
Calculate the distance that the tape must be from the damage as
follows:
(1) Measure 1.0 in. (25,4 mm) from the edge of the damage for
each ply of the panel which is damaged, and add 0.75 in.
(19,1 mm) for an outer layer of fiberglass fabric
(CoMat 02-167).
(2) Carefully apply the teflon tape so that it goes around the
area in a 2.0 in. (50,8 mm) wide strip.
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. DO NOT
USE A LIQUID WITH THE ABRASIVE PAPER.
B. Make the surface of the repair area rough with waterproof abrasive
paper (CoMat 05-021), making sure to remove the sharp edges of the
damage.
(1) Wear lint-free gloves (CoMat 02-097) and cut one piece of dry
carbon fibre fabric (CoMat 08-059) so that it has a 2.0 in.
(50,8 mm) overlap around the damage (Ref. step 1.D.).
(1) Wear lint-free gloves (CoMat 02-097) and use dry carbon
fibre fabric (CoMat 08-059), and cut each subsequent repair
ply
2.0 in. (50,8 mm) longer and 2.0 in. (50,8 mm) wider. There
must be one repair ply for each ply of the panel which is
damaged (Ref. step 1.D.).
(1) Wear lint-free gloves (CoMat 02-097) and cut one piece of
fiberglass fabric so it has a 1.0 in. (25,4 mm) overlap
around the area identified by the teflon tape.
A. Dry the repair area. Use the heat lamp to keep the repair area of
the panel at 176oF (80oC) for six hours. The repair materials must
be applied immediately at the end of the six hours.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Soak the carbon fibre and fiberglass plies with the mixed adhesive.
(2) Apply the adhesive to each ply with the brush (CoMat 02-087)
and cover each ply with another sheet of non-porous parting
film.
(3) Use the roller to force the adhesive into each ply
thoroughly.
(1) Cut approximately 1.0 in. (25,4 mm) off each edge of the
plies.
(2) Make sure the first ply has a 1.0 in. (25,4 mm) overlap
around the damage.
(3) Make sure that each subsequent ply extends 1.0 in. (25,4 mm)
more around the damage.
(5) Cut the fiberglass ply so that it is the same shape as the
area identified by the teflon tape (CoMat 02-007).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Fill the damaged area of the panel with the adhesive using a clean
metal spatula. Make sure the mixture is level with the top carbon
ply of the panel.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) Remove one sheet of non-porous parting film from the first
repair ply.
(2) Put the first repair ply, with the adhesive side down, onto
the repair area, making sure that the damage is located in
the center of the ply.
(3) Use the roller to remove air and unwanted adhesive from the
ply.
(4) Remove the remaining non-porous parting film from the first
repair ply.
(1) Remove one sheet of non-porous parting film from the second
repair ply.
(2) Put the second repair ply, with the adhesive side down, onto
the repair area, making sure that it has an equal overlap
around the first repair ply.
(3) Use the roller to remove air and unwanted adhesive from the
ply.
(4) Remove the remaining non-porous parting film from the first
repair ply.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.D.
(1) Repeat step C. above for the fiberglass ply, making sure that
it has an equal overlap around the last carbon fibre repair
ply, and is adjacent to, but not touching the teflon tape.
F. Remove unwanted adhesive from the teflon tape with a clean metal
spatula.
A. Get a heat blanket, which must be larger all around than the repair
area.
C. Cut the breather fabric (CoMat 08-057) into sheets the same size as
the porous parting film (Ref step B. above). The number of sheets
of breather fabric must equal the number of plies used in the
repair.
D. Put the porous parting film onto the repair area, making sure that
it has an equal overlap around the repair area. Put the layers of
breather fabric on top of the porous parting film. Use one layer of
breather fabric for each carbon ply used in the repair.
(2) Make sure that each strand connects the breather fabric with
the area around the silicone rubber sheet.
NOTE: With the fiberglass tows installed, gasses can not collect
below the silicone rubber sheet when the adhesive cures.
G. Put the non-porous parting film (Ref step E. above) onto the repair
area first, making sure that it has an equal overlap around the
repair area. Put the silicone rubber sheet on top of the non-porous
parting film.
H. Put the heat blanket and breather cloth on to the repair area.
(2) Put the two pieces of the breather cloth on to the repair
area.
(3) Put the heat blanket on top of the breather cloth, making
sure that the heat blanket has an overlap all around the
repair area.
(1) Use nylon bagging film (CoMat 02-163) and sealant tape (CoMat
08-051).
(2) Make sure that the vacuum bag has an overlap of approximately
by 2.0 in. (50,8 mm) around the breather cloth.
(3) Install the vacuum hose, from the suction pump, so that it
goes directly on to the breather cloth.
A. Use the vacuum pump to decrease the pressure in the repair area,
making sure it gives an indication of at least 25.0 in. (635,0 mm)
of mercury while the adhesive cures.
B. Use the heat blanket to keep the temperature of the repair area at
190o - 210oF (88o - 99oC) for 220 minutes.
D. Start to measure the cure time when the temperature gets to 190 oF
(88oC).
A. When the cure process is completed, remove the layup materials from
the repair.
A. Remove all unwanted material from the repair area with a suction
cleaner.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, SRM 54-01-00 Composite Structure Tap Test, to
confirm that the repair is correctly bonded.
REPAIR 026
LEFT FAN COWL LATCH BEARING PLATE REPLACE
(VRS2721)
1. General
B. This repair can only be done with the repair for replacing the
hinges. (Ref Engine Manual TASK 71-13-17-300-004).
2. Referenced Information
A. Standard Tools
One-shot drills
Suction cleaner
Standard workshop tools and equipment
C. Repair Parts
D. Component Material
5. Examine the Air Start Door and the Hinge (Ref Figure 201)
(1) The diameter of the holes must not be greater than 0.253
in. (6.43 mm).
B. Use a marking pen (Comat 06-131) to make a mark beside each hole
that has a diameter between 0.193 to 0.253 in. (4.90 to 6.43
mm).
(2) Make sure that the diameter of the holes is between 0.250
to 0.253 in. (6.35 to 6.43 mm).
B. Use temporary fasteners to hold the air start door and the
hinge together in the correct position.
(2) Use standard tools to remove all burrs and sharp edges.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Clean the interfaces between the air start door and the hinge
with methylethylketone (coMat 01-076) and lint-free cloth
(Comat 02-099). Wipe the area dry.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
(2) Let the parts dry in the air for 10 minutes before they
are assembled.
B. Align the holes in the hinge with the holes in the air start
door.
(1) Make sure that each bolt is installed into the correct
diameter of hole.
(1) Use a ring wrench to turn the collars and an allen key to
hold the bolts.
(3) Second, tighten each of the collars until the hexagon nut
breaks off of the collar.
NOTE: The procedure is the same for the upper and the lower
hinge.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Clean the hinge and the air start door with methylethylketone
(CoMat 01-076) and lint-free cloth (CoMat 02-099). Wipe the
area dry.
A. Make a visual inspection to make sure that the repair has been
done in accordance with these procedures.
HI-LOK/HI-LITE COLLAR
LOWER HI-LOK/HI-LITE
HINGE BOLT
HI-LOK/HI-LITE COLLAR
sh00014297B
REPAIR 028
AIR-START BLOW-OFF DOOR HINGE REPAIR
(VRS2950)
1. General
A. This procedure may be used to replace the hinge on the air start
blow off door.
2. Referenced Information
A. Standard Tools
C. Repair Parts
D. Component Material
(2) Put an Allen key into the pin to hold it stationary and
remove the collar with pliers.
(3) Remove the washer if fitted from the pin. Push the pin out
of the air start door.
(4) Discard the pins, the washers if fitted, the collars and
the hinge.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
B. Clean the interfaces between the air start door and the hinge
with methylethylketone (CoMat 01-076) and lint-free cloth
(CoMat 02-099). Wipe the area dry.
7. Examine the Air Start door and the Hinge (Ref Figure 201)
(2) If the diameter of the holes are not within the limits
given, or if the holes are damaged, oversize fasteners
must be used (Ref. SRM REPAIR 026).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
(2) Let the parts dry in the air for 10 minutes before they
are assembled.
B. Align the holes in the hinge with the holes in the air start
door.
(1) Use a ring wrench to turn the collars and an Allen key to
hold the bolts.
(3) Second, tighten each of the collars until the hexagon nut
breaks off of the collar.
NOTE: The procedure is the same for the upper and the lower
hinge.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Clean the hinge and the air start door with methylethylketone
(CoMat 01-076) and lint-free cloth (CoMat 02-099). Wipe the
area dry.
A. Make a visual inspection to make sure that the repair has been
done in accordance with these procedures.
HI-LOK/HI-LITE COLLAR
LOWER HI-LOK/HI-LITE
HINGE BOLT
HI-LOK/HI-LITE COLLAR
sh00014297B
REPAIR 029
LEFT FAN COWL ACCESS PANELS INSTALL OVERSIZE FASTENERS
(VRS2741)
1. General
B. This repair can only be done with the repair for replacing the
hinges. (Ref Engine Manual TASK 71-13-14-300-002).
2. Referenced Information
A. Standard Tools
One-shot drills
Suction cleaner
Standard workshop tools and equipment
C. Repair Parts
D. Component Material
5. Examine the Oil Filler Door and the Hinge (Ref Figure 201)
(1) The diameter of the holes must not be greater than 0.206
in. (5.23 mm).
B. Use a marking pen (CoMat 06-131) to make a mark beside each hole
that has a diameter between 0.200 to 0.206 in. (5.08 to 5.23
mm).
(2) Make sure that the diameter of the holes is between 0.202
to 0.206 in. (5.13 to 5.23 mm).
B. Use temporary fasteners to hold the oil filler door and the
hinge together in the correct position.
(2) Use standard tools to remove all burrs and sharp edges.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Clean the interfaces between the oil filler door and the hinge
with methylethylketone (CoMat 01-076) and lint-free cloth
(CoMat 02-099). Wipe the area dry.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
(2) Let the parts dry in the air for 10 minutes before they
are assembled.
B. Align the holes in the hinge with the holes in the oil filler
door.
(1) Make sure that each bolt is installed into the correct
diameter of hole.
(2) Put the collars and the washers onto the bolts.
(1) Use a ring wrench to turn the collars and an Allen key to
hold the bolts.
(3) Second, tighten each of the collars until the hexagon nut
breaks off of the collar.
NOTE: The procedure is the same for the upper and the lower
hinge.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Clean the hinge and the oil filler door with methylethylketone
(CoMat 01-076) and lint-free cloth (CoMat 02-099). Wipe the
area dry.
A. Make a visual inspection to make sure that the repair has been
done in accordance with these procedures.
REPAIR 030
OIL FILLER DOOR HINGE REPAIR
(VRS2849)
1. General
2. Referenced Information
A. Standard Tools
C. Repair Parts
D. Component Material
(2) Put an Allen key into the pin to hold it stationary and
remove the collar with pliers.
(3) Remove the washer if fitted from the pin. Push the pin out
of the oil filler door.
(4) Discard the pins, the washers if fitted, the collars and
the hinge.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
B. Clean the interfaces between the oil filler door and the hinge
with methylethylketone (CoMat 01-076) and lint-free cloth
(CoMat 02-099). Wipe the area dry.
7. Examine the Oil Filler Door and the Hinge (Ref Figure 201)
(2) If the diameter of the holes are not within the limits
given, or if the holes are damaged, oversize fasteners
must be used (Ref. SRM REPAIR 029).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
(2) Let the parts dry in the air for 10 minutes before they
are assembled.
B. Align the holes in the hinge with the holes in the oil filler
door.
(1) Use a ring wrench to turn the collars and an Allen key to
hold the bolts.
(3) Second, tighten each of the collars until the hexagon nut
breaks off of the collar.
(1) Do again steps A. thru D. Where you see oil filler door
read left fan cowl.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Clean the hinge and the oil filler door with methylethylketone
(CoMat 01-076) and lint-free cloth (CoMat 02-099). Wipe the
area dry.
A. Make a visual inspection to make sure that the repair has been
done in accordance with these procedures.
REPAIR 031
FAN COWLS-LIGHTENING STRIKE PROTECTION REPAIR
(VRS2748/2749)
1. General
C. This repair removes the layer of resin around the damaged area
and installs a wire-mesh patch.
2. Referenced Information
TASK 70-38-07-380-501
A. Standard Tools
C. Component Material
A. The damage must be less than 12.0 in. (304.8 mm) wide. Make sure
the damage is only to the lightening strike protection and not
the plies below.
A. Use the CoMat 06-131 marking pen and make a mark, the smallest
symmetrical shape possible, around all the areas of damage.
B. Apply the CoMat 02-007 teflon tape in 2.0 inch (50.8 mm) wide
strips, approximately 1.25 in. (31.75 mm) from the mark around
the damaged area.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Use a suction cleaner and remove any unwanted material from the
repair area.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
(2) Use the CoMat 02-087 brush and apply the resin to each
side of the repair patch.
(5) Use the roller to force the resin into the repair patch.
Make sure that the repair patch is fully soaked.
(2) Cut the repair patch until it is the same shape as the
area identified by the teflon tape.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
(2) Put the repair patch, with the resin side down, on the
repair patch. Make sure the repair patch does not overlap
the Teflon tape.
(5) Remove the teflon tape from around the repair area.
A. Get a heat blanket that is larger all around than the repair
area.
(1) Use the CoMat 02-007 Teflon tape and attach not less than
two temperature probes.
(2) Make sure the temperature probes do not touch the repair
patch.
C. Put the porous parting film and the breather fabric on the
repair area.
(3) Put the sheet of porous parting film on the repair patch
with an equal overlap all around.
D. Put the non-porous parting film, the silicone rubber sheet and
the breather cloth on the repair area.
(6) Put the two sheets of CoMat 02-166 breather cloth on top
of the sheet of silicone rubber with an equal overlap all
around.
E. Put the heat blanket on top of the two sheets of breather cloth
with an equal overlap all around.
(1) Cut the nylon bagging film CoMat 02-163 approximately 2.0
in. (50.8 mm) larger all around than the breather cloth.
(2) Install the suction hose, from the suction pump, through
the nylon bagging film and directly onto the breather
cloth.
(3) Use the sealant tape CoMat 08-051 and attach and seal the
nylon bagging film to the outer skin.
A. Use the vacuum suction pump and decrease the pressure in the
repair area.
NOTE: Make sure the pressure indication is not more than 25.0
in. (635.0 mm) of mercury during the resin cure
process.
B. Use the blanket to raise and keep the temperature of the repair
area between 194º and 200ºF (90º and 93ºC) for 220 minutes.
NOTE: The cure time starts when the temperature gets to 194ºF
(90ºC).
A. Remove all the repair materials from around the repair patch
when the cure process is completed.
A. Use a suction cleaner and remove any unwanted material from the
repair area.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CANCELLATION NOTICE
1. General
2. Referenced Information
A. Standard Equipment
B. Special Tools
D. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Left Fan Cowl Composite Structure
Right Fan Cowl Composite Structure
A. The repair area is prepared to re-bond all the damaged plies in the
damage area.
(1) Put a strip of masking tape (CoMat 02-007) around the damaged
area and 1.5 in. (38.1 mm) rearward of the leading edge.
CAUTION: BE CAREFUL WHEN YOU MAKE THE SURFACE OF THE REPAIR AREA
ROUGH. DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL.
DO NOT USE A LIQUID WITH THE ABRASIVE PAPER.
(2) Lightly rub the damaged area with waterproof silicon carbide
abrasive paper (CoMat 05-019) to make the surface rough.
NOTE: Make sure that all the paint is removed from the repair area.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) Use a heat lamp and dry the repair area at a temperature of
140oF (60oC) for 3 hours.
NOTE: Make sure that the structural adhesive is not applied until
the repair area is cool.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
NOTE: The milled glass fibres are not required if the alternative
structural adhesive EA934NA is used.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) Use the brush (CoMat 02-087) and apply a 0.015 in. (0.38 mm)
layer of structural adhesive to the repair area.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) Remove the damaged area from the leading edge as follows:
(c) Remove an area of not more than 1.5 in. (38.1 mm) wide
and with a maximum taper of 0.020 in. (0.51 mm).
(1) The damage to the forward edge of the repair area must be
less than 5 plies/0.075 in. (1.91 mm) thick.
(b) Remove an area of not more than 0.25 in. (6.35 m) wide
and with a maximum taper of 5 plies/0.075 in. (1.91 mm).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) Use the brush (CoMat 02-087) and apply a 0.005 in. (0.13 mm)
layer of structural adhesive to the repair area.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Using the sonic test equipment (1N20444) and the tap test method,
SRM 54-01-00 Composite Structure Tap Test, examine the repair and
make sure that the structural adhesive has bonded correctly.
A. Make a visual inspection to make sure that the repair has been done
in accordance with these procedures.
1. General.
B. This repair removes the damaged area and installs carbon fibre
filler plies, a carbon fibre patch and a fiberglass sanding ply.
C. This repair can only be done in the areas indicated, and must not
be more than 1.0 in. (25,4 mm) wide. The damage on the hinged edge
must not be more than 0.5 in. (12,7 mm), and 0.6 in. (15,2 mm) long
on the other edges. The damage must be a sufficient distance from
the edge of the panel, fittings, brackets, hinges and flanges to
install all the repair plies and the sanding ply on the outer
surface. Only one repair for each land is permitted. Refer to
Figures 201 and 202.
D. Examine the fan cowl lands for signs of damage. If the fan cowl is
damaged, refer to REPAIR No. 007 (VRS2839/VRS2923).
E. The orientation of the carbon fibre repair plies must follow the
sequence as follows:
Filler Plies - (0-90)/(±45)/(±45)/(0-90)/(0-90)/(±45)/(±45)/(0-90)
Repair Plies - (0-90)/(±45)/(±45)/(0-90)/(0-90)/(±45)/(±45)/(0-90)
2. Referenced Information.
A. Standard equipment
B. Special Tools
D. Repair parts
None
E. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Oil filler door Composite structure
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Mask around the repair area with 2.0 in. (50,8 mm) wide strips of
teflon tape (CoMat 02-007). Calculate the distance that the tape
must be from the damage as follows:
(1) Measure a minimum of 8.75 in. (222,3 mm) each side along the
door land.
(2) On the external surface, measure 8.75 in. (222,3 mm), plus
the damage length (0.5 in. (12,7 mm) or 0.6 in. (15,2 mm)
maximum) from the door edge.
(4) Carefully apply the teflon tape along the marks on the
measured repair area.
CAUTION: BE CAREFUL WHEN YOU MAKE THE SURFACE OF THE REPAIR AREA
ROUGH. DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL.
DO NOT USE A LIQUID WITH THE ABRASIVE PAPER.
(1) Find the centre of the damaged area, measure 0.5 in.
(12,7 mm) each side along the door land and make a mark.
(2) Measure 0.6 in. (15,2 mm) from the door edge and make a mark
to show the door land area. On the hinged area, measure
0.5 in. (12,7 mm).
A. Let the repair area dry for 6 hours at 176oF (80oC) using heat
lamps.
10. Cut the filler and repair plies (Ref. Fig. 202).
(1) Wear lint-free gloves (CoMat 02-097) and cut eight pieces of
dry carbon fibre fabric (CoMat 08-059) 1.0 in. (25,4 mm)
larger all around (except at the door edge) than the cut-out
repair area.
NOTE: Make sure that the ply fibres follow the orientation as
given in step 1.D.
(1) Wear lint-free gloves (CoMat 02-097) and cut one piece of dry
carbon fibre fabric (CoMat 08-059) a minimum of 2.0 in.
(50,8 mm) larger all around (except at the door edge) than
the cut-out repair area.
NOTE: Make sure that the ply fibres follow the orientation as
given in step 1.D.
(1) Wear lint-free gloves (CoMat 02-097) and cut seven pieces of
dry carbon fibre fabric (CoMat 08-059), each piece 1.0 in.
(25,4 mm) larger all around (except at the door edge) than
the previous piece.
NOTE: Make sure that the ply fibres follow the orientation as
given in step 1.D.
(1) Wear lint-free gloves (CoMat 02-097) and cut one piece of
fiberglass fabric (CoMat 02-167) so it is 0.75 in. (19,0 mm)
larger all around (except at the door edge) than the largest
ply.
(4) Make sure that the backing plate has a good contour with the
door land and a good overlap of the cut-out area.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Soak the fiberglass and the carbon plies with the adhesive.
(2) Apply the adhesive to the two sides of each ply with the
brush (CoMat 02-087) and put a second sheet of non-porous
parting film on each ply.
(3) Use the roller to force the adhesive into each ply
thoroughly.
(1) Cut each filler ply to the same dimensions as the cut-out
area.
(2) Find a long side on each ply and cut two corners to a radius
of 0.25 in. (6,3 mm).
(1) Cut the first repair ply 1.0 in. (25,4 mm) larger all around
(except at the door edge) than the cut-out repair area.
(2) Find a long side on the first repair ply and cut two corners
approximately 0.5 in. (12,7 mm) from the end at an angle of
45 degrees.
(3) Cut each subsequent repair ply 2.0 in. (50,8 mm) longer and
1.0 in. (25,4 mm) wider.
(4) Find a long side on each ply and cut two corners
approximately 1.0 in. (25,4 mm) from the end at an angle of
45 degrees.
(1) Cut the fiberglass sanding ply 0.75 in. (19,0 mm) larger all
around (except at the door edge) than the last repair ply, so
that it has the same shape as the area identified by the
teflon tape.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Apply an equal level of the adhesive mix to the cut-out area and
the edges using a brush (CoMat 02-087).
(1) Remove the parting film from one side of the first filler
ply.
(2) Put the first filler ply, with the adhesive side down, in the
cut-out area, and align it with the edge of the door land.
NOTE: Make sure that the ply fibres follow the orientation as
given in step 1.D.
(3) Remove air and unwanted adhesive from the ply with a clean
metal spatula.
(4) Remove the remaining parting film from the first filler ply.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) Remove the non-porous parting film (CoMat 02-367) from one
side of the first repair ply.
(2) Put the first repair ply, with the adhesive side down, onto
the repair area and align it with the door edge, making sure
that it has an equal 1.0 in. (25,4 mm) overlap around the
repair area.
NOTE: Make sure that the ply fibres follow the orientation as
given in step 1.D.
(4) Remove the remaining non-porous parting film from the first
repair ply.
C. Put the seven subsequent carbon repair plies on to the repair area.
(1) Repeat step B. above for the remaining repair plies, making
sure each subsequent repair ply has an equal 1.0 in.
(25,4 mm) overlap around the previous one.
(1) Remove the non-porous parting film from one side of the
fiberglass ply.
(2) Put the fiberglass ply, with the adhesive side down, on to
the repair area making sure that fiberglass ply has an equal
overlap of 0.75 in. (19,0 mm) around the last carbon repair
ply and touches the teflon tape.
(3) Use the roller to remove air which is caught in the trapped
and to make the fiberglass ply smooth.
(4) Remove the unwanted adhesive from the teflon tape with a
clean metal spatula.
A. Get a heat blanket, which must be larger all around than the repair
area.
B. Cut a sheet of porous parting film (CoMat 02-169) making sure that
it is larger than the heat blanket and has an overlap of at least
3.0 in. (76.2 m) around the fiberglass ply.
C. Cut one sheet of breather fabric (CoMat 08-057) for each carbon and
fiberglass ply on the repair area. Make sure that the breather
fabric has the same dimensions as the porous parting film.
D. Put the porous parting film on to the repair area, making sure that
it has an equal overlap around the repair area. Put the layers of
breather fabric on top of the porous parting film.
(2) Make sure that each strand connects the breather fabric with
the area around the silicon rubber sheet.
G. Put the non-porous parting film on to the repair area, making sure
that it has an equal overlap around the repair area. Put the
silicone rubber sheet on top of the non-porous parting film.
H. Put the heat blanket and breather cloth on to the repair area.
(2) Put the two sheets of breather cloth on to the repair area.
(3) Put the heat blanket on top of the breather cloth, making
sure that the heat blanket has an overlap all around the
repair area.
(1) Use nylon bagging film (CoMat 02-163) and sealant tape
(CoMat 08-051).
(2) Make sure that the bagging film is approximately four times
larger than the door.
(3) Make sure that the vacuum bag has an overlap of approximately
2.00 in. (50.8 mm) around the breather cloth.
(4) Install the vacuum hose, from the suction pump, so that it
goes directly on to the breather cloth.
(5) Attach and seal the bagging film to the cowl with the sealant
tape (CoMat 08-051).
A. Use the vacuum suction pump to decrease the pressure in the repair
area, making sure it gives an indication of at least 25.0 in.
(635.0 mm) of mercury while the adhesive cures.
B. Use the heat blanket to keep the temperature of the repair area at
190o - 210oF (88o - 99oC) for 220 minutes.
D. Start to measure the cure time when the temperature reaches 190oF
(88oC).
(1) Measure between 0.12 - 0.16 in. (3,0 - 4,0 mm) from the
internal surface and make a mark.
(2) Chamfer the hinge area along the edge of the internal surface
at an angle of 45 degrees.
(1) Use the latch as a template and make a mark for the fastener
hole(s).
(1) Use the latch as a template and make a mark for the latch
opening.
(2) Remove the material from the latch opening as necessary using
standard workshop tools.
(1) Measure approximately 0.35 in. (8,9 mm) from the door edge
and apply teflon tape (CoMat 02-007).
(2) Radius chamfer the repair plies and the sanding ply.
(2) Close the access door, and make sure that the aerodynamic
contour on the external surface is correct and the hinge area
does not catch.
A. Use a brush (CoMat 02-087) and apply epoxy varnish (CoMat 07-085)
to the cut and chamfered edges, and let the varnish dry.
NOTE: Use longer fasteners if necessary, and make sure that they
are properly secured.
A. Remove all unwanted material from the repair area with a suction
cleaner.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Make a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, SRM 54-01-00 Composite Structure Tap Test, to
confirm that the repair is correctly bonded.
1. General.
B. This repair fills the damaged area with epoxy adhesive mixed with
microballoons and installs carbon fibre repair plies and a
fiberglass sanding ply.
C. The damage must be a sufficient distance from the edge of the panel
to install all the repair plies and sanding ply. Refer to Para. 6A
and Fig. 201 and 202. The damage can be nearer to the edge if less
plies are damaged. There must be a minimum of 10.0 in. (254,0 mm)
between damaged areas. The damage on the Oil Filler Door must not
go through more than 3 plies on the outer and the inner surfaces.
The damage must be a sufficient distance from the edge of the
panel, fittings, brackets, hinges and flanges to install all the
repair plies and the sanding ply.
2. Referenced Information.
A. Standard equipment
B. Special Tools
D. Repair parts
None.
E. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Left fan cowl Composite structure
oil filler door
A. Referring to Fig. 202 examine the repair area to assess the amount
of damage and, using the standard workshop tools, measure the depth
of the damage. Do this in several places where the extent of the
damage permits. From this information the number of repair plies
should be calculated as follows:
Where doubt can arise over the exact magnitude of the damage
penetration, i.e. deciding between 0.030in. (0,41 mm) and 0.031in.
(0,79 mm), assume the larger figure as the criteria for selecting
the number of repair plies to use. That is, 3 plies rather than 2,
for this example. If the damage goes through the panel, refer to
Goodrich.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the repair area with the methylethylketone (CoMat 01-076) and
lint free cloth (CoMat 02-099). Wipe the area with a clean piece of
lint free cloth before the fluid dries.
A. Apply the teflon tape (CoMat 02-007) to the repair area. Calculate
the distance that the tape must be from the damage as follows:
(1) Measure 1.0 in. (25,4 mm) from the edge of the damage for
each ply of the panel (ref. step 4.), and add 0.75 in.
(19,05 mm) for an outer layer of fiberglass fabric
(CoMat 02-167).
(2) Carefully apply the teflon tape so that it goes around the
area in a 2.0 in. (50,8 mm) wide strip.
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. DO NOT
USE A LIQUID WITH THE ABRASIVE PAPER.
B. Make the surface of the repair area rough and remove the sharp
edges from the damage with the abrasive paper (CoMat 05-021).
A. Cut the first repair ply so that it has a 2.0in. (50,8 mm) overlap
around the damage. Use carbon fabric (CoMat 08-059) and lint free
gloves (CoMat 02-097). To prevent fraying, the plies may be cut to
the finished dimensions after soaking in adhesive (Ref. steps 1.D
and 9.C).
B. Cut the remaining repair plies if they are required using the
carbon fabric and lint free gloves. Cut each subsequent repair ply
2.0in. (50,8 mm) longer and 2.0in. (50,8 mm) wider. There must be a
repair ply for each ply of the panel which is damaged and these
must be covered by a single fiberglass ply (CoMat 02-167). To
prevent fraying, the plies may be cut to the finished dimensions
after soaking in adhesive (Ref. steps 1.D and 9.C).
A. Use heat lamps to dry the repair area. Keep the temperature at 176oF
(80oC) for six hours. The repair materials must be applied
immediately at the end of the six hours.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
NOTE: After the plies are soaked, the remaining adhesive is used on
the repair area (Ref. step 12.).
C. Cut approximately 1.0 in. (25,4 mm) off each edge of the plies.
Make sure the first ply has a 1.0 in. (25,4 mm) overlap around the
damage. The overlap for each subsequent ply must be 1.0 in.
(25,4 mm). Cut the corners of the repair plies to an angle of
approximately 45 degrees with a length of approximately 0.5 in.
(12,7 mm). Cut the fiberglass ply to the shape defined by the
teflon tape (CoMat 02-007).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Fill the damaged area of the panel with the mixture using a clean
metal spatula. The filled damage must be level with the top carbon
fibre ply of the panel.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Remove the parting film from one side of the first repair ply and
position the ply over the damage with the adhesive side down. Make
sure the damage is located in the center of the ply. Use the roller
to remove air caught in the adhesive. Remove the remaining parting
film.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.D.
C. Remove the parting film from one side of the second repair ply (if
it is required) and position it over the repair area with the
adhesive side down. Make sure it has an equal overlap around the
first ply. Use the roller to remove the air caught in the adhesive.
Remove the remaining parting film.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.D.
NOTE: The fiberglass (sanding) ply must touch the teflon tape
(CoMat 02-007) all around.
E. Remove unwanted adhesive from the teflon tape with a clean metal
spatula.
B. Cut the porous parting film (CoMat 02-169). Make sure that the film
is larger than the heat blanket and overlaps the last (fiberglass)
repair ply by at least 3.0 in. (76,2 mm) all around.
C. Cut the breather fabric (CoMat 08-057) into pieces the same size as
the porous parting film (Ref step B. above). The number of pieces
must equal the number of plies used in the repair.
D. Put the porous parting film on to the repair area so that it has an
equal overlap. Put the breather fabric on top of the porous parting
film. Use one layer of breather fabric for each repair ply used.
F. Put four fiberglass tows onto the repair area using one strand of
the fiberglass fabric (CoMat 02-167) in each of four positions
around the repair. Each of the strands must connect the breather
fabric with the area around the silicone rubber sheet.
NOTE: With the fiberglass tows installed, gasses can not collect
below the silicone rubber sheet when the adhesive cures.
G. Put the non-porous parting film (Ref step E. above) onto the repair
area first. Make sure that it has an equal overlap around the
repair area. Put the silicone rubber sheet on top of the non-porous
parting film.
H. Cut two pieces of breather cloth (CoMat 02-166), at least 2.0 in.
(50,8 mm) larger on each side than the silicone rubber sheet. Put
the two pieces of the breather cloth on to the repair area. Put the
heat blanket on top of the breather cloth. The heat blanket must
have an overlap all around the repair area.
J. Put the nylon bagging film (CoMat 02-163) over the repair area so
that the bag overlaps the breather cloth by 2.0 in. (50,8 mm) all
around. Install the vacuum hose from the suction pump so that it
goes directly on to the breather cloth. Attach and seal the film to
the bulkhead with the sealant tape (CoMat 08-051).
A. Decrease the pressure in the repair area with the vacuum suction
pump. During the cure, the reading must show at least 25.0 in.
(635,0 mm) of mercury.
B. Increase the temperature and keep at 190o - 210oF (88o - 99oC) for
220 minutes. The rate of increase and subsequent decrease must not
be faster than 5.4oF (3oC) in each minute. Start to measure the time
for the adhesive to cure when the temperature gets to 190oF (88oC).
A. When the cure process is completed, remove the layup materials from
the repair area.
A. Make the repair area smooth. The contours of the repair area must
be smooth and there must not be an edge or step, between the repair
area and the outer skin of the door. Use the abrasive paper
(CoMat 05-021).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, SRM 54-01-00 Composite Structure Tap Test, to
confirm that the repair is correctly bonded.
1. General
B. This repair fills the damaged area with epoxy adhesive mixed with
microballoons and installs carbon fiber repair plies and a
fiberglass sanding ply.
Ply orientation is given from the outer most ply to the inner.
2. Referenced Information
A. Standard equipment
C. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Left Fan Cowl
Oil filler door Composite structure
A. Examine the damaged area to assess the amount of damage and, using
the standard workshop tools, measure the depth of the damage. Do
this in several places where the extent of the damage permits.
From this information the number of repair plies should be
calculated as follows:
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Mask around the repair area with 2.0 in. (50.8 mm) wide strips of
teflon tape (CoMat 02-007). Calculate the distance that the tape
must be from the damage as follows:
(1) Measure 1.0 in. (25.4 mm) from the edge of the damage for
each ply of the cowl which is damaged.
(2) Add 0.75 in. (19.05 mm) for an outer layer of fiberglass
fabric (CoMat 02-167).
CAUTION: BE CAREFUL WHEN YOU MAKE THE SURFACE OF THE REPAIR AREA
ROUGH. DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL.
DO NOT USE A LIQUID WITH THE ABRASIVE PAPER.
B. Remove the sharp edges from the damage and the lightning strike
protection over the repair area. Make the surface of the repair
area rough with waterproof abrasive paper (CoMat 05-021).
A. Wear lint-free gloves (CoMat 02-097) and cut one piece of dry
carbon fibre fabric (CoMat 08-059) so that it has a 2.0 in.
(50.8 mm) overlap around the damaged area.
B. Wear lint free gloves (CoMat 02-097) and cut the second repair ply
(if necessary) from dry carbon fibre fabric (CoMat 08-059) 2.0 in.
(50.8 mm)larger all around than the previous piece. Cut one repair
ply for each ply of the cowl which is damaged.
C. Wear lint free gloves (CoMat 02-097) and cut one piece of
fiberglass fabric (CoMat 02-167) so that it has a 1.0 in. (25.4 mm)
overlap around the area which the teflon tape (CoMat 02-007)
identifies.
A. Let the repair area dry for 6 hours at 176oF (80oC) using heat
lamps.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Soak the fiberglass and the carbon plies with the adhesive.
(2) Apply the adhesive to the two sides of each ply with the
brush (CoMat 02-087) and put a second sheet of non-porous
parting film on each ply.
(3) Use the roller to force the adhesive into each ply
thoroughly.
(1) Cut approximately 1.0 in. (25.4 mm) off each edge of the
repair plies. Make sure that the first repair ply has a 1.0
in. (25.4 mm) overlap around the damage, and the second
repair (if necessary) ply has a 1.0 in. (25.4 mm) overlap
around the repair ply below it. Trim the corners of the
repair plies to 45 degrees by 0.5 in. (12.7 m). Cut the
fiberglass ply so that it is the same shape as the area
identified by the teflon tape (CoMat 02-007).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Apply the adhesive mix to the damaged area of the cowl with a clean
metal spatula. Make sure the adhesive is level with the top carbon
ply of the door.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) Remove the non-porous parting film (CoMat 02-367) from one
side of the first repair ply.
(2) Put the first repair ply, with the adhesive side down, onto
the repair area, making sure that the damaged area is in the
center of the repair ply.
NOTE: Make sure that the ply fibres follow the orientation
as given in step 1.E.
(4) Remove the remaining non-porous parting film from the repair
ply.
C. Put the second carbon repair (if necessary) ply on to the repair
area.
(1) Remove the non-porous parting film from one side of the
second repair ply.
(2) Put the second repair ply, with the adhesive side down, on to
the repair area, making sure that the second repair ply has
an equal overlap around the first repair ply.
NOTE: Make sure that the ply fibres follow the orientation as
given in step 1.E.
(4) Remove the remaining non-porous parting film from the repair
ply.
(1) Remove the non-porous parting film from one side of the
fiberglass ply.
(2) Put the fiberglass ply, with the adhesive side down, on to
the repair area making sure that fiberglass ply has an equal
overlap around the last carbon repair ply to the teflon mask
area.
(3) Use the roller to remove air which is trapped in the adhesive
and to make the fiberglass ply smooth.
(4) Remove the unwanted adhesive from the teflon tape with a
clean metal spatula.
A. Get a heat blanket, which must be larger all around than the repair
area.
B. Cut a sheet of porous parting film (CoMat 02-169) making sure that
it is larger than the heat blanket and has an overlap of at least
3.0 in. (76.2 m) around the fiberglass ply.
C. Cut one sheet of breather fabric (CoMat 08-057) for each carbon and
fiberglass ply on the repair area. Make sure that the breather
fabric has the same dimensions as the porous parting film.
D. Put the porous parting film on to the repair area, making sure that
it has an equal overlap around the repair area. Put the layers of
breather fabric on top of the porous parting film.
F. Put four fiberglass tows onto the repair area using one strand of
the fiberglass fabric (CoMat 02-167) in each of four positions
around the repair. Each of the strands must connect the breather
fabric with the area around the silicone rubber sheet.
NOTE: With the fiberglass tows installed, gasses can not collect
below the silicone rubber sheet when the adhesive cures.
G. Put the non-porous parting film on to the repair area, making sure
that it has an equal overlap around the repair area. Put the
silicone rubber sheet on top of the non-porous parting film.
H. Put the heat blanket and breather cloth on to the repair area.
(1) Cut two sheets of breather cloth (CoMat 02-166), at least 2.0
in. (50.8 mm) larger on each side than the silicone rubber
sheet.
(2) Put the two sheets of breather cloth on to the repair area.
(3) Put the heat blanket on top of the breather cloth, making
sure that the heat blanket has an overlap all around the
repair area.
(1) Cover the repair area with the nylon bagging film
(CoMat 02-163) that must have a minimum overlap of 2.00 in.
(50.8 mm) around the breather cloth.
(2) Install the vacuum hose, from the suction pump, so that it
goes directly on to the breather cloth.
(3) Attach and seal the bagging film to the cowl with the sealant
tape (CoMat 08-051).
A. Use the vacuum suction pump to decrease the pressure in the repair
area, making sure it gives an indication of at least 25.0 in.
(635.0 mm) of mercury while the adhesive cures.
B. Use the heat blanket to keep the temperature of the repair area at
190o - 210oF (88o - 99oC) for 220 minutes.
D. Start to measure the cure time when the temperature reaches 190oF
(88oC).
A. When the cure process is completed, remove the layup materials from
the repair.
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. ONLY
REMOVE MATERIAL FROM THE EDGE OF THE OUTER PLY. DO NOT USE A
LIQUID WITH THE ABRASIVE PAPER.
A. Remove all unwanted material from the repair area with a suction
cleaner.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, (Ref. SRM 54-01-00) Composite Structure Tap Test,
to confirm that the repair is correctly bonded.
1. General
A. This repair is only applicable to the main area left and right fan
cowl. The main area is the area where skin thickness is 2 plies of
8HSW only. Refer to Figures 201 and 202.
C. The damage must be more than 2.75 in (69,9 mm) from the fittings,
brackets, hinges and flanges. The damage must not be more than
4.0 in. (101,6 mm) wide and 4.0 in. (101,6 mm) long. There must be
a minimum of 20.0 in. (508,0 mm) between the edge of each repair
area. Only four repairs are permited on each door.
Ply orientation is given from the outer most ply to the inner.
2. Referenced Information
A. Standard equipment
C. Special Tools
D. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Fan Cowl Composite structure
A. Determine the extent of the disbond using the sonic test equipment
(1N20444) and the tap test method, SRM 54-01-00 Composite
Structure Tap Test, and mark the approximate outline of the area
using a marking pen (CoMat 06-131).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Mask around the repair area with 2.0 in. (50,8 mm) wide strips of
teflon tape (CoMat 02-007). Calculate the distance that the tape
must be from the damage as follows:
(1) Measure 2.0 in. (50,7 mm) from the edge of the damage,
1.0 in. (25,4 mm) for each ply of the cowl which is damaged.
(2) Add 0.75 in. (19,1 mm) for an outer layer of fiberglass
fabric (CoMat 02-167).
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. ONLY
REMOVE MATERIAL FROM THE EDGE OF THE OUTER PLY. DO NOT USE A
LIQUID WITH THE ABRASIVE PAPER.
(1) Use a high speed rotary cutter to remove the plies from the
damaged area in step 4A.
A. Remove all unwanted material from the repair area with a suction
cleaner.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Let the repair area dry for 6 hours at 176 oF (80oC) using heat
lamps.
9. Apply the epoxy paste adhesive to the honeycomb core (Ref. Fig. 203).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Mix the epoxy paste adhesive (CoMat 08-021) for the honeycomb core
in accordance with the manufacturer’s instructions.
C. Use a marking pen (CoMat 06-131) to mark the contour of the repair
area on the non-porous parting film.
G. Slowly ease the non-porous parting film away from the cells, take
care not to remove the compound from the cells. Use a knife, if
necessary, to help remove the compound from the non-porous parting
film.
H. Use a clean metal spatula to smooth the compound level with the
upper surface of the honeycomb cells.
NOTE: Use a spatula to add more compound to any cells that are not
fully closed.
I. Use a clean cloth to remove any compound from the skin around the
repair area.
(1) Use heat lamps to cure the epoxy paste adhesive for 1 hour
between 190o - 210oF (88o - 99oC)
K. When the adhesive has cured, make the adhesive flush with the upper
surface of the honeycomb cells upper surface. Use abrasive paper
(CoMat 05-021).
10. Prepare the cap ply, the fiberglass ply, the filler plies and the repair
plies
A. Wear lint-free gloves (CoMat 02-097) and cut two filler plies.
(1) Cut the dry carbon fibre fabric (CoMat 08-059) so that it has
a 1.0 in. (25,4 mm) overlap around the repair cut-out.
NOTE: Make sure that the ply fibres follow the orientation as
given in step 1.E.
C. Wear lint-free gloves (CoMat 02-097) and cut the first repair ply.
(1) Cut one piece of dry carbon fibre fabric (CoMat 08-059) so
that it has a 2.0 in. (50,8 mm) overlap around the potted
core.
D. Wear lint-free gloves (CoMat 02-097) and cut the second repair ply.
(1) Cut another piece of dry carbon fibre fabric (CoMat 08-059)
for the second repair ply, so that it has a 1.0 in. (25,4 mm)
overlap repair ply below.
E. Wear lint-free gloves (CoMat 02-097) and cut the fiberglass ply.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
F. Mix the EA9390 epoxy paste adhesive (CoMat 08-050) for the
fiberglass and carbon plies in accordance with the manufacturer’s
instructions.
G. Soak the fiberglass and the carbon plies with the adhesive.
(2) Apply the adhesive to the two sides of each ply with the
brush (CoMat 02-087) and put a second sheet of non-porous
parting film on each ply.
(3) Use the roller to force the adhesive into each ply
thoroughly.
H. Cut the cap ply and the filler plies to their finished dimensions.
(1) Let the two pieces of the non-porous parting film stay on
each ply until the installation procedure.
(2) Cut each filler ply and the cap ply until it does not have an
overlap on the sides of the repair cut-out.
(1) Let the two pieces of the non-porous parting film stay on
each ply until the installation procedure.
(2) Cut approximately 1.0 in. (25,4 mm) off each of the repair
plies.
(3) Make sure the first repair ply has a 1.0 in. (25,4 mm)
overlap around the potted core. The second repair ply must
have an 1.0 in. (25,4 mm) overlap around the repair ply below
it.
J. Cut the fiberglass ply until it is the same shape as the area
identified by the teflon tape.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
12. Install the cap ply, the filler plies and the repair plies
(Ref. Fig. 203).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Put the cap ply and first filler ply into the repair cut-out.
(1) Remove the non-porous parting film (CoMat 02-168) from one
side of the cap ply.
(2) Install the fiberglass cap ply, with the adhesive side down,
into the repair cut-out. Make sure that the cap ply is flat
and in the correct position.
(4) Remove the remaining non-porous parting film from the cap
ply.
(5) Remove the non-porous parting film from the first filler
ply.
(6) Install the first filler ply, with the adhesive side down,
into the repair cut-out. Make sure that the filler ply is
flat.
NOTE: Make sure that the ply fibres follow the orientation
as given in step 1.E.
(8) Remove the remaining non-porous parting film from the filler
ply. Use a clean metal spatula to make sure the filler ply is
flat and in the correct position.
(1) Remove the non-porous parting film from one side of the
second filler ply.
(2) Put the second filler ply, with the adhesive side down, on to
the repair area. Make sure that the second filler ply has an
equal overlap around the first filler ply.
NOTE: Make sure that the ply fibres follow the orientation as
given in step 1.E.
(4) Remove the remaining non-porous parting film from the filler
ply.
(1) Remove the non-porous parting film from one side of the
repair ply.
(2) Put the first repair ply, with the adhesive side down, on to
the repair area. Make sure that the repair cut-out is in the
center of the repair ply.
NOTE: Make sure that the ply fibres follow the orientation as
given in step 1.E.
(4) Remove the remaining non-porous parting film from the repair
ply.
(1) Remove the non-porous parting film from one side of the
repair ply.
(2) Put the second repair ply, with the adhesive side down, on to
the repair area. Make sure that the second repair ply has an
equal overlap around the first repair ply.
NOTE: Make sure that the ply fibres follow the orientation as
given in step 1.E.
(4) Remove the remaining non-porous parting film from the repair
ply.
(1) Remove the non-porous parting film from one side of the
fiberglass ply.
(2) Put the fiberglass ply, with the adhesive side down, on to
the repair area making sure that fiberglass ply has an equal
overlap around the last carbon repair ply to the teflon mask
area.
(3) Use the roller to remove air which is trapped in the adhesive
and to make the fiberglass ply smooth.
(4) Remove the unwanted adhesive from the teflon tape with a
clean metal spatula.
A. Get a heat blanket, which must be larger all around than the repair
area.
B. Cut a sheet of porous parting film (CoMat 02-334) and make sure
that it is larger than the heat blanket and has an overlap of at
least 3.0 in. (76.2 m) around the fiberglass ply.
C. Cut one sheet of breather fabric (CoMat 08-057) for each carbon and
fiberglass ply on the repair area. Make sure that the breather
fabric has the same dimensions as the porous parting film.
D. Put the porous parting film on to the repair area. Make sure that
it has an equal overlap around the repair area. Put the layers of
breather fabric on top of the porous parting film.
F. Put four fiberglass tows onto the repair area using one strand of
the fiberglass fabric (CoMat 02-167) in each of four positions
around the repair. Each of the strands must connect the breather
fabric with the area around the silicone rubber sheet.
NOTE: With the fiberglass tows installed, gasses can not collect
below the silicone rubber sheet when the adhesive cures.
G. Put the non-porous parting film on to the repair area. Make sure
that it has an equal overlap around the repair area. Put the
silicone rubber sheet on top of the non-porous parting film.
H. Put the heat blanket and breather cloth on to the repair area.
(2) Put the two sheets of breather cloth on to the repair area.
(3) Put the heat blanket on top of the breather cloth. Make sure
that the heat blanket has an overlap all around the repair
area.
(1) Cover the repair area with the nylon bagging film
(CoMat 02-163) that must have a minimum overlap of 2.0 in.
(50,8 mm) around the breather cloth.
(2) Install the vacuum hose, from the suction pump, so that it
goes directly on to the breather cloth.
(3) Attach and seal the bagging film to the cowl with the sealant
tape (CoMat 08-051).
A. Use the vacuum suction pump to decrease the pressure in the repair
area. Making sure it gives an indication of at least 25.0 in.
(635,0 mm) of mercury while the adhesive cures.
B. Use the heat blanket to keep the temperature of the repair area at
190o - 210oF (88o - 99oC) for 220 minutes.
D. Start to measure the cure time when the temperature reaches 190 oF
(88oC).
A. When the cure process is completed, remove the layup materials from
the repair.
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. ONLY
REMOVE MATERIAL FROM THE EDGE OF THE OUTER PLY. DO NOT USE A
LIQUID WITH THE ABRASIVE PAPER.
A. Remove all unwanted material from the repair area with a suction
cleaner.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, (Ref. SRM 54-01-00) Composite Structure Tap Test,
to confirm that the repair is correctly bonded.
1. General
2. Referenced Information
A. Standard equipment
C. Repair Parts
None
D. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Hinge Fitting Casting, HC 101
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) For holes between 0.2521 in. (6,40 mm) and 0.2676 in. (6,80
mm) diameter refer to A319/320/321 SRM 51-44-11 and SRM 51-
44-21 to carefully ream the hole through the hinge fitting
and fan cowl to 0.2656 in. (6,75 mm) to 0.2676 in. (6,80 mm)
diameter.
(2) For holes between 0.2677 in. (6,79 mm) and 0.2832 in. (7,19
mm) diameter refer to A319/320/321 SRM 51-44-11 and SRM 51-
44-21 to carefully ream the hole through the hinge fitting
and fan cowl to 0.2812 in. (7,14 mm) to 0.2832 in. (7,19 mm)
diameter.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
NOTE: If there are any cracks present, reject and replace the hinge
fitting.
Total for Holes between 0.2521 in. (6,40 mm) and 0.2676 in. (6,80 mm)
TABLE I
Total for Holes between 0.2677 in. (6,80 mm) and 0.2832 in. (7,19 mm)
TABLE II
REPAIR NO.054
FAN COWL HINGE FITTING SURFACE DAMAGE REPAIR - VRS7510
1. General
B. This repair may be used to repair surface damage on the hinge fit-
tings on the fan cowl doors (Ref. Fig.201).
(1) The area common to the hinge lug (Ref. Fig 202).
2. Referenced Information
A. Standard Equipment
C. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Hinge Fitting Casting, HC 101
D. Repair Parts
None
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
5. Remove the damaged area (Ref. Fig 202 and Fig 203)
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
7. Inspection.
A. Do a visual check of the repair. Make sure that the repair was done
as given in this procedure.
B. Use penetrant dye inspection at all repair areas. (Ref SPM TASK 70-
23-01-230-501).
NOTE: If there are any cracks, reject and replace the hinge fit-
ting.
1. General
A. This repair is only applicable to the main area left and right fan
cowl. The main area is the area where skin thickness is 2 plies of
8HSW only. Refer to Zone C, Figure 201 (Sheets 1 and 2).
D. The damage must be more than 10.00 in (254,0 mm) from the fittings,
brackets, hinges and flanges and must be more than 5.0 in.
(127,0 mm) from the edge of the of the 2-ply region. The damage
must not be more than 20.0 in. (508,0 mm) wide and 20.0 in.
long in the upper 2-ply region and not more than 14.0 in.
(355,6 mm) wide and 20.0 in. long in the lower 2-ply region. There
must be a minimum of 10.0 in. (254,0 mm) between the edge of each
repair area. Only two repairs are permitted on each door. Refer to
Figure 201.
Ply orientation is given from the outer most ply to the inner.
2. Referenced Information
A. Standard equipment
C. Special Tools
D. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Fan Cowl Composite structure
A. Determine the extent of the disbond using the sonic test equipment
(1N20444) and the tap test method, SRM 54-01-00 Composite
Structure Tap Test, and mark the approximate outline of the area
using a marking pen (CoMat 06-153).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Mask around the repair area with 2.0 in. (50,8 mm) wide strips of
teflon tape (CoMat 02-007). Calculate the distance that the tape
must be from the damage as follows:
(1) Measure 2.0 in. (50,7 mm) from the edge of the damage,
1.0 in. (25,4 mm) for each ply of the cowl which is damaged.
(2) Add 0.75 in. (19,1 mm) for an outer layer of fiberglass
fabric (CoMat 02-167).
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. ONLY
REMOVE MATERIAL FROM THE EDGE OF THE OUTER PLY. DO NOT USE A
LIQUID WITH THE ABRASIVE PAPER.
(1) Use a high speed rotary cutter to remove the plies from the
damaged area in step 4A.
A. Remove all unwanted material from the repair area with a suction
cleaner.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Let the repair area dry for 6 hours at 176oF (80oC) using heat
lamps.
A. Wear lint-free gloves (CoMat 02-97) and cut two plies for the
filler plate.
B. Put the two plies together to make the support plate on a sheet of
non-porous parting film (CoMat 02-367).
C. Align the plies and put them onto a hard, flat surface with the
same profile as the repair area.
A. Get a heat blanket, which must be larger all around than the filler
plate.
B. Cut a sheet of porous parting film (CoMat 02-334) and make sure
that it is larger than the heat blanket and has an overlap of at
least 3.0 in. (76.2 m) around the filler plate.
C. Cut one sheet of breather fabric (CoMat 08-057) for each pre-preg
carbon ply on the filler plate. Make sure that the breather fabric
has the same dimensions as the porous parting film.
D. Put the porous parting film on to the filler plate. Make sure that
it has an equal overlap around the filler plate. Put the layers of
breather fabric on top of the porous parting film.
F. Put four fiberglass tows onto the filler plate using one strand of
the fiberglass fabric (CoMat 02-167) in each of four positions
around the plate. Each of the strands must connect the breather
fabric with the area around the silicone rubber sheet.
NOTE: With the fiberglass tows installed, gasses can not collect
below the silicone rubber sheet when the adhesive cures.
G. Put the non-porous parting film on to the filler plate. Make sure
that it has an equal overlap around the filler plate. Put the
silicone rubber sheet on top of the non-porous parting film.
H. Cut two sheets of breather cloth (CoMat 02-166), at least 2.0 in.
(50.8 mm) larger on each side than the silicone rubber sheet.
J. Put the heat blanket on top of the breather cloth. Make sure that
the heat blanket has an overlap all around the filler plate.
M. Cover the filler plate with the nylon bagging film (CoMat 02-163)
that must have a minimum overlap of 2.0 in. (50,8 mm) around the
breather cloth.
N. Install the vacuum hose, from the suction pump, so that it goes
directly on to the breather cloth.
O. Attach and seal the bagging film to the cowl with the sealant tape
(CoMat 08-051).
A. Use the vacuum suction pump to decrease the pressure. Making sure
it gives an indication of at least 25.0 in. (635,0 mm) of mercury
while the adhesive cures.
B. Use the heat blanket to keep the temperature of the repair area at
345.2°F - 363.2°F (174° - 185°C) for 120 minutes.
E. When the cure process is completed, remove the layup materials from
the filler plate.
A. Wear lint-free gloves (CoMat 02-097) and cut the first repair ply.
(1) Cut one piece of dry carbon fibre fabric (CoMat 08-059) so
that it has a 2.0 in. (50,8 mm) overlap around the repair
cut-out core.
B. Wear lint-free gloves (CoMat 02-097) and cut the second repair ply.
(1) Cut another piece of dry carbon fibre fabric (CoMat 08-059)
for the second repair ply, so that it has a 1.0 in. (25,4 mm)
overlap repair ply below.
C. Wear lint-free gloves (CoMat 02-097) and cut the fiberglass ply.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
D. Mix the EA9390 epoxy paste adhesive (CoMat 08-050) for the
fiberglass and carbon plies in accordance with the manufacturer’s
instructions.
E. Soak the fiberglass and the carbon plies with the adhesive.
(2) Apply the adhesive to the two sides of each ply with the
brush (CoMat 02-087) and put a second sheet of non-porous
parting film on each ply.
(3) Use the roller to force the adhesive into each ply
thoroughly.
(1) Let the two pieces of the non-porous parting film stay on
each ply until the installation procedure.
(2) Cut approximately 1.0 in. (25,4 mm) off each of the repair
plies.
(3) Make sure the first repair ply has a 1.0 in. (25,4 mm)
overlap around the potted core. The second repair ply must
have an 1.0 in. (25,4 mm) overlap around the repair ply below
it.
G. Cut the fiberglass ply until it is the same shape as the area
identified by the teflon tape.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Cut two plies of FM 300-2 film adhesive (CoMat 08-136) the same
size as the repair cut-out.
B. Apply the two FM 300-2 film adhesive (CoMat 08-136) plies to the
repair area.
C. Install the filler plate into the repair cut-out. Make sure that
the filler plate is the same profile as the repair area.
A. Get a heat blanket, which must be larger all around than the repair
area.
B. Cut a sheet of porous parting film (CoMat 02-334) and make sure
that it is larger than the heat blanket and has an overlap of at
least 3.0 in. (76.2 m) around the repair area.
C. Cut one sheet of breather fabric (CoMat 08-057) for each carbon and
fiberglass ply on the repair area. Make sure that the breather
fabric has the same dimensions as the porous parting film.
D. Put the porous parting film on to the repair area. Make sure that
it has an equal overlap around the repair area. Put the layers of
breather fabric on top of the porous parting film.
F. Put four fiberglass tows onto the repair area using one strand of
the fiberglass fabric (CoMat 02-167) in each of four positions
around the repair. Each of the strands must connect the breather
fabric with the area around the silicone rubber sheet.
NOTE: With the fiberglass tows installed, gasses can not collect
below the silicone rubber sheet when the adhesive cures.
G. Put the non-porous parting film on to the repair area. Make sure
that it has an equal overlap around the repair area. Put the
silicone rubber sheet on top of the non-porous parting film.
H. Put the heat blanket and breather cloth on to the repair area.
I. Cut two sheets of breather cloth (CoMat 02-166), at least 2.0 in.
(50.8 mm) larger on each side than the silicone rubber sheet.
K. Put the heat blanket on top of the breather cloth. Make sure that
the heat blanket has an overlap all around the repair area.
N. Cover the repair area with the nylon bagging film (CoMat 02-163)
that must have a minimum overlap of 2.0 in. (50,8 mm) around the
breather cloth.
O. Install the vacuum hose, from the suction pump, so that it goes
directly on to the breather cloth.
P. Attach and seal the bagging film to the cowl with the sealant tape
(CoMat 08-051).
A. Use the vacuum suction pump to decrease the pressure in the repair
area. Making sure it gives an indication of at least 25.0 in.
(635,0 mm) of mercury while the adhesive cures.
B. Use the heat blanket to keep the temperature of the repair area at
257° - 275°F (125° - 135°C) for 120 minutes.
D. Start to measure the cure time when the temperature reaches 257°F
(125°C).
F. When the cure process is completed, remove the layup materials from
the repair.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
(1) Remove the non-porous parting film from one side of the
repair ply.
(2) Put the first repair ply, with the adhesive side down, on to
the repair area. Make sure that the repair cut-out is in the
center of the repair ply.
NOTE: Make sure that the ply fibres follow the orientation
as given in step 1.E.
(4) Remove the remaining non-porous parting film from the repair
ply.
(1) Remove the non-porous parting film from one side of the
repair ply.
(2) Put the second repair ply, with the adhesive side down, on to
the repair area. Make sure that the second repair ply has an
equal overlap around the first repair ply.
NOTE: Make sure that the ply fibres follow the orientation
as given in step 1.E.
(4) Remove the remaining non-porous parting film from the repair
ply.
(1) Remove the non-porous parting film from one side of the
fiberglass ply.
(2) Put the fiberglass ply, with the adhesive side down, on to
the repair area making sure that fiberglass ply has an equal
overlap around the last carbon repair ply to the teflon mask
area.
(3) Use the roller to remove air which is trapped in the adhesive
and to make the fiberglass ply smooth.
(4) Remove the unwanted adhesive from the teflon tape with a
clean metal spatula.
A. Get a heat blanket, which must be larger all around than the repair
area.
B. Cut a sheet of porous parting film (CoMat 02-334) and make sure
that it is larger than the heat blanket and has an overlap of at
least 3.0 in. (76.2 m) around the fiberglass ply.
C. Cut one sheet of breather fabric (CoMat 08-057) for each carbon and
fiberglass ply on the repair area. Make sure that the breather
fabric has the same dimensions as the porous parting film.
D. Put the porous parting film on to the repair area. Make sure that
it has an equal overlap around the repair area. Put the layers of
breather fabric on top of the porous parting film.
F. Put four fiberglass tows onto the repair area using one strand of
the fiberglass fabric (CoMat 02-167) in each of four positions
around the repair. Each of the strands must connect the breather
fabric with the area around the silicone rubber sheet.
NOTE: With the fiberglass tows installed, gasses can not collect
below the silicone rubber sheet when the adhesive cures.
G. Put the non-porous parting film on to the repair area. Make sure
that it has an equal overlap around the repair area. Put the
silicone rubber sheet on top of the non-porous parting film.
H. Put the heat blanket and breather cloth on to the repair area.
(2) Put the two sheets of breather cloth on to the repair area.
(3) Put the heat blanket on top of the breather cloth. Make sure
that the heat blanket has an overlap all around the repair
area.
(1) Cover the repair area with the nylon bagging film
(CoMat 02-163) that must have a minimum overlap of 2.0 in.
(50,8 mm) around the breather cloth.
(2) Install the vacuum hose, from the suction pump, so that it
goes directly on to the breather cloth.
(3) Attach and seal the bagging film to the cowl with the sealant
tape (CoMat 08-051).
A. Use the vacuum suction pump to decrease the pressure in the repair
area. Making sure it gives an indication of at least 25.0 in.
(635,0 mm) of mercury while the adhesive cures.
B. Use the heat blanket to keep the temperature of the repair area at
190o - 210oF (88o - 99oC) for 220 minutes.
D. Start to measure the cure time when the temperature reaches 190oF
(88oC).
A. When the cure process is completed, remove the layup materials from
the repair.
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. ONLY
REMOVE MATERIAL FROM THE EDGE OF THE OUTER PLY. DO NOT USE A
LIQUID WITH THE ABRASIVE PAPER.
A. Remove all unwanted material from the repair area with a suction
cleaner.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, (Ref. SRM 54-01-00) Composite Structure Tap Test,
to confirm that the repair is correctly bonded.
1. General
C. For hole locations with damage greater than 0.4415in. (11,2141 mm)
diameter, refer to Repair No. 058 (VRS7530).
2. Referenced Information
A. Standard equipment
C. Repair Parts
None
D. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Hinge Fitting Casting, HC 101
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
C. For hole locations with elongated wear damage over 0.4650 in.
(11,811 mm) diameter and hole locations with concentric wear
damage over 0.4950 in. (12,573 mm) diameter, reject and replace the
hinge fitting.
D. For hole locations with damage less than 0.4415 in. (11.2141
mm)diameter, refer to repair No.057 (VRS7511).
2. Referenced Information
A. Standard equipment
C. Repair Parts
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Bushing Stainless Steel CRES 17-4 PH 900 or CRES
17-4 PH1050
D. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Hinge Fitting Casting, HC 101
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
NOTE: Make sure that you keep the larger holes concentric with the
initial holes.
NOTE: Make sure that a minimum edge distance of 0.352in. (8.94 mm)
is maintained to the edge of lug.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
NOTE: If there are any cracks, reject and replace the hinge fit-
ting.
8. Manufacture the Stainless Steel Bushes for each hole. (Ref Fig.202).
NOTE: If there are any cracks, reject and manufacture new bushes.
10. Install the stainless Steel Bushes in each hole. (Ref Fig.202)
B. Clamp the hinge fitting onto a hand operated press with the hole
vertical and the correct face of the component up.
D. Align the bush in a vertical position with the hole and lower the
press into contact with the bush.
H. Repeat steps ‘A’ to ‘G’ to install the remaining bush in the second
lug.
A. Check the assembly to make sure that the protective finish in the
area around the bushes has not been damaged. Apply again the pro-
tective finish if required (Ref. SPM TASK 70-38-07-380-501).
B. Make sure that the faces and the bore of the bushes are free from
traces of locking adhesive.
C. Make sure that the installed bushes are free from cracks when exam-
ined with a 5x or 10x hand lens.
NOTE: If there are any cracks, reject and replace the hinge fit-
ting.
1. General
2. Structure Description
3. Structure Identification
Figure and Table numbers ending with an “A” are for Translating Sleeve
serial numbers 5001001 and on.
The purpose of the tables is to help you to easily locate and identify
components which may be damaged. This is then used to help you to:
13506
I
TRANSLATING SLEEVE
INNER BARREL
(SEE FIGURE 3)
PRESSURE
PANEL ASSEMBLY
(SEE FIGURE 2)
a5s528
DETAIL II
8
SEE
DETAIL II
10
12
11 14
16
13
18
15
17
6 8
7
SECTION B - B
19
20
21
22
23 24
26 DETAIL III
25 27 28
13508
8 5
29
30
31
DETAIL IV
32
5
33
34
13509
SECTION D - D
46
47
46
48
DETAIL III
50
49
DETAIL IV
44 45
DETAIL V
44
13511
SEE
3 10 9 8
DETAIL I
11
12 4
13
5
14
15
16
SEE 17
DETAIL III 18
19
2
20
21
22
23
24
25 26
27 7
6 DETAIL II
28
29 37
5 36
35
30 31 1 32 33 34
2 14 13 40 39 38
15
35 41 16
36 17
37 7 6
18
20 19
THRU 20
31
21
42 22
23
SEE 24
DETAIL II
43
SEE 25 26 27 28 29 30 31
DETAIL IV 4 SEE
DETAIL V 5 6
3
2
1
DETAIL I
7 13516
46
47
46
48
DETAIL III
50
49
DETAIL IV
44 45
DETAIL V
44
13511
B B
4
3
A
C C
2 5
8 6
D D
2 1
SECTION B-B 5
7 4 (5 PLACES)
2
1
SECTION C-C 4 5
7 (4 PLACES)
2
1
VIEW D-D 9
13938
B D F 12
C H
A 5 E 10 G
6
8
3
1
2 13
7 9
1 4
11
31
1 32
28 30 14
16 15
29
20
22 31
32
24
22
14
109 16
22
22
18
17
27 19
23
21
26 25
A C E 20 G
H
21
B D F 13517
6 33
34
35
1
36
22
21 22 36
34
26 35
SECTION A - A
13518
33
2
37
2
6
38
1
39
40
36 21 22
38
41 26
42
SECTION B - B
13519
43
38
6
36
1
2
4
5
29
36
22
24
22
25 SECTION C - C
21 22
36
38 13520
46 30 44
47 45
48 38
49
16
7
36
30
38
8
49
49
31
16 32
16
20
22
SECTION D - D
36
21 22
38
41
42
13521
50
51
7
16
49
36 16
31
32
20
22
36
22 SECTION E - E
21
38
13522
41
42
10
52
51
9
14
14
36
19
16
22 49
31
54 53 20 32 36
38
55
49
SECTION F - F
13523
56
14 12
36
57
36
12
14
36
14
17
57
58
59
60
SECTION G - G
VIEW LOOKING FORWARD
13524
13
57
56
20
36
58
59
60 17 36 15
57
SECTION H - H
13525
F 7 B
A 6 8
2 E 5
1 3 G H
4 I
7
H
I
E G 9
F
2 3 10
2
11
C
20
D D
12
3 SEE G-G
SEE F-F
SEE E-E J
J B
3 2 3 3
5 14
3 A
A5S523
18
19
12
K
1
15
26
10
18
10
15
19 N
26
16
18 L 12
17
1 L
SECTION A-A
13940
25
22
18
8
25
10
9
22
18
R
1
10
2
18
12
3
15
15
2 18
12
12
18 SECTION C-C
10
1 15
10
16 1
N
M
A5S524
14
7 9 8
10
SECTION D-D
18 18
19 19
24
22
23
3
3 10 18
1
1 1
21
10
20 5
18
12
10 12
SECTION G-G
21
24
23 25
25
25
22
25 22
18 18
10
8
10
8
6
6
7
SECTION H-H SECTION I-I
10
18
22
13534
13535
13536
13537
SECTION F-F
A5S556
C
D
13542B
15
38
14
41 5
41
37
15
42
40
43
39
39
19
45
44
17
46
47
48
SECTION A-A
18
13543
37
49
41 5
41
15 42
51 50
39
45
39
5
19
52
17
53
SECTION B-B
54
18
13544
55 6
56
4
3
57
58
15 7
9
28
45
59
27
60 20 22
28 25 5
61
21
SECTION C-C
13545A
4
2 3
57
58
64 7
67
33
69 65
34
70
24 63
71 59 66
73
30
62 7
75
15
76
15 67
72
74 77 68
78
5
15
79
24
80 29
75
81
82
25
27 28
SEE
DETAIL I
25
3 5
2
FWD
SEE
DETAIL II
6
ICN-V25-X-543000-01116-S-001
8
SECTION A-A
10
11 18
12 20
17 19
21
16
15
14
DETAIL I
13
17
18,19
22
23
20,21
24
DETAIL II
13549
INNER BARREL
D ASSEMBLY
A (SEE FIGURE 3)
6
13950
E
10
7
8
9
12
11
E 13
13 12
13
14
14
OUTER
BARREL
ASSEMBLY
13
14
12
13
15
14 13
12
INNER
BARREL 13
ASSEMBLY
14
14 13 13
G
12
13
10
12
8
9
16
11
G
13951
SECTION A-A
17
9 PRESSURE
18 PANEL
ASSEMBLY
21 17
20
19 5
INNER BARREL
9 ASSEMBLY
SECTION B-B
17
INNER BARREL
ASSEMBLY 22
24
INNER BARREL
25 ASSEMBLY
23
SECTION C-C
26
20
27 28
OUTER BARREL
25 20 26 ASSEMBLY
19
30
29
7
34
33
32 8
31 INNER BARREL
ASSEMBLY
SECTION E-E
33
1
SECTION F-F
13953
1
H
16
29
20 26
OUTER BARREL
ASSEMBLY
SECTION G-G
36
37 38
39
45 37
43 44
40 41
41 41 42
42 42
H
(R. H. SIDE)
13954
OUTER BARREL
ASSEMBLY
PRESSURE PANEL (SEE FIGURE 1)
ASSEMBLY
(SEE FIGURE 2A)
A 1 2
INNER BARREL
ASSEMBLY
(SEE FIGURE 3A)
13945
3 C
4 8
5 9
6 10
C
7 OUTER BARREL
ASSEMBLY
INNER BARREL
ASSEBMLY 6
D D
11
6
12
E
10
5 9
E
VIEW A-A 13946
12 OUTER BARREL
ASSEMBLY
22 21
3
18 17 16 15 14 13
20 19 INNER BARREL 5 6
VIEW C-C ASSEMBLY
17
5
28
4
24 23
10
25
6
PRESSURE PANEL
29 ASSEMBLY
2 30
26
27
10 INNER BARREL
ASSEMBLY
27
OUTER BARREL
ASSEMBLY
VIEW D-D
VIEW B-B
13947
36
34 F 37 INNER BARREL
38 4
18 17 ASSEMBLY
28
34
33 35 5
3
32
F 31
27
VIEW E-E
OUTER BARREL
ASSEMBLY
INNER BARREL
ASSEMBLY (RH)
35 34
35
39
35
40
35 34
INNER BARREL
ASSEMBLY (LH)
2
3
13949
1. Introduction
This section contains the allowable damage limits for both sheet
metal and bonded panel structural components of the V2500 Thrust
Reverser. Any damage which is found to be more than the allowable
damage limits should be repaired in accordance with the procedures
found in 54-30-00, Repairs, Page block 201.
2. Zones
3. Section Organization
A. General
TS1 - Area 5.0 in. (127 mm) or less from the upper or lower
sliders on the Outer Barrel and Fairing, Pressure Shelf and
Inner Barrel.
TS2 - Area 1.0 in. (25.4 mm) or less from the Pressure Shelf
fore and aft edges.
TS3 - 3.0 in. (76.2 mm) from forward and aft edges of the
Translating Sleeve.
TS8 - Areas 2.0 in. (50.8 mm) or less, forward and aft,
from the Translating Sleeve Inner and Outer Barrel joint.
TS9 - Areas 2.0 in. (50.8 mm) or less from the fitting that
attaches the actuator to the Translating Sleeve.
GRAPHITE
COMPOSITE
OUTER SKIN
LOWER
SLIDERS
5.0 in. OR LESS
TYP. BOTH SIDE
ZONE ZONE TS1
TS3 ALUMINUM CORE
GRAPHITE SKIN ZONE
FRAMES ZONE TS6 ZONE
TS5
ZONE TS7 ZONE
TS8 TS3
ZONE
ICN-V25-X-543000-01708-S-001
TS10
ZONE DYNAROHR SKIN OVER
TS9 COMPOSIT SHEET (CONFIG 1) ZONE
ALUMINUM CORE PREFORATED SKIN (CONFIG 2) TS11
GRAPHITE SKIN (CONFIG 1) ZONE TS4
ALUMINUM CORE
ALUMINUN SKIN (CONFIG 2)
ZONE TS2
A-A
NOTE: See Figures 102 and 103 for limitations where damage is not
allowed
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Abrasion All Damage allowed to Finishes only Operator
Zones surface resin only. option-
Unlimited use prevent
No fiber damage. growth
For TS7, See
Apply applicable Figure 102 where
sealing tape to damage is
protect damage area allowed.
from moisture.
Replace the tape if For TS10, See
it becomes peeled or Figure 103 where
damaged. damage is
allowed.
Crack TS5 No cracks within 3.0 in. (76.2 mm) Airplane
TS10 10.0 in. (254.0 mm) max. length “A”
of any other crack allowed. check
damage.
For TS10, See
Maximum of 5 cracks Figure 103 where
per barrel half. damage is
allowed.
Cracks wider than
0.1 in. (2.54 mm) Time Limited
are treated as
holes.
Cracks 0.01 in.
(0.254 mm) deep or
less are treated the
same as scratches.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Crack Cont’d For metals, stop
drill both ends of Unlimited use Airplane
the cracks per SRM of terminated “A” check
54-02-00, Stop Drill crack between
Cracks. any two fasteners
in a joint of ten
Apply the applicable or more
sealing tape to fasteners.
protect the crack
damage area from Time limited
moisture. Replace
the tape if it
becomes peeled or
damaged.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Gouge/ TS5 No two within 10.0 in. 0.01 in. Airplane
Scratch TS6 (254.0 mm). (0.254 mm) max. “A” check
TS7 depth, 10.0 in.
TS9 Maximum of 10.0 gouges (254.0 mm) max.
TS10 and 10.0 scratches per length, 0.1 in.
barrel half. (2.54 mm) max.
width.
Apply the applicable
sealing tape to the For TS7, See
damage area to protect Figure 102
it from moisture. where damage is
Replace the tape if it allowed.
becomes peeled or
damaged. For TS10, See
Figure 103
Scratched deeper than where damage is
25% of material allowed.
thickness are treated
as cracks. Unlimited use.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Hole/Dent TS5 No two within 10.0 in. For TS7, 1.0 Airplane
TS7 (254.0 mm). Max. of 5 in. diameter “A” check
TS10 holes per barrel half. hole max. See
Cracks wider than 0.10 Figure 102
in. (2.54 mm) are to where damage is
be treated as holes. allowed.
Time limited
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Nick TS5 Max. of 14 nicks per 0.01 in. Airplane
TS6 square foot (92903 (0.254 mm) max. “A” check
TS7 square mm) of panel/ depth.
TS9 stiffener. Apply the
TS10 applicable sealing 0.10 in.
tape to the damage (2.54 mm) max.
area to protect it width or length.
from moisture.
Replace the tape if For TS7, See
it becomes peeled or Figure 102 where
damaged. damage is
allowed.
Unlimited use.
TS1 - Area 5.0 in. (127 mm) or less from the upper or lower
sliders on the Outer Barrel and Fairing, Pressure Shelf and
Inner Barrel.
TS2 - Area 1.0 in. (25.4 mm) or less from the Pressure Shelf
fore and aft edges.
TS3 - 3.0 in. (76.2 mm) from forward and aft edges of the
Translating Sleeve (Land Areas - Skin only).
TS8 - Areas 2.0 in. (50.08 mm) or less, forward and aft,
from the Translating Sleeve Inner and Outer Barrel joint.
TS9 - Areas 2.0 in. (50.08 mm) or less from the fitting
that attaches the actuator to the Translating Sleeve.
NOTE: See Figures 104,105, 106, 107, 108, 109 and 110 for limitations
where damage is not allowed.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Abrasion All For composites, Finishes only Operator
zones damage option-
allowed to surface Unlimited use prevent
resin only growth
No fiber damage
Apply applicable
sealing tape to
protect damage area
from moisture.
Replace the tape if
it becomes peeled or
damaged.
Crack TS5 No cracks within For TS6, TS7 and Airplane
TS6 10.0 in. (254.0 mm) TS10 0.25 in. “A” check
TS7 of any other crack (6.35 mm) max.
TS10 damage. length in any
direction allowed.
Maximum of 5 cracks For TS5 3.0in.
per barrel half (76.2 mm) max.
length in any
Crack wider than 0.1 direction allowed.
in. (2.54 mm) are
treated as holes. For TS7, See
Cracks 0.01 in. Figure 106 where
(0.254 mm) deep or damage is allowed.
less are treated the
same as scratches For TS10, See
Figure 108 where
damage is allowed.
Time limited
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Crack Cont’d For metals, stop Unlimited use of Airplane
drill both ends of terminated crack “A” check
the cracks per SRM between any two
54-02-00, Stop Drill fasteners in a
Cracks. joint of ten or
more fasteners.
For composites, apply
the applicable Time limited
sealing tape to
protect the crack
damage area from
moisture. Replace the
tape if it becomes
peeled or damaged.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Delamination For TS1 and TS3, the For TS1 and TS3, For TS1 and
/Disbond edge of the damage see Figure 110 TS3 inspect
Cont’d must be at least 5D where damage is every 150
(D= damage diameter) allowed. FH. If any
away from the edge of additional
any other damage or damage is
previous repair and found
at least 3 inches or during
2D (D= damage inspection,
diameter), whichever repair per
is greater, away from SRM or
the edge of fastener contact
or attachment Collins
Aerospace
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Gouge/ TS4 No gouge/scratch 0.01 in. (0.254 mm) Airplane
Scratch TS5 within 10.0 in. max. depth, 10.0 in “A” check
TS6 (254.0 mm) of any (254.0 mm) max.
TS7 other damage. length, 0.1 in.
TS9 (2.54 mm) max
TS10 Maximum of 10 gouges width.
and 10 scratches per
barrel half. For metallic com-
ponents 0.005 in.
For composites, apply (0.127 mm) deep or
the applicable less in skins 0.020
sealing tape to the in. (0.51 mm) or
damage area to 0.025 in. (0.635
protect it from mm) thick.
moisture. replace the For skins thicker
tape if it becomes than 0.025 in.
peeled or damaged. (0.635 mm) 0.010
in. (0.254 mm) deep
Scratches deeper than or less
25% of the material
thickness are treated For TS4, see Figure
as cracks. 105 where damage is
allowed.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Gouge/ For TS10, See
Scratch Figure 108 where
Cont’d damage is
allowed.
Unlimited use.
Hole/Dent TS4 No hole/dent within For TS4, TS5, Airplane
TS5 10.0 in. (254.0 mm) TS7 and field “A” check
TS7 of any other areas of TS10
TS10 damages. Max. of 5 3.0 in.(76.2 mm)
holes per barrel diameter hole/
half. Cracks wider dent max.
than 0.10 in. (2.54
mm) are to be
treated as holes.
For TS4 and TS7,
Apply the applicable See Figure 104
sealing tape to where damage is
protect the damage allowed.
area from moisture.
Replace the tape if
it becomes peeled or
damaged. For TS10, See
Figure 108 where
Repair at next “C” damage is
check. allowed.
Time limited.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Nick TS4 Maximum of 14 nicks 0.01. (0.254 mm) Airplane
TS5 per square foot max. depth “A” check
TS6 (92903 mm²) of
TS7 panel/stiffener. For 0.10 in.
TS9 composites, apply (2.54 mm)
TS10 the applicable maximum width or
sealing tape to the length.
damage area to
protect it from For metallic
moisture. Replace components 0.005
the tape if it in. (0.127 mm)
becomes peeled or deep or less in
damaged. skins 0.020 in.
(0.51 mm) or
0.025 in.
(0.635 mm)
thick.
For skins
thicker than
0.025 in.
(0.635 mm) 0.010
in. (0.254 mm)
deep or less.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Nick For TS7 and TS9,
Cont’d See Figure 107
where damage is
allowed.
Unlimited use.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Chafe TS11 No Cracks Depth of damage If the mating
(Inner Allowed. No (material removed) Common Nozzle
perfo- Damage beyond less or equal to Assembly (CNA)
rated TS11 boundar- 0.0073 in. (0,185 serial number
Skin), ies. Refer to mm) or 0.0177 in. is within
Refer Figure 109 . (0.449 mm)remaining 8137001-
to thickness, any 10606001.
Figure legnth. Inspect by
109. Measuring the
damage depth
every 12000
Flight Hours,
9000 Flight
cycles, or 40
months, which-
ever occur
first until
Service
Bulletin V2500
NAC-78-0242 is
carried out on
the mating CNA
If the mating
CNA serial
number is
outside
8137001-
10606001
Range, no
further action
is required
Blend damage per SRM
Chapter 54-02-00,
Repair No. 12. Do
not blend beyond the
damage depth.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Chafe Depth of damage If the mating
(Cont) (material removed) Common
less or equal to 0.0145 Nozzle Assy
in. (0,368 mm) or (CNA) serial
0.0105 in. (0.267 number is
mm)remaining thick- within
ness, any length. 8137001-
10606001.
Inspect by
Measuring the
damage depth
every 6000
Flight Hours,
4500 Flight
cycles, or 20
months,
whichever
occur first
until Service
Bulletin
V2500 NAC-78-
0242 is car-
ried out on
the mating
CNA. If the
mating CNA
serial number
is outside
8137001-
10606001
range, no
further
action is
required
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Chafe Blend damage per SRM
(Cont) Chapter 54-02-00,
Repair No. 12. Do not
blend beyond the
damage depth.
3.0 in.
(76 mm)
3.5 in.
(89 mm)
9.0 in.
(229 mm)
5.5 in.
(140 mm)
DAMAGE ALLOWED IN CROSS HATCHED AREA
A5S514
2.0 in.
5.0 in. 3.0 in. (TS8)
(TS1)
UP
TS8 SPLIT
AFT
LHS
LOOKING
OUTBOARD
ICN-V25-X-543000-01709-S-001
5.0 in.
(TS1)
3.0 in.
DAMAGE ALLOWED IN CROSS HATCHED AREAS
FS5 - 2.00 in. (50.8 mm) maximum from the upper and lower
bifurcation corner radii.
NOTE: Make sure the fire shield is not damaged and replaced
after repair or inspection is performed on the hot side
of the fixed structure.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Disbond FS1 Separated from other 3.0 in. (76 mm) Inspect
FS2 disbonds by a fully maximum every 600
FS3 bonded panel 4 times diameter. Flight
FS4 the diameter of the Hours, 750
disbond. No other Flight
damage on the Cycles or
opposite face sheet 100 days
opposed or Time limited
overlapped. Maximum 2
disbonds per 1.0ft²
(0.09 m²) of panel.
Minimum of 1.5 in.
(38.1 mm) from edges,
splices, joints and
fittings. Refer below
for restrictions on
allowable damage
areas.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Disbond Restrictions on Allowable Damage Areas
Cont’d -No Damaged Allowed
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Dent FS1 No Face sheet 2 in. (50.8 mm) Inspect
FS3 thinning. maximum diameter. every 600
FS2 Core crush Flight
FS4 acceptable. 0.20 in. (5.08 mm) Hours, 750
No two within 3.0 in. max depth. Flight
(76.2 mm). Cycles or
Min. 1.5 in. (38.1 0.25 in. (6.35 mm) 100 days
mm) from edges, minimum radius.
splices, joints, and
fittings. Dent diameter to
dent depth ratio >
20
Unlimited Use
Gouge FS1 Surface damage of 1.5 in. (38.1 mm) Inspect
FS2 face sheet only. max. length every 600
FS3 No core crushed. Flight
FS4 No two gouges within 0.01 in. Hours, 750
3.0 in. (76 mm). (0.254 mm) max. Flight
Minimum distance of depth Cycles or
1.5 in. (38.1 mm) 100 days
from edges, splices, 0.1 in. (2.54 mm)
joints and fittings. max. width.
No sharp edges
allowed. Unlimited use
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Nick FS1 No two within 2.0 in. 0.5 in. Inspect
FS2 (50.8 mm). Min. 1.5 (12.7 mm) max. every 600
FS3 in. (38.1 mm) from length Flight
FS4 edges, splices, Hours, 750
joints and fittings. 0.01 in. Flight
No sharp edges (0.254 mm) max. Cycles or
allowed. depth 100 days
0.1 in.
(2.54 mm) max.
width.
Unlimited use
Rip/Tear FS6 No disbond of wire Inspect
Woven mesh from the 100% max. depth every 600
wire perforated face Flight
Mesh sheet. 0.25 in. Hours, 750
No two within 3.0 in. (6.35 mm) max. Flight
(76 mm). length. Cycles or
Minimum distance of 100 days
1.5 in. (38.1 mm)
from edges, splices, Unlimited use
joints and fittings.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Scratch FS1 No two within 3.0 in. 1.5 in.(38.1 mm) Inspect
FS2 (76 mm). Min 1.5 in. max. length every 600
FS3 (38.1 mm) from edges, Flight
FS4 splices, joints and 0.01 in.(0.254 mm) Hours, 750
fittings. maximum depth Flight
If damage exceeds Cycles or
basic material 0.05 in. (1.27 mm) 100 days
thickness, consider max. width.
the damage as a
crack. Unlimited use
No sharp edges
allowed.
FS6 No disbond from the 1.5 in. (38.1 mm) Inspect
perforated face max. length every 600
sheet. Flight
0.005 in. Hours, 750
(0.127 mm) Flight
maximum depth. Cycles or
100 days
0.05 in. (1.27 mm)
maximum width.
Unlimited use
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Crack FS3 No two within 10.0 in. 1.0 in. Inspect
FS4 (254.0 mm). Stop drill (25.4 mm) every 600
crack (refer to maximum length. Flight
section Hours, 750
54-02-00). Apply speed Time limited. Flight
tape over damage area. Cycles or
Refer below for 100 days
restrictions on
allowable damage
areas.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Partial FS1 No two within 10.0 in. 3.0 in. Inspect
Penetration/ FS2 (254.0 mm). No other (76.2 mm) max. every 600
Hole FS3 damage on opposite diameter Flight
FS4 skin surface within Hours, 750
10.0 in. (254 mm) Time limited Flight
No sharp edges Cycles or
allowed. 100 days
Apply speed tape over
damage area.
Refer below for
additional
requirements.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Delamination/ BC1 No None.
Disbond BC2 delaminations or
BC3 disbonds allowed.
BC4
BC5
Dent BC1 No dents None.
BC3 allowed.
BC5
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Nick/Gouge BC1 No None.
BC3 nicks/gouges
allowed.
BC5 No Unlimited
nicks/gouges use.
allowed.
Clean area with
CoMat 01-438. Fill
damage with CoMat
08-149, (Epocast
1617 A/B). Cure at
125°F (51.7°C) for 5
hours.
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Scratch BC2 No delamination 0.005 in. 20 Months,
BC4 from face sheet. (0.127) max 6000 Flight
depth Hours or
4500 Flight
0.4 in.(10,2 mm) cycles,
max length. whichever
occurs
Unlimited use. first.
Unlimited use.
BC5 No Scratches
allowed. Clean area
with CoMat 01-438.
Fill damage with
CoMat 08-149,
(Epocast 1617 A/B)
Cure at 125°F
(51.7°C) for 5
hours.
Crack BC1 No cracks allowed. None.
BC2
BC3
BC4
BC5
Partial BC1 No penetration None.
Penetration/ BC2 allowed.
Hole BC3
BC4
BC5
Full BC1 No penetration None.
Penetration/ BC2 allowed.
Hole BC3
BC4
1.0 in
ZONE 2 (25.4 mm)
C 2.0 in
L (50.8 mm)
2.0 in
ZONE 2 (50.8 mm) ZONE 3
ZONE 1
1.0 in B
(25.4 mm) C ZONE 3
ZONE 3
13662B
ZONE 4
CRACK
TANG
WITHOUT
DAMAGE
BROKEN OR
MISSING
MATERIAL
TANG
WITH CROSSOVER BEAM
DAMAGE CROSS-SECTION AREA
C
A5S557
Field of panel, more than 2.0 in. (50.8 mm) from panel
edges
Field of panel, more than 2.0 in. (50.8 mm) from panel
edges
BC5 No scratches
allowed. Clean area
with CoMat 01-438.
Fill damage with
CoMat 08-149,
(Epocast 1617 A/B).
Cure at 125°F
(51.7°C) for 5
hours.
Crack BC1 No cracks allowed. None.
BC2
BC3
BC4
BC5
Partial BC1 No penetration None.
Penetration/ BC2 allowed.
Hole BC3
BC4
BC5
Full BC1 No penetration None.
Penetration/ BC2 allowed.
Hole BC3
BC4
(b) The last nine (9) rivets at the outer panel skin
bottom edge (longitudinal), forward of the Forward
Split Line of the Translating sleeve.
75
RIVETS
EXISTING FWD
SPLIT LINE
LH
TRANSLATING
SLEEVE
LH OUTER SKIN
AFT EDGE
11
RIVETS
EXISTING AFT
DOUBLE LATCH
LH OUTER PANEL
SKIN BOTTOM EDGE
EXISTING DRAIN
HOLE (TYP)
9
RIVETS
PUSH PUSH
BL
100.0
RH OUTER PANEL SKIN
BOTTOM EDGE
Translating Sleeve
Figure 114
INNER BARREL-
PANEL ASSEMBLY
SEAL
RETAINER
INNER V-BLADE
A5S513
A A
A5S512
0.25 in.
(6,4 mm)
NO DAMAGE ZONE
NO REPAIR
SECTION A - A
CONE
FORWARD FRAME
INNER FAIRING
OUTER
"V” BLADE
SEAL
a5s531
SECTION A - A
LOOKING FORWARD
a5s529
NO DAMAGE ZONE
NO REPAIR
0.320 IN
REPAIRABLE (8,13 mm)
ZONE NO DAMAGE ZONE
0.252 IN NO REPAIR
(6,40 mm)
0.557 IN
(14,15 mm)
0.304 IN 0.204 IN
(7,72 mm) (5,18 mm)
0.125 IN
(3,18 mm)
NO DAMAGE ZONE
BREAK SHARP EDGES NO REPAIR
REPAIRABLE ZONE
MINIMUM REMAINING MATERIAL
a5s530
GENERAL REPAIR
1. General
Repairs given in this section are for structural damage exceeding the
limits shown in the Allowable Damage section. The repairs are written
to restore a part to it’s original strength and configuration as when
it was manufactured. Procedures to refinish a repaired area are also
given
2. Adhesive Preparation
Some repairs call for the use of certain adhesives. The following are
the procedures to use in the preparation of the adhesives.
A. EA956/L3 Adhesive
B. EA956 Adhesive
C. EA934NA Adhesive
D. EA9390 Resin
D. Both the original skin and the repair material must be clean
and dry before the repair can be started. Water on the surface
or in the materials will make the repair weak. All water must be
removed before the repair can be done. Use heat lamps at 230ºF-
250ºF for one hour.
Woven wire cloth is bonded to the perforated inner skin of the panel.
it contributes to the noise reduction ability of the panel.
REPAIR 001
FIXED DUCT HEATSHIELD RIVETED REPAIR
(VRS2005/2006)
1. General
A. This repair may be used to repair a hole greater than 0.50 in.
(12,7 mm) in diameter in the hot side of the heatshield of
either the left or the right fixed duct. It may also be used to
repair a tear or a crack greater than 0.5 in. in length.
B. This repair may not be used to repair holes greater than 6.0 in.
(152 mm) diameter. Contact Goodrich if damage is greater than
6.0 in (152 mm) diameter and lost or contamination of
insulation.
D. The damage must be a minimum of 3.0 in. (76,2 mm) edge to edge
from others repairs.
2. Referenced Information
VRS2005
VRS2006
A. Standard Equipment.
C. Repair Parts
D. Component Material
A. Cut away any torn heatshield skin pieces with metal cutters.
A. Find the size of the repair area. Mark around the damage and add
0.5 in. (12,7 mm) on all sides.
B. Cut out the cres sheet (CoMat 12-029) patch to the marked size.
CAUTION: YOU MUST PUNCH A VENT HOLE IN THE PATCH ONLY IF THE PATCH
IS TO COVER AN AREA WHERE A VENT HOLE EXIST. THERE MUST BE
A HOLE FOR EVERY 4 FT² (0,3716 M²) OF HEATSHIELD SURFACE
OR ONE VENT HOLE IN EACH CLOSED SEGMENT. VENT SHIELDS MUST
BE INSTALLED OVER THE VENT HOLES.
C. Make a vent hole through the patch with a 0.25 in. (6,35 mm)
diameter hand punch if the patch is to cover a vent hole.
A. Make the vent shield from foil CoMat 12-030 1 in. X 2 in. (25,4
mm X 50,8 mm).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Clean the surface around the vent hole on the repair patch and
the faying surface of the vent shield. Use Turco 6646 (CoMat
01-438) and wiping cloth
(CoMat 02-091). Wipe the surface dry before the solvent
evaporates.
NOTE: Use lint free gloves (CoMat 02-097) when you touch the
parts.
C. Drill or punch the rivet holes in the vent shield to make 0.128
in (3,25 mm) diameter holes.
(1) Use the vent shield as a template and put the corner of
the shield over the vent hole.
(2) Point the open side of the vent shield down towards the
lower edge of the heatshield.
(3) Drill 0.143 to 0.146 in. (3,63 to 3,70 mm) diameter holes
through the patch.
NOTE: The steps which follow apply to a repair which does not cover
a vent hole.
A. Drill or punch the rivet holes on the vent shield to make 0.128
in. (3,25 mm) diameter holes.
(1) Use the pre-drill patch as a template and put the center
of the patch over the damage hole.
(2) Drill 0.143 in. to 0.146 in. (3,63 to 3,70 mm) diameter
holes through the heatshield skin. Do not damage the
insulation material under the heatshield skin.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the faying surfaces around the patch and the repair area
of heatshield. Use Turco 6646 (CoMat 01-0438) and a wiping
cloth (CoMat 02-091). Wipe the surface dry before the solvent
evaporates.
NOTE: Use lint free gloves (CoMat 02-097) when you touch the
parts.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
E. Apply the sealant to the faying surface of the patch and the
heatshield.
F. Align the rivet holes of the patch and the heatshield and
install the rivet and the washers with the DAPCO 2100 sealant.
Make sure that the upper edge of the patch and the riveted edges
of the vent shield (if used) are sealed.
G. Remove unwanted sealant from the repair area with wiping cloth
(CoMat 02-091) before the sealant cures.
H. Let the sealant cure for two hours at 72° F (22° C) before it is
moves. The sealant will cure fully in 24 hours.
A. Make a mark VRS2005 for the left C-duct and VRS2006 for the
right C-duct adjacent to the assembly number.
CLEAN AREA
ALL AROUND
1.00 in.
(25,4 mm)
HOT SIDE
PREPARATION PATCH
STRAIGHTEN OR
REMOVE TORN FOIL
0.146 in.(3,70 mm)
DRILL DIA. HOLE
0.143 in.(3,63 mm)
HOT SIDE
FAYING
SURFACE SEAL HEAT SHIELD
ICN-V25-Y-543000-05037-S-001
INSULATION
0.25 in.(6,3 mm)
(Typical) 1.50 in.(38,1 mm)
SPACING
(Typical)
1.00 in.
(25.4 mm)
SPACING
(Typical) 0.25 in.(6,3 mm)
PATCH INSTALLATION (Typical) A5S515A
FAYING SURFACE
SEAL (3 sides only)
0.25 in.
(6,3 mm)
(Typical)
REPAIR 002
PERFORATED SKIN PARTIAL PENETRATION REPAIR
LEFT OR RIGHT FIXED DUCT ACOUSTIC PANEL
(VRS2007/2008)
1. General
(3) There must be a minimum distance of 2.0 in. (50,8 mm) from
the edge closures and splices to the edge of the damage.
(4) The hole area can be up to 144 square inches. (929 square
cm).
(5) There must be a minimum distance of 2.0 in. (50,8 mm) from
the edge of the damage to the junction of the barrel and
the bifurcation.
2. Reference Information
A. Standard Equipment
E. Component Material
F. Repair Parts
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: MAKE SURE YOU REMOVE ALL LOOSE WOVEN WIRE. THE STAINLESS
WOVEN WIRE HAS A STRONG ELECTROLYTIC REACTION WHEN IT IS
IN CONTACT WITH ALUMINUM ALLOYS. THIS CAUSES CORROSION TO
OCCUR.
A. Clean the surface with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub surface dry before solvent
evaporates.
C. Make a border 1.5 in. (38,1 mm) more than the cutout all around
on the perforated side of the panel. Use the
CoMat 02-161 Teflon tape. (For SN 1-5001 this also shows the
area of woven wire to be cut and removed from the repair area.)
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACE. THIS PREVENTS CONTAMINATION.
A. SN 1-5000 only (SN 5001 and on go to step 5B): Cut the woven
wire as marked. Use a sharp knife. Do not cut into the
perforated skin. Remove the cut woven wire from the repair
area. Remove the burrs.
B. Rub the surfaces lightly with CoMat 05-020 abrasive paper. Make
the surface rough in the area that was marked in step 4.C. Do
not cause damage to the perforated skin.
C. Cut and remove the damaged skin and core from the area marked.
Use a drive motor and routing tools. Remove the core. Remove
adhesive glossy finish and remaining core residue by lightly
hand sanding adhesive surface on solid skin. It is acceptable
for core imprint to remain. Take extra care not to sand through
adhesive. Use the CoMat 05-020 and CoMat 05-081 abrasive
papers. Do not cut into the solid skin.
D. Remove the sharp edges. Use the CoMat 05-020 and 05-081
abrasive papers.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
E. Clean the repair area with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub surface dry before solvent
evaporates.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Make the core plug from CoMat 02-324 core material. Make sure
the replacement core has the same shape, size, density, and
ribbon direction as the core that you removed. Remove the
burrs.
B. Put the core plug inside the cutout. Cut the edges as
necessary. The space between the plug and the core must not be
more than 0.05 in. (1,3 mm) all around. Make sure that the skin
and the plug are the same height and contour.
NOTE: Make the doubler from 0.045 in. (1,14 mm) material if
you will install it above the 74° splice line. Make the
doubler from 0.025 in (0,635 mm) material if you will
install it below the 74° splice line. If the cutout is
rectangular, use a minimum radius of 0.50 in. (12,7 mm)
at all corners of the repair doubler.
A. Install and cure the repair core plug per SRM 54-02-00, REPAIR
009 (VRS2372), using Method 4.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED CORE AND DOUBLER. THIS HELPS PREVENT
CONTAMINATION.
A. Clean the doubler and the repair area. Use a CoMat 02-099 lint
free cloth made moist with CoMat 01-438 solvent. Rub surface
dry before solvent evaporates.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
C. Apply adhesive primer to all edges of the core plug, the inner
surface of the solid skin, and all surfaces of the repair
doubler. Refer to SRM 54-02-00, General REPAIR 006 (VRS2374).
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH FILM
ADHESIVES AND THE CLEANED REPAIR PARTS. THIS HELPS PREVENT
CONTAMINATION.
A. If necessary, clean the doubler and the repair area. Use a dry
CoMat 02-099 lint free cloth. Rub the surface lightly to clean.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Prepare a vacuum bag for the repair doubler per SRM 54-02-00,
REPAIR 004 (VRS2370).
E. Disconnect the heat blankets and the vacuum source. Remove the
bagging materials and thermocouples.
F. Inspect the repair to make sure the doubler has not moved out of
position. If doubler has moved, remove doubler and repeat the
above steps for installation.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
NOTE: The rivet hole diameter is 0.129 to 0.132 in. (3,28 to 3,35
mm). The typical edge distance is 0.32 in. (8,1 mm). The
typical center-to-center distance and row spacing between the
holes is 0.50 in. (12,7 mm). Remove the burrs.
C. Wet install the rivets with CoMat 08-104 adhesive. See Figure
202 for rivet callout and approximate location.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED CORE AND DOUBLER. THIS HELPS TO PREVENT
CONTAMINATION.
A. Clean the repair area. Use a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub surface dry before solvent
evaporates.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Clean the repair area. Use a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub surface dry before solvent
evaporates.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
E. Cure the adhesive for one hour at 180° to 200°F (82° to 93°C).
Use an explosion proof heat lamp.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Remove the sharp edges. Make the surface in the repair area
smooth with the adjacent surface. Use the Comat 05-020 and 05-
081 abrasive papers.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
B. Clean the surface with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub surface dry before solvent
evaporates.
C
SOLID 2024-T3
SHEET DOUBLER
0.025 in. (0,635 mm)
BELOW 74° SPLICE
0.045 in. (1,143 mm)
ABOVE 74° SPLICE
REPAIR 003
FULL PENETRATION REPAIR
LEFT AND RIGHT FIXED DUCT ACOUSTIC PANEL
(VRS2009/2010)
1. General
(3) There must be a minimum distance of 2.0 in. (50,8 mm) from
the edge closures and splices to the edge of the damage.
(4) The hole area can be up to 144 square inches (929 square
cm).
(5) There must be a minimum distance of 2.0 in. (50,8 mm) from
the edge of the damage to the junction of the barrel and
the bifurcation.
2. Reference Information
A. Standard Tools
E. Component Material
F. Repair parts
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: MAKE SURE YOU REMOVE ALL LOOSE WOVEN WIRE. THE STAINLESS
WOVEN WIRE HAS A STRONG ELECTROLYTIC REACTION WHEN IT IS
IN CONTACT WITH ALUMINUM ALLOYS. THIS CAUSES CORROSION
SOURCES.
A. Clean the surfaces with CoMat 02-099 lint free cloth made moist
with CoMat 01-438 solvent. Rub surface dry before solvent
evaporates.
B. Make a mark of the damage area to be cut out. Use CoMat 06-131
marking pen. The cutout must go through the two sides of the
panel. It must have the smallest regular shape that will remove
the damage completely from the panel. The cutout can be
circular or rectangular.
C. Make a border 1.5 in. (38,1 mm) more than the cutout all around
on the perforated side of the panel. Use CoMat 02-161 Teflon
tape. (For SN 1-5000, this side also shows the area of woven
wire to be cut and removed from the repair area.)
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
A. SN 1-5000 only (SN 5001 and on, go to step 5B): Cut the woven
wire as marked. Use a sharp knife. Do not cut into the
perforated skin. Remove the cut woven wire from the repair
area. Remove the burrs.
B. Rub the surface lightly with CoMat 05-020 abrasive paper. Make
the surface rough in the area that was marked in step 4.C. Do
not cause damage to the perforated skin.
C. Cut and remove the damaged skins and core from the cutout area
as marked. Use a drive motor and routing tools. Remove the
burrs.
D. Remove the sharp edges. Use CoMat 05-020 and 05-081 abrasive
paper.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
E. Clean the repair area with CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub surface dry before solvent
evaporates.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
NOTE: Make the doubler from 0.045 in (1,14 mm) material if you
will install it above the 74° splice line. Make the doubler
from 0.025 in. (0,635 mm) material if you will install it
below the 74° splice line.
B. Make the core plug from the applicable thickness core material.
Use CoMat 02-324 core material. The core plug must have the
same ribbon direction, size, shape and density as the core you
removed. Remove the burrs.
A. Install and cure the repair core plug per SRM 54-02-00, REPAIR
009 (VRS2372) using Method 4.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
A. Clean the doublers and the repair area. Use CoMat 02-099 lint
free cloth made moist with CoMat 01-438 solvent. Rub surface
dry before solvent evaporates.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
C. Apply BR6750 adhesive primer to all edges of the core plug and
the inner surface of the repair doublers. Cure in reference to
the manufacturer’s data sheet.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
A. If necessary, clean the doublers and the repair area. Use CoMat
02-099 lint free cloth made moist with CoMat 01-438 solvent.
Rub the surface dry before the solvent evaporates.
F. Inspect repair to make sure the doublers have not moved out of
position. If the doublers have moved, remove doublers and
repeat the above steps for reinstallation.
A. Drill two rows of rivet holes through each doubler and the
adjacent skin. Do not drill through the opposite skin.
The rivet hole diameter is 0.129 to 0.132 in. (3,28 to 3,35 mm).
The typical edge distance is 0.32 in. (8,1 mm). The typical
center-to-center distance and row spacing between the holes is
0.50 in. (12,7 mm). Remove burrs.
NOTE: See Figure 202 for rivet callout and approximate location.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
A. Clean the repair area. Use a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface dry before the
solvent evaporates.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
A. Clean the repair area on the perforated skin side. Use a CoMat
02-099 lint free cloth made moist with CoMat 01-438 solvent.
Rub surface dry before solvent evaporates.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
E. Cure the adhesive for one hour at 180° to 200°F (82° to 93°C).
Use an explosive proof heat lamp.
A. Remove sharp edges. Make the surface in the repair area smooth
with the adjacent surfaces. Use CoMat 05-020 and
05-081 abrasive papers.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
B. Clean the surface with CoMat 02-099 lint free cloth made moist
with CoMat 01-438 solvent. Rub surface dry before solvent
evaporates.
A. Visually examine the repair area and do a tap test to check for
disbonds. No disbonds are allowed. Make sure that the
procedures in this repair are done. If necessary, do the
applicable steps again.
REPAIR 004
FIXED DUCT WOVEN WIRE SCRATCH, RIP, OR TEAR REPAIR
(VRS2011/2012)
1. General
2. Reference Information
VRS2011
VRS2012
A. Standard tools
Explosion proof heat lamp
Plastic spatula
Knife
E. Component Material
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
CAUTION: 1. MAKE SURE THAT ALL LOOSE WOVEN WIRE IS CUT AWAY. THE
STAINLESS WOVEN WIRE HAS A STRONG ELECTROLYTIC REACTION
WHEN IT IS IN CONTACT WITH ALUMINUM ALLOYS. THIS CAUSES
GALVANIC REACTION TO OCCUR.
A. Clean the surface with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface clean before
the solvent becomes dry.
B. Apply CoMat 02-160 teflon tape around the damage area. Add 0.4
in. (10 mm) around all sides of the damage. This makes an area
that is 0.8 in. (20,3 mm) wide.
C. Cut away all loose woven wire from the repair area. Use a sharp
knife. Do not cut into the perforated skin.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-091 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
A. Clean the repair area with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface clean before
solvent becomes dry.
D. Cure the adhesive for one hour at 180ºF to 200ºF (82ºC to 93ºC).
Use an explosion proof heat lamp.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Remove the sharp edges from the stabilized area. Use the CoMat
05-020 and 05-081 abrasive papers.
C. Clean the repair area with a Comat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface clean before
solvent becomes dry.
TEAR
RIP
ACOUSTIC PANEL
CORE
TEFLON TAPE
SMOOTH DAMAGE
SCRATCH
PERFORATED SKIN
BACK SKIN
APPLY ADHESIVE
13591
THIS SRM REPAIR HAS BEEN CANCELLED AND SHOULD NO LONGER BE APPLIED.
IF PREVIOUSLY ACCOMPLISHED, REFER TO V2500-NAC-78-0231 FOR DISPOSITION.
REPAIR 006
PERFORATED SKIN CRACK REPAIR
LEFT OR RIGHT FIXED DUCT ACOUSTIC PANEL
(VRS2015/2016)
1. General
F. The perforated skin must not be disbonded from the core in the
area around the crack. If there is a disbond, refer to REPAIR
002.
2. Referenced Information
A. Standard tools.
E. Component Material
F. Repair parts
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
CAUTION: 1. MAKE SURE THAT ALL LOOSE WOVEN WIRE IS CUT AWAY.
STAINLESS WOVEN WIRE HAS A STRONG ELECTROLYTIC REACTION
WHEN IT IS IN CONTAT WITH ALUMINUM ALLOYS. THIS CAUSES
GALVANIC REACATION TO OCCUR.
A. Clean the surface with CoMat 02-099 lint free cloth made moist
with CoMat 01-438 solvent. Rub the surface dry before the
solvent dries.
2. Cut the woven wire (SN 1 thru 5000 only) around the
crack as necessary to do the inspection. Use a sharp
knife. Do not cut into the perforated skin. Remove
the cut woven wire from the crack area. Remove the
burrs.
C. Drill 0.19 in. (4,8 mm) diameter holes at the two ends of the
crack. Remove the burrs.
2. Before you cut the woven wire, record and keep the
dimensions for the doubler to be used later.
G. Cut the woven wire as marked. Use a sharp cutting tool. Do not
cut into the perforated skin. Remove the cut woven wire from
the repair area. Remove the burrs.
H. Lightly mark the surface rough in the area where the woven wire
was removed. Use CoMat 05-020 abrasive paper. Do not cause
damage to the perforated skin.
I. Clean the area with CoMat 02-099 lint free cloth made moist
with CoMat 01-438 solvent. Rub the surface dry before the
solvent dries.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
DOUBLER. THIS PREVENTS CONTAMINATION.
A. Clean the doubler and repair area. Use CoMat 02-099 lint free
cloth made moist with CoMat 01-438 solvent. Rub the surface dry
before the solvent dries.
D. Cure the adhesive for one hour at 180° to 200°F (82° to 93°C)
with an explosion proof heat lamp.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
A. Put CoMat 02-161 Teflon tape around the outer area of the woven
wire 0.2 in. (5 mm) more than the woven wire cutout.
D. Serial Number 1 thru 5000 (SN 5001 and on go to step 8.E.): Make
sure the woven wire is stable. Apply a thin layer of the
adhesive mixture to the area between the CoMat 02-161 Teflon
tape and the doubler. Add more adhesive to completely cover the
cut edges of the wire.
E. Serial Number 5001 and on: Apply a thin layer of the adhesive
mixture to the area between the CoMat 02-161 Teflon tape and
the doubler.
F. Remove the CoMat 02-161 Teflon tape from the edges of the
adhesive mixture. Remove any unwanted adhesive with CoMat 02-
099 lint free cloth.
G. Cure the adhesive for one hour at 180° to 200°F (82° to 93°C).
Use an explosive proof lamp.
A. Drill two rows of rivets holes through the doubler and the
perforated skin. Do not drill through the opposite skin.
The rivet hole diameter is 0.129 to 0.132 in. (3,28 to 3,35 mm).
The typical edge distance is 0.32 in. (8,13 mm). The typical
center-to-center distance and row spacing between holes is 0.50
in. (12,7 mm). Remove the burrs.
B. Remove the drilling particles. Use CoMat 02-099 lint free cloth
made moist with CoMat 01-438 solvent. Rub the surface dry
before the solvent dries.
C. Wet install the rivets with CoMat 08-104 adhesive. See Figure
202 for the rivet call out and approximate location.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
B. Clean the surface with CoMat 02-099 lint free cloth made moist
with CoMat 01-438 solvent. Rub the surface dry before the
solvent dries.
REPAIR 007
THRUST REVERSER FIXED DUCT ACOUSTIC PANEL
OUTER PERFORATED SKIN SMALL HOLE REPAIR
(VRS2017/VRS2018)
1. General
D. Damage must be in field areas only. Refer to Figure 202 and 203
(5) For damage that occurs on the outer perforated skin and
inner solid skin in separate locations, the damage
separation from the edge of one damage to the edge of
another damage must be 4X diameter of the largest hole,
after damage removal
2. Referenced Information
A. Standard equipments
E. Component Material
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND
GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU
OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED.
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP, AND DISCARD CHEMICALS.
A. Clean the surface with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Wipe the surface dry.
B. Use a CoMat 06-131 marking pen to mark the repair area to the
smallest diameter that makes sure that all of the damage is
removed.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND
GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU
OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED.
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP, AND DISCARD CHEMICALS.
A. For SN 1-5000 only (For SN 5001 and on, go to step 5B): Cut the
woven wire as marked. Use a sharp knife. Do not cut into the
perforated skin. Remove the cut woven wire from the repair
area. Remove the burrs.
B. Cut and remove the damaged perforated skin and core to the
smallest diameter and depth possible to remove damage. Use a
drill or hole saw. Remove the burrs.
C. Remove the sharp edges. Use the CoMat 05-020 and 05-081
abrasive papers.
D. Clean the repair area with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Clean the surface before the
solvent dries.
8. If Woven Wire is on the Panel, Seal the Edges of the Woven Wire
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND
GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU
OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED.
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP, AND DISCARD CHEMICALS.
A. Make the surfaces in the repair area smooth with the adjacent
surfaces. Use the CoMat 05-020 and 05-081 abrasive papers.
B. Clean the surface with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Clean the surfaces before the
solvent dries.
RIGHT C-DUCT
OUTER
SKIN
FITTING
TANGENT
POINT
TYPICAL
A
PORTS ACOUSTIC STAY OUT ZONE ON UPPER
PANEL BIFURCATION WALL OUTER
DUCT INNER SKIN SKIN ZONE FS4 TYPICAL
REF
LEFT C-DUCT
ACOUSTIC
PANEL
INNER SKIN
REF
FITTING PORT
7.0 in.
(177,8 mm)
FIELD AREA
4 in. OUTER SKIN
4.0 in. ZONE FS1
(101,6 mm) (101,6 mm)
SPLIT
LINE
37.0 in.
(939,8 mm)
7.0 in 4.0 in.
(177,8 mm) (101,6 mm)
4.0 in.
(101,6 mm)
7.0 in.
(177,8 mm)
3.0 in.
(76,2 mm)
Figure 202
Repairable Damage in Field Areas Only
Of Outer Skin Zone FS1
7.0 in.
(177,8 mm)
4 in.
(101,6 mm)
SPLIT
4.0 in.
37.0 in. LINE
(101,6 mm)
(939,8 mm)
6.0 in.
(152,4 mm)
FIELD AREA
OUTER SKIN
ZONE FS1
3.0 in.
(76,2 mm) 3.0 in.
(76,2 mm)
9.0 in. 4 in.
(228,6 mm) (101,6 mm)
15.0 in. B
(381 mm) 31.0 in. LEFT HAND ASSEMBLY
(787,4 mm) VIEW LOOKING INBOARD
(Typical)
Note: Do not make repairs in these areas:
Figure 203
Repairable Damage in Field Areas Only
Of Outer Skin
REPAIR 008
TRANSLATING SLEEVE OUTER BARREL LAMINATED SKIN
FULL PENETRATION HOLE REPAIR
(VRS2019/2020)
1. General
This repair may be used to repair a hole in either the left or right
translating sleeve outer barrel which completely penetrates the
composite skin where there is no honeycomb core material.
A. Repair and Damage limits> See Figure 201, View C-C & D-D.
(3) For repair of damage to the fwd and aft edge of the left
or right translating sleeve see chapter 54-30-00, REPAIR
016.
(8) Minimum distance from the edge of the holes to the edge of
the repair cutout is: X3=8.0 in. (203,2 mm).
2. Referenced Information
VRS2019
VRS2020
A. Standard Equipment
D. Component Material
4. Prepare the Damaged Panel for Repair (See Figure 201 & 202)
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
B. Mark the repair area to the smallest diameter that makes sure
that all of the damage is removed. Make sure the shape of the
cutout will allow a backup plate to be inserted through the
hole and provide 1 1.0 in. (25,4 mm) overlap on the inboard
surface.
C. Cut out the damaged skin and use a minimum radius of 0.50-in.
(12.7 mm) at all corners. Chamfer the edges of the outer
surface of the skin panel to 45 degrees and remove all loose
particles.
D. Mask around the repair area with 2.00-in. wide Teflon Tape
(CoMat 02-161). Add 5.00-in. (127,0 mm) to the repair area all
around the hole to give an overlap area.
CAUTION: DO NOT TAPER OR BREAK THE CARBON FIBERS OF THE TOP SURFACE
OF THE OUTER SKIN PLY.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
H. Let the repair area dry for one hour at 230°F-250°F (110°C-
121°C) with an explosion proof heat lamp.
5. Prepare the Fiberglass Fabric Backup Plate (See Figure 202 and 203)
A. Find the size and shape of the backup plate. The plate must pass
through the cutout and overlap the cutout by 1.00-in. (25.4 mm)
all around when it is installed.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
(2) Apply the EA9390 resin (CoMat 08-050) to the ply and cove
the ply with another sheet of the Non-porous Parting Film
(CoMat 02-168).
(3) Use a roller to force the EA9390 resin (CoMat 08-050) into
the ply thoroughly.
(4) Remove the top sheet of Non-porous Parting Film (CoMat 02-
168) from the first ply.
(5) Do steps (1), (2), and (3) for the second ply.
(7) Smooth out any wrinkles and remove the top sheet of Non-
porous Parting Film (CoMat 02-168).
(8) Do steps (1) through (7) again for the third ply.
(9) Trim the ply stack to the correct size and shape.
F. Cover the Silicone Rubber Sheet (CoMat 02-170) with the heat
blanket and two plies of 181-Fiberglass Fabric (CoMat 02-167)
to serve as a breather cloth.
G. Cover the repair area with the Nylon Bagging Film (CoMat 02-
163) that is a minimum of 2.00-in. (5038 mm) larger all around.
Put the vacuum connector under the vacuum bag and seal the
edges with the Tacky Tape (CoMat 12-024).
H. Attach the vacuum pump hose to the vacuum connector and connect
the heat blanket to an electrical source.
B. After the EA9390 resin (CoMat 08-050) has cured, remove the
layup materials from the backup plate.
A. Drill 0.070-in. (1.9mm) holes through the backup plate near the
centerline. Drill the holes as sets spaced 0.38-in. (9.5 mm)
apart.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
D. Apply the resin mix to an area 1.00-in. (25.4 mm) wide all
around the inner faying surface of the skin through the cutout
and to the faying surface of the backup plate.
E. Put the backup plate through the cutout and put it against the
inner skin surface.
F. Put a rod over the cutout and twist the Lockwire (CoMat 02-156)
ends around it to firmly hold the backup plate to the inner skin
surface.
NOTE: Do not twist the Lockwire (CoMat 02-156) ends too tightly
or you may warp the backup plate.
I. After the EA9390 resin (CoMat 08-050) is cured, remove the heat
lamp and the support rod. Cut the Lockwire (CoMat 02-156) even
with the surface of the backup plate.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS..
A. Cut four (4) Graphite Fabric (CoMat 02-165) filler plies to the
shape of the cutout. Make enough plies to give the same
thickness as the adjacent skin. Cut the plies so that their
warps are at 0°/+45°/-45°/0° to each other. Repeat warp
sequence if addtional filler plies are required..
NOTE: Cut the plies 0.50-in. (12.7 mm) larger all around so
that they do not get frayed. Trim them to the correct
size after they are impregnated with resin.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
(2) Apply the EA9390 resin (CoMat 08-050) to the ply and cover
the ply with another sheet of the Non-porous Parting Film
(CoMat 02-168).
(3) Use a roller to force the EA9390 resin (CoMat 08-050) into
the ply thoroughly.
(4) Remove the top sheet of Non-porous Parting Film (CoMat 02-
168) from the first ply.
(5) Do steps (1), (2) and (3) for the second ply.
(7) Smooth out any wrinkles and remove the top sheet of Non-
porous Parting Film (CoMat 02-168).
(8) Do steps (1) through (7) again for any additional plies.
D. Trim the ply stack to the size and shape of the cutout.
10. Install the Outer Skin Repair Patch (See Figure 204)
(1) Cut ply no. 1 with the warp at 0 degrees. Cut the ply
1.00-in. (25.4 mm) larger all around than the cutout. Trim
the corners 45 degrees by 1.00-in. (25.4 mm).
(2) Cut ply no. 2 with the warp at +45 degrees. Cut the ply
0.75-in. (19.1 mm) larger all around than the first ply.
Trim the corners 45 degrees by 1.00-in. (25.4 mm).
(3) Cut ply no. 3 with the warp at -45 degrees. Cut the ply
0.75-in. (19.1 mm) larger all around than the first ply.
Trim the corners 45 degrees by 1.00-in. (25.4 mm).
(4) Cut ply no. 4 with the warp at 0 degrees. Cut the ply
1.00-in. (25.4 mm) larger all around than the cutout. Trim
the corners 45 degrees by 1.00-in. (25.4 mm).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
E. Use a roller to force the EA9390 resin (CoMat 08-050) into the
ply thoroughly.
G. Smooth out any wrinkles and remove the top sheet of Non-porous
Parting Film (CoMat 02-168).
F. Cover the Silicone Rubber Sheet (CoMat 02-170) with the heat
blanket and two plies of 181-Fiberglass Fabric (CoMat 02-167)
to serve as a breather cloth.
G. Cover the repair area with the Nylon Bagging Film (CoMat 02-
163) that is a minimum of 2.00-in. (50.8 mm) larger all around.
Put the vacuum connector under this vacuum bag and seal the
edges with the Tacky Tape (CoMat 12-024).
H. Attach the vacuum pump hose to the vacuum connector and connect
the heat blanket to an electrical source.
J. After the EA9390 resin (CoMat 08-050) has cured, remove the
layup materials from the repair.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
o
45
0.75 in.(19,0 mm) (Typical)
REPAIR PLY
NO.1 1.0 in. (25 mm) 0.50 in.
(12,7 mm)
REPAIR PLY RADIUS
NO.2
A A
CUTOUT
REPAIR PLY
NO.3
REPAIR PLY
NO.4 1.0 in.
(25 mm)
(Typical)
SANDING PLY
FILLER PLIES
o SKIN PANEL
BACKUP PLATE 45 CUTOUT
CUTOUT
BACKUP PLATE
ROD
A A
LOCKWIRE HOLES,
PLATE 4 HOLES, LOCATED
INSERTION NEAR THE CENTERLINE
POSITION OF THE BACK-UP
PLATE AS SHOWN
SKIN PANEL
LOCKWIRE
ROD
45°
13912A
VACUUM HOSE
TEFLON TAPE
TEFLON TAPE
SEALANT
CUTOUT
o
45 BACKUP PLATE
PANEL SKIN
THERMOCOUPLE
13913B
REPAIR 009
FIXED DUCT ACOUSTIC PANEL SOLID SKIN CRACK REPAIR
(VRS2021/2022)
1. General
F. The solid skin must not be disbonded from the core in the area
around the crack. If there is a disbond, refer to REPAIR 010.
2. Reference information
A. Standard Equipment
E. Component Material
F. Repair Parts
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND
GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU
OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED.
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP, AND DISCARD CHEMICALS.
A. Clean the surface with CoMat 02-099 lint free cloth made moist
with CoMat 01-438 solvent. Rub the surface dry before the
solvent dries.
C. Drill 0.19 in. (4,83 mm) diameter holes at the two ends of the
crack. Remove the burrs.
2. Before you cut the woven wire, record and keep the
dimensions for the doubler to be used later.
H. Clean the area with CoMat 02-099 lint free cloth made moist
with CoMat 01-438 solvent. Rub the surface dry before the
solvent dries.
B. Put the repair doubler above the damaged area. Refer to figure
202 for overlap.
C. Drill two rows of rivet holes through the repair doubler and
the solid skin assembly. Do not drill through the opposite
skin.
D. The rivet hole diameter is 0.129 to 0.132 in. (3,28 to 3,35 mm).
The typical edge distance is 0.32 in. (8,13 mm). The typical
center-to-center distance and row distance between the holes is
0.50 in. (12,7 mm). Remove the burrs.
E. Remove the drilling particles from the repair doubler and skin
assembly. Use a CoMat 02-099 lint free cloth made moist with
CoMat 01-438 solvent. Clean the surfaces before solvent dries.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND
GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU
OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED.
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND
GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU
OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED.
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP, AND DISCARD CHEMICALS.
C. Clean the surface with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Clean the surface before the
solvent dries.
REPAIR 010
FIXED DUCT ACOUSTIC PANEL PARTIAL PENETRATION
THROUGH THE SOLID INNER SKIN REPAIR
(VRS2023/VRS2024)
1. General
E. There must be a minimum distance of 2.0 in. (50,8 mm) from the
edge of the damage to the junction of the barrel and the
bifurcation. There must be a minimum distance of four times the
diameter of the damage between the edges of two adjacent damage
areas
2. Referenced Information
A. Standard Equipment
E. Component Material
F. Repair Parts
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND
GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU
OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED.
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
A. Clean the surface with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface clean and dry
before the solvent dries.
B. Make a mark of the damaged area. Use CoMat 06-131 marking pen.
The cutout must have the smallest regular shape that removes
all of the damage. The cutout can be circular or rectangular.
C. Make a border 1.5 in. (38,1 mm) more than around the cutout. Use
the CoMat 02-161 Teflon tape.
D. Cut and remove the damaged skin and core from the area marked.
Use a drive motor and routing tools. Remove the core. Remove
adhesive glossy finish and remaining core residue by lightly
hand sanding adhesive surface on solid skin. It is acceptable
for core imprint to remain. Take extra care not to sand through
adhesive. Use the CoMat 05-020 and CoMat 05-081 abrasive
papers. Do not cut into the perforated skin.
E. Remove the sharp edges. Use the CoMat 05-020 and CoMat 05-081
abrasive papers.
F. Clean the repair area with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Clean the surfaces before the
solvent dries
A. Make the core plug from CoMat 02-324 core material. Make sure
the replacement core has the same shape, size, density, and
ribbon direction as the core that you removed. Remove the
burrs.
B. Put the core plug into the cutout. Trim the edges as
necessary. The space between the plug and the existing core
must not be more than 0.05 in. (1,27 mm) around. Make the core
plug the same height and contour with the solid skin of the
acoustic panel.
A. Install and cure the repair core plug per SRM 54-02-00, REPAIR
009 (VRS2372) using Method 4.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND
GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU
OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED.
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
A. Clean the doubler and the repair area. Use a CoMat 02-099 lint
free cloth made moist with CoMat 01-438 solvent. Clean the
surfaces before solvent dries.
B. Force air dry for 30 minutes at 190o to 210oF (88o to 99o C).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND
GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU
OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED.
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
A. Prepare a vacuum bag for the repair area use SRM 54-02-00,
REPAIR 006 (VRS2370) as guide.
E. Disconnect the heat blankets and the vacuum source. Remove the
bagging materials and thermocouples.
F. Examine the repair to make sure doubler has not moved out of
position. If doubler has moved, remove doubler and do again the
above steps for installation.
A. Drill two rows of rivet holes through the doubler and the solid
skin. Do not drill through to the opposite skin.
B. The rivet hole diameter is 0.129 to 0.132 in. (3,28 to 3,35 mm).
The typical edge distance is 0.32 in. (8,1 mm). The
typical center-to-center distance and row spacing between the
holes is 0.50 in. (12,7 mm). Remove the burrs.
D. Wet install the rivets with CoMat 08-104 adhesive. See Figure
203 for rivet call out and approximate location.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
A. Clean the repair area. Use a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Clean the surface before
solvent dries.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND
GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU
OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED.
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP, AND DISCARD CHEMICALS.
A. Remove the sharp edges. Make the surface in the repair area
smooth with the adjacent surface. Use the CoMat 05-020 and 05-
081 abrasive papers.
B. Clean the surface with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Clean the surface before the
solvent dries.
28.0 in.
31.0 in. (711,2 mm)
(787,4 mm)
20.0 in.
(508,0 mm)
7.0 in.
(177,8 mm)
4 in.
(101,6 mm)
SPLIT
4.0 in.
37.0 in. LINE
(101,6 mm)
(939,8 mm)
6.0 in.
(152,4 mm)
3.0 in.
(76,2 mm) 3.0 in.
(76,2 mm)
9.0 in. 4 in.
(228,6 mm) (101,6 mm)
15.0 in. B
(381 mm) 31.0 in. LEFT HAND ASSEMBLY
(787,4 mm) VIEW LOOKING INBOARD
(Typical)
Note: Do not make repairs in these areas:
THIS SRM REPAIR HAS BEEN CANCELLED AND SHOULD NO LONGER BE APPLIED.
IF PREVIOUSLY ACCOMPLISHED, REFER TO V2500-NAC-78-0231 FOR DISPOSITION.
REPAIR 012
SOLID INNER SKIN SMALL HOLE REPAIR – NOT FULLY THROUGH PANEL
LEFT OR RIGHT FIXED DUCT ACOUSTIC PANEL
(VRS2027/2028)
1. General
(2) Minimum distance from the edge of this damage to the edge
of other damage is 5.0 in. (127 mm).
2. Reference Information
VRS2027
VRS2028
A. Standard tools
Drill and drilling equipment
Heat lamp (explosion proof)
Heat blanket
Hole saw
Plastic spatula
Routers and routing tools
Temperature controller
D. Component Material
4. Prepare the Damaged Area For Repair, (See Figure 201, Sheet 3)
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Make a mark of the damage area with the smallest diameter that
removes all the damage. Apply CoMat 02-160 teflon tape around
the marked area.
B. Remove the damaged skin and core from the repair area to the
smallest depth possible. Use a hole saw. Do not cut into the
perforated skin.
C. Remove the sharp edges. Use the CoMat 05-020 and 05-081
waterproof silicon carbide abrasive papers.
D. Clean the repair area with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface clean before
the solvent dries.
CAUTION: PUT ON COMAT 02-097 LINT FREE GLOVES BEFORE YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
B. When you fill the damage area with the adhesive, make sure that
the adhesive does not flow out of the perforated skin. To stop
the flow of adhesive, put a piece of CoMat 02-168 non-porous
parting film over the perforated skin side of the panel in the
repair area. Use pieces of CoMat 02-160 teflon tape to hold the
non-porous parting film in place. Apply pressure as necessary.
C. Fill the damage area with CoMat 08-104 adhesive. Fill the
damage area until a small quantity of adhesive is higher than
the adjacent surface.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Use the CoMat 05-020 and 05-081 abrasive papers. Remove the
sharp edges. Make the surface in the repair area smooth with
the adjacent surface.
B. Clean the surface with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface clean before
the solvent dries.
A. Write the repair numbers VRS2027 for the left fixed duct
acoustic panel or VRS2028 for the right fixed duct acoustic
panel adjacent to the assembly number. Use a CoMat 06-131
marking pen of a color that contrasts.
28.0 in.
(711,2 mm) 31.0 in.
(787,4 mm)
20.0 in.
(508,0 mm)
7.0 in.
(177,8 mm)
4 in.
(101,6 mm)
SPLIT
3.0 in. LINE 4.0 in. 37.0 in.
(76,2 mm) (101,6 mm) (939,8 mm)
6.0 in.
(152,4 mm)
3.0 in.
4 in. (76,2 mm)
(101,6 mm)
9.0 in.
4 in. (228,6 mm)
(101,6 mm) 15.0 in.
31.0 in. (381 mm)
(787,4 mm)
31.0 in.
28.0 in.
(787,4 mm)
(711,2 mm)
3.0 in.
(76,2 mm) 20.0 in.
(508,0 mm)
7.0 in.
(177,8 mm)
6.0 in.
7.0 in. (152,4 mm)
(177,8 mm)
4.0 in.
(101,6 mm)
CORE
PERFORATED SKIN
AND WOVEN WIRE
SMALL HOLE DAMAGE TEFLON TAPE
TYPICAL DAMAGE
PERFORATED SKIN
AND WOVEN WIRE DRILL TO MINIMUM
NON-POROUS DEPTH AND DIAMETER
PARTING FILM APPLY PRESSURE TO REMOVE DAMAGE
SECTION A-A
VRS2027-3
REPAIR 013
FULL PENETRATION HOLE REPAIR THROUGH THE FORWARD FRAME
LEFT OR RIGHT TRANSLATING SLEEVE OUTER BARREL
(VRS2029/2030)
1. General
2. Reference Information
VRS2029
VRS2030
A. Standard tools
Cutters and cutting tools
Drills and drilling tools
Explosive proof heat lamp
Heat blanket
Standard shop tools
Temperature controller
Temperature recorder
Thermocouples
Vacuum probe
Vacuum pump
E. Component material
F. Component materials
4. Prepare the Damaged Area For Repair, (See Figure 201 and 202)
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Clean the surface with CoMat 02-099 lint free cloth made moist
with CoMat 01-438 solvent. Rub surface dry before solvent
becomes dry.
C. Cut out the damaged skins and core as marked. Use cutters and
cutting tools. If the cutout is rectangular, use a minimum
radius of 0.50 in. (12,7 mm) at all corners.
F. Remove all of the surfaces finish and lightly make the surfaces
rough in the area between the pieces of Teflon tape. Use CoMat
05-81 abrasive papers.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
H. Let the repair area dry for one hour at 230° to 250°F (110° to
121°C). Use an explosive proof heat lamp.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Make a repair plug from repair core material to fit the size and
length of the removed damage core. Make the repair plug with
the same ribbon direction ad the original core. See
54-30-00 Structural identification to determine the type,
density and thickness of the core material.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Find the size and shape of the filler plies. Cut the plies 0.50
in. (12,7 mm) larger than the cutout all around. Cut the filler
plies to the correct size after they are impregnated with
resin.
B. Cut the first filler ply from the CoMat 02-167 fiberglass
fabric. Cut the filler plies from CoMat 02-165 graphite fabric.
Cut the filler plies with alternating warp directions of 0°/
+45°/-45°/0° degrees. Make enough plies to give the same
thickness as the inner skin.
NOTE: Visually examine the filler plies to make sure that they
have the correct warp orientation.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
(1) Put the first filler ply on a sheet of CoMat 02-168 non-
porous parting film.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
(3) Use a roller to force the resin fully into the ply.
(4) Repeat steps (1), (2) and (3) for the other filler plies.
(5) Remove the non-porous parting film from the top of the
first 0° degree filler ply. Remove the non-porous parting
film from the bottom of the second ply.
(6) put the second filler ply (+45° degrees) over the center
of the first filler ply (0° degree) and smooth out all
wrinkles.
(7) Repeat steps (5) and (6) for the remaining graphite filler
plies to make a stack of filler plies.
(8) Cut the edges of the stack of the filler plies to the
correct size of the cutout.
7. Install the Inner Skin Repair Plies, (See Figures 202 and 203)
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Cut the repair plies from the CoMat 02-165 graphite fabric. Cut
the corners of the plies 45 degrees by 1.0 in. (25,4 mm). See
Figure 202.
(1) Cut ply No. 1 with the warp at 0° degree. Cut the ply 1.0
in. (25,4 mm) larger that the cutout all around.
(2) Cut ply No. 2 with the warp at 0° degree. Cut the ply 0.75
in. (19 mm) larger than the first ply all around.
(3) Cut ply No. 3 with warp at 0° degree. Cut the ply 0.75 in.
(19 mm) larger than the second ply all around.
(4) Cut ply No. 4 with warp at 0° degree. Cut the ply 0.75 in.
(19 mm) larger than the third ply all around.
NOTE: Do not cover the Teflon tape with the fiberglass sanding
ply.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
E. Put another sheet of parting film above the repair ply. Use a
roller to force the resin fully into the ply.
(1) Remove the bottom sheet of nonporous parting film from the
repair ply. Put repair ply above the cutout and filler
plies.
(2) Press the ply into position and remove the wrinkles. Use a
roller if necessary.
(3) Remove the top sheet of the non-porous parting film from
the ply.
G. Do Steps D., E., and F for the remaining repair plies and for
the fiberglass sanding ply.
NOTE: Make sure repair plies are put together with the correct
warp direction. Make sure you remove the non-porous
parting films from the plies.
8. Install the Outer Skin Filler Plies, (See Figure 202 and 203)
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Find the size and shape of the filler plies. Cut the plies 0.50
in. (12,7 mm) larger than the cutout all around. Cut the filler
plies to the correct size after they are impregnated with
resin.
B. Cut the first filler ply from the CoMat 02-167 Fiberglass
fabric. Cut the remaining filler plies from the CoMat 02-165
Graphite fabric. Cut the filler plies with warp directions of
0°/+45°/-45°/0° degrees to each other. Repeat warp sequence if
additional filler lies are needed. Make enough filler plies to
give the same thickness as the outer skin.
NOTE: Visually examine the repair plies to make sure that they
have the same warp orientation as the original acoustic
panel outer skin.
(1) Put the first filler ply on a sheet of CoMat 02-168 non-
porous parting film.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
(2) Apply the resin to the ply. Put another sheet of parting
film above the filler ply.
(3) Use a roller to force the resin fully into the ply.
(4) Do steps (1), (2) and (3) for the other filler plies.
(5) Remove the non-porous parting film from the top of the
first ply. Remove the non-porous parting film from the
bottom of the second ply.
(6) Put the second ply over the center of the first ply and
smooth out all wrinkles. Warp direction of the warp
sequence for additional filler plies.
(7) Repeat steps (5) and (6) for the remaining graphite filler
plies to make a stack of filler plies.
(8) Cut the edges of the crack of the filler plies to the
correct size of the cutout.
9. Prepare Vacuum Bags For the Repair on the Two Sides, (See Figure 203)
A. Prepare a vacuum bag for the outer surface side of the repair.
(2) Put a sheet of CoMat 02-169 porous parting film above the
repair area. The sheet must be 3.0 in. (76,2 mm) larger
than the repair area all around.
(3) Put four plies of CoMat 02-167 fiberglass fabric above the
porous parting film. This will serve as the bleeder cloth.
(7) Put two plies of CoMat 02-166 breather cloth above the
heat blanket.
(8) Put a sheet of CoMat 02-163 nylon bagging film above the
repair area. THe sheet must be 2.0 in. (50,8 mm) larger
than the repair pieces all around.
(9) Put a vacuum probe under the nylon bagging film. Seal the
thermocouples and vacuum probe. Use CoMat 12-024 sealant.
Seal the edges of the nylon bagging film to the skin. Use
CoMat 12-024 sealant.
B. Prepare a vacuum bag for the inner surface side of the repair.
Repeat the above steps for the inner surface, but do not use a
caul plate. When you do step (5), put a sheet of CoMat 02-170
silicone rubber above the non-porous parting film.
A. Cure the repair for 220 minutes at 190° to 210°F (88° to 99°C).
Keep a steady vacuum pressure on 22 inches of mercury during
the cure.
B. Disconnect the heat blanket and the pressure source. Remove the
bagging materials.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Remove sharp edges in the repair area on the outer surface. Use
the CoMat 05-020 and 05-081 abrasive papers.
B. Clean the surface with a CoMat 01-438 solvent. Rub surface dry
before the solvent becomes dry.
12. Install the Outer Skin Repair Plies, (See Figure 202)
A. Cut the repair plies from the CoMat 02-165 graphite fabric. Cut
the corners of plies 45° degrees by 1.0 in. (25,4 mm). See
Figure 202.
(1) Cut ply No. 1 with warp at 0° degree. Cut the ply 1.0 in.
(25,4 mm) larger than the cutout all around.
(2) Cut ply No. 2 with warp at +45° degrees. Cut the ply 0.75
in. (19 mm) larger than the first ply all around.
(3) Cut ply No. 3 with the warp at -45° degrees. Cut the ply
0.75 in. (19 mm) larger than the second ply all around.
(4) Cut ply No. 4 with warp at 0° degree. Cut the ply 0.75 in.
(19 mm) larger than the third ply all around.
NOTE: Do Not cover the Teflon tape with the fiberglass sanding
ply.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
E. Put another sheet of parting film above the repair ply. Use a
roller to force the resin full into the ply.
(2) Press the ply into position and remove the wrinkles. Use a
roller if necessary.
(3) Remove the top sheet of the non-porous parting film from
the ply.
G. Repeat steps D., E., and F. for the remaining repair plies and
for the fiberglass sanding ply.
NOTE: Make sure the repair plies are put together with the
correct warp direction. Make sure you remove the non-
porous parting film from the plies.
13. Prepare a Vacuum Bag For the Repair Plies On The Outer Surface (See
Figure 204)
A. Prepare a vacuum bag for the outer surface side of the repair.
(2) Put a sheet of CoMat 02-169 porous parting film above the
repair area. The sheet must be 3.0 in. (76,2 mm) larger
than the repair area all around.
(3) Put four plies of CoMat 02-167 fiberglass fabric above the
porous parting film. This will serve as the bleeder cloth.
(7) Put two plies of CoMat 02-166 breather cloth above the
heat blanket.
(8) Put a sheet of CoMat 02-163 nylon bagging film above the
repair area. THe sheet must be 2.0 in. (50,8 mm) larger
than the repair pieces all around.
(9) Put a vacuum probe under the nylon bagging film. Seal the
thermocouples and vacuum probe. Use CoMat 12-024 sealant.
Seal the edges of the nylon bagging film to the skin. Use
CoMat 12-024 sealant.
A. Cure the repair for 220 minutes at 190° to 210°F (88° to 99°C).
Keep a steady vacuum pressure on 22 inches of mercury during
the cure.
B. Disconnect the heat blanket and the pressure source. Remove the
bagging materials.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Remove sharp edges in the repair area on the outer surface. Use
the CoMat 05-020 and 05-081 abrasive papers.
B. Clean the surface with a CoMat 01-438 solvent. Rub surface dry
before the solvent becomes dry.
A. Apply the external paint to the repair area. See SRM 54-30-00,
Repair No. 023 (VRS2049/2058).
REPAIR 014
OUTER BARREL PARTIAL PENETRATION HOLE REPAIR OUTER STIFFENER FRAMES
LEFT OR RIGHT TRANSLATING SLEEVE OUTERSKIN
(VRS2031/2032)
1. General
(3) Closure plies for the frames are not punctured or damaged.
C. Damage and repair limits for the forward frame (sta 11.9) are
as Follows:
2. Reference Information
VRS2031
VRS2032
A. Standard tools
Cutters and cutting tools
Drills and drilling tools
Explosive proof heat lamp
Heat blanket
Standard shop tools
Temperature controller
Temperature recorder
Thermocouples
Vacuum probe
Vacuum pump
E. Component materials
F. Repair parts
4. Prepare the Damaged Area For Repair, (See Figure 202 and 203)
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Clean the surface with CoMat 02-099 lint free cloth made moist
with CoMat 01-438 solvent. Rub surface dry before solvent
becomes dry.
C. Cut out the damaged skins and core as marked. Use cutters and
cutting tools. If the cutout is rectangular, use a minimum
radius of 0.50 in. (12,7 mm) at all corners.
D. Remove the damage core from the frame up to the inside surface
of the inner skin. DO not remove the adhesive nuggets from the
inner skin surface. Do not damage the skin fibers. Chamfer the
edges. Remove all loose pieces and fibers. Make the edges
smooth. Use CoMat 05-020 and 05-081 abrasive papers.
F. Remove all of the surfaces finish and lightly make the surfaces
rough in the area between the pieces of Teflon tape. Use CoMat
05-81 abrasive papers.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
H. Let the repair area dry for one hour at 230° to 250°F (110° to
121°C). Use an explosive proof heat lamp.
A. Make a repair plug from repair core material to fit the size and
length of the removed damage core. Make the repair plug with
the same ribbon direction ad the original core.
See 54-30-00 Structural identification to determine the type,
density and thickness of the core material.
NOTE: Visually examine the repair plug to make sure that it has
the correct dimensions and ribbon direction. Make sure it
aligns with the core material acoustic panel.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
6. Install the Outer Skin Fillers Plies, (See Figure 202 and 203)
A. Find the size and shape of the filler plies. Cut the plies 0.50
in. (12,7 mm) larger than the cutout all around. Cut the filler
plies to the correct size after they are impregnated with
resin.
B. Cut the first filler ply from the CoMat 02-167 fiberglass
fabric. Cut the filler plies from CoMat 02-165 graphite fabric.
Cut the filler plies with alternating warp directions of 0°/
+45°/-45°/0° degrees. Repeat sequence if additional filler
plies are needed. Make enough plies to give the same thickness
as the outer skin. See 54-30-00 Structural Identification
Figure 1, Table 1 for correct warp orientation.
NOTE: Visually examine the filler plies to make sure that they
have the correct warp orientation as the original
acoustic panel outer skin.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
(1) Put the first filler ply on a sheet of CoMat 02-168 non-
porous parting film.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
(3) Use a roller to force the resin fully into the ply.
(4) Repeat steps (1), (2) and (3) for the other filler plies.
(5) Remove the non-porous parting film from the top of the
first 0° degree filler ply. Remove the non-porous parting
film from the bottom of the second ply.
(6) Put the second filler ply (+45° degrees) over the center
of the first filler ply (0° degree) and smooth out all
wrinkles.
(7) Repeat steps (5) and (6) for the remaining graphite filler
plies to make a stack of filler plies.
(8) Cut the edges of the stack of the filler plies to the
correct size of the cutout.
7. Install the Outer Skin Repair Plies, (See Figures 202 and 203)
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Cut the repair plies from the CoMat 02-165 graphite fabric. Cut
the corners of the plies 45º by 1.0 in. (25,4 mm). See Figure
202.
(1) Cut ply No. 1 with the warp at 0° degree. Cut the ply 1.0
in. (25,4 mm) larger that the cutout all around.
(2) Cut ply No. 2 with the warp at 0° degree. Cut the ply 0.75
in. (19 mm) larger than the first ply all around.
(3) Cut ply No. 3 with warp at 0° degree. Cut the ply 0.75 in.
(19 mm) larger than the second ply all around.
(4) Cut ply No. 4 with warp at 0° degree. Cut the ply 0.75 in.
(19 mm) larger than the third ply all around.
NOTE: Do not cover the Teflon tape with the fiberglass sanding
ply.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
E. Put another sheet of parting film above the repair ply. Use a
roller to force the resin fully into the ply.
(1) Remove the bottom sheet of nonporous parting film from the
repair ply. Put repair ply above the cutout and filler
plies.
(2) Press the ply into position and remove the wrinkles. Use a
roller if necessary.
(3) Remove the top sheet of the non-porous parting film from
the ply.
G. Do Steps D., E., and F for the remaining repair plies and for
the fiberglass sanding ply.
NOTE: Make sure repair plies are put together with the correct
warp direction. Make sure you remove the non-porous
parting films from the plies.
8. Prepare Vacuum Bags For the Repair On the Two Sides, (See Figure 204)
A. Prepare a vacuum bag for the outer surface side of the repair.
H. Put two plies of CoMat 02-166 breather cloth above the heat
blanket.
I. Put a sheet of CoMat 02-163 nylon bagging film above the repair
area. THe sheet must be 2.0 in. (50,8 mm) larger than the repair
pieces all around.
J. Put a vacuum probe under the nylon bagging film. Seal the
thermocouples and vacuum probe. Use CoMat 12-024 sealant. Seal
the edges of the nylon bagging film to the skin. Use CoMat 12-
024 sealant.
K. Prepare a vacuum bag for the inner surface side of the repair.
Repeat the above steps for the inner surface, but do not use a
caul plate. When you do step (5), put a sheet of CoMat 02-170
silicone rubber above the non-porous parting film.
A. Cure the repair for 220 minutes at 190° to 210°F (88° to 99°C).
Keep a steady vacuum pressure on 22 inches of mercury during
the cure.
B. Disconnect the heat blanket and the pressure source. Remove the
bagging materials.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Remove sharp edges in the repair area on the outer surface. Use
the CoMat 05-020 and 05-081 abrasive papers.
B. Clean the surface with a CoMat 01-438 solvent. Rub surface dry
before the solvent becomes dry.
REPAIR 015
OUTER BARREL LAMINATED SKIN SURFACE DAMAGE REPAIR
LEFT OR RIGHT TRANSLATING SLEEVE OUTER SKIN
(VRS2033/2034)
1. General
(2) Bottom outer skin composite ply is damaged but not fully
penetrated.
2. Reference Information
VRS2033
VRS2034
A. Standard tools
Explosive proof heat lamp
Heat blanket
Temperature controller
Temperature recorder
Thermocouples
Vacuum probe
Vacuum pump
E. Component materials
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Clean the surface with CoMat 02-099 lint free cloth made moist
with CoMat 01-438 solvent. Rub surface dry before solvent
becomes dry.
C. Make a border around the marked area with CoMat 02-161 Teflon
tape. To make a border, add 4.75 in. (120,6 mm) all around the
repair area for four (4) repair plies and one (1) fiberglass
sanding ply as shown in Figure 202.
D. Remove the damaged skin fibers. Use the CoMat 05-020 and
05-081 abrasive papers. Remove the minimum amount of material
that will remove the damage completely. Remove the surface
finish and lightly make the surface rough in the area between
the pieces of Teflon tape.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
E. Clean the repair area with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface dry before the
solvent becomes dry.
F. Let the repair area dry for one hour at 230° to 250°F (110° to
121°C). Use an explosive proof heat lamp.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
C. Cure the resin for 220 minutes at 190° to 210°F (88° to 99°C).
Use a heat lamp.
D. Make the resin smooth with the adjacent surface. Use the CoMat
05-020 and 05-081 abrasive papers.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
E. Clean the repair area with CoMat 02-099 lint free cloth and
made moist with CoMat 01-438 solvent. Rub the surface dry
before the solvent becomes dry.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Cut the repair plies from the CoMat 02-165 graphite fabric. Cut
the corners of the plies 45º by 1.0 in. (25,4 mm). Make one (1)
graphite fabric repair ply for each damaged outer skin ply,
plus one (1) additional fiberglass sanding ply. See Figure 202.
(1) Cut ply No. 1 with the warp at 0° degree. Cut the ply 1.0
in. (25,4 mm) larger that the cutout all around.
(2) Cut ply No. 2 with the warp at 0° degree. Cut the ply 0.75
in. (19 mm) larger than the first ply all around.
(3) Cut ply No. 3 with warp at 0° degree. Cut the ply 0.75 in.
(19 mm) larger than the second ply all around.
(4) Cut ply No. 4 with warp at 0° degree. Cut the ply 0.75 in.
(19 mm) larger than the third ply all around.
NOTE: Do not cover the Teflon tape with the fiberglass sanding
ply.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
E. Put another sheet of parting film above the repair ply. Use a
roller to force the resin fully into the ply.
(1) Remove the bottom sheet of nonporous parting film from the
repair ply. Put repair ply above the cutout and filler
plies.
(2) Press the ply into position and remove the wrinkles. Use a
roller if necessary.
(3) Remove the top sheet of the non-porous parting film from
the ply.
G. Do Steps D., E., and F for the remaining repair plies and for
the fiberglass sanding ply.
NOTE: Make sure repair plies are put together with the correct
warp direction. Make sure you remove the non-porous
parting films from the plies.
G. Put two plies of CoMat 02-166 breather cloth above the heat
blanket.
H. Put a sheet of CoMat 02-163 nylon bagging film above the repair
area. The sheet must be 2.0 in. (50,8 mm) larger than the repair
pieces all around.
I. Put a vacuum probe under the nylon bagging film. Seal the
thermocouples and vacuum probe. Use CoMat 12-024 sealant. Seal
the edges of the nylon bagging film to the skin. Use CoMat 12-
024 sealant.
J. Connect the vacuum pump hose to the vacuum source. Connect the
heat blanket to an electrical source.
A. Cure the repair for 220 minutes at 190° to 210°F (88° to 99°C).
Keep a steady vacuum pressure on 22 inches of mercury during
the cure.
B. Disconnect the heat blanket and the pressure source. Remove the
bagging materials.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Remove sharp edges in the repair area on the outer surface. Use
the CoMat 05-020 and 05-081 abrasive papers.
B. Clean the surface with a CoMat 01-438 solvent. Rub surface dry
before the solvent becomes dry.
VACUUM BAG
FIBERGLASS FABRIC BREATHER PLIES
VACUUM HOSE
TEFLON TAPE
BAG SEALANT
THERMOCOUPLE
13907B
REPAIR 016
FORWARD AND AFT EDGE REPAIR
LEFT OR RIGHT TRANSLATING SLEEVE
(VRS2035/2036)
1. General
(1) For all skin plies missing, the maximum length and width
of damage area is: L1 Maximum = 30.0 in. (762 mm) and
X1 = 1.00 in. (25,4mm).
(2) First four (4) outer skin plies are nicked, scratched,
gouged or missing. The inner skin closure plies are not
damaged. The maximum length and width of the damage area
is: L1 = 30.0 in. (762 mm) and X2 = 1.50 in. (38,1 mm).
E. Repair and damage limits applicable to this repair for the aft
edge are as follows:(Refer to Figure 201)
(1) For all skin plies missing, the maximum length and width
of damage area is: L2=4.0 in. (101,6 mm) and X3=1.0 in.
(25,4 mm).
(2) First four (4) outer skin plies are nicked, scratched,
gouged or missing. The inner skin closure plies are not
damaged. The maximum length and width of the damage area
is: L2=4.0 in. (101,6 mm) and X4=2.0 in.
(50,8 mm).
2. Reference Information
VRS2035
VRS2036
A. Standard Tools
E. Component Materials
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Clean the surface with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface dry before
solvent evaporates.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
C. Cut out only damaged plies from the damaged skin as marked.
Remove all loose particles and bond separations. Use cutters
and cutting tools. If the cutout is rectangular, use a minimum
radius of 0.25 in. (6,4 mm) at all corners. Taper the sides of
the cutout 45 degrees towards the out surface of the skin.
D. Make a border around the cutout with CoMat 02-161 teflon tape.
Distance between the edge of the cutout and edge of the teflon
tape shall be as follows:
NOTE: The size of the border can vary depending on the number
of repair plies used. Distance between the edge of the
fiberglass sanding ply and the edge of the Teflon tape
shall be approximately 0.75 in. (19,05 mm).
E. Remove all of the surface finish and lightly make the outer
surface rough in the area between the pieces of teflon tape.
Use the CoMat 05-020 and 05-081 abrasive paper.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
F. Clean the repair area with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub surface dry before the
solvent evaporates.
G. Let the repair area dry for one hour at 230° to 250°F (110° to
121°C). Use an explosive proof heat lamp.
NOTE: The back-up plate must have the same contour as the
damaged area. The plate must align with the contour of
the land with light finger pressure.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Find the size, shape and number of filler plies needed to make
the filler ply stack the same thickness as the adjacent
surface.
B. Cut the filler plies from CoMat 02-165 graphite fabric. Cut the
plies 0.50 in. (12,7 mm) larger than the cutout all around. Cut
the plies to the correct size after they are impregnated with
resin. See Figure 201.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
(3) Use a roller to force the resin fully into the ply.
(4) Do steps (1), (2) and (3) for the other filler plies.
(5) Remove the non-porous release film from the top of the
first ply. Remove the non-porous release film from the
bottom of the second ply.
(6) Put the second ply over the center of the first ply and
smooth out all wrinkles.
(7) Repeat steps (5) and (6) for the remaining filler plies to
make a stack of the filler plies.
(8) Cut the edges of the sack of filler plies to the correct
size of the cutout.
NOTE: Make sure the repair plies are put together with the
correct warp direction. Make sure you remove the
non-porous release film from the plies before you
put them together.
NOTE: The back-up plate must have the same contour as the
damaged area. The plate must align with the contour
of the land with light finger pressure.
(3) Remove the bottom non-porous release film from the stack
of filler plies.
(4) Put the stack into the cutout. Press the stack into
position against the back-up plate. Remove the wrinkles.
Use the roller if necessary.
(5) Remove the top non-porous release film from the stack of
filler plies.
7. Prepare A Vacuum Bag For the Filler Ply Stack (See Figure 203)
NOTE: You can co-cure the filler ply stack and the repair plies,
if you are sure you can get the correct contour. If filler
and repair plies are to be co-cured proceed to step 10.
G. Put two plies of CoMat 02-166 breather cloth above the heat
blanket.
H. Put a sheet of CoMat 02-163 nylon bagging film above the repair
area. The sheet must be 2.0 in. (50,8 mm) larger than the repair
pieces all around.
I. Put the vacuum probe under the nylon bagging film. Seal the
thermocouples and vacuum probe. Use CoMat 12-024 sealant. Seal
the edges of the nylon bagging film to the skin. Use CoMat 12-
024 sealant.
J. Connect the vacuum pump hose the vacuum source. Connect the
heat blanket to an electrical source.
A. Cure the repair for 220 minutes at 190° to 210°F (88° to 99°C).
Keep a steady vacuum pressure of 22 inches of mercury during
the cure.
B. Disconnect the heat blanket and the pressure source. Remove the
bagging materials. Remove the teflon tape.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Remove sharp edges. Make the filler ply surface in the repair
area smooth with the adjacent surface. Use CoMat 05-020 and 05-
081 abrasive papers.
B. Shape the forward and/or aft edge of the ply stack to a 4:1
ratio taper. Use the CoMat 05-020 and 05-081 abrasive papers.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
C. Clean the surface with CoMat 02-099 lint free cloth made moist
with CoMat 01-438 solvent. Rub the surface dry before the
solvent evaporates.
10. Install the Outer Skin Repair Patch (See Figure 202)
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. For the forward edge repair patch, cut five repair plies from
the CoMat 02-165 graphite fabric. Cut the corners of the plies
45 degrees by 1.0 in. (25,4 mm). See Figure 202.
(1) Cut ply No.1 with the warp at zero degrees. Cut the ply
1.0 in. (25,4 mm) larger than the cutout all around.
(2) Cut ply No. 2 with the warp at +45 degrees. Cut the ply
0.75 in. (19,0 mm) larger than the first ply all around.
(3) Cut ply No. 3 with the warp at -45 degrees. Cut the ply
0.75 in. (19,0 mm) larger than the second ply all around.
(4) Cut ply No. 4 with the warp at zero degrees. Cut the ply
0.75 in. (19,0 mm) all around.
(5) Cut ply No. 5 with the warp at zero degrees. Cut the ply
0.75 in. (19,0 mm) all around.
B. For the aft edge repair patch, cut five repair plies from the
CoMat 02-165 graphite fabric. Cut the corners of plies at 45
degrees by 1.0 in. (25,4 mm). See Figure 202.
(1) Cut ply No.1 with the warp at zero degrees. Cut the ply
1.0 in. (25,4 mm) larger than the cutout all around.
(2) Cut ply No. 2 with the warp at +45 degrees. Cut the ply
0.75 in. (19,0 mm) larger than the first ply all around.
(3) Cut ply No. 3 with the warp at -45 degrees. Cut the ply
0.75 in. (19,0 mm) larger than the second ply all around.
(4) Cut ply No. 4 with the warp at zero degrees. Cut the ply
0.75 in. (19,0 mm) all around.
(5) Cut ply No. 5 with the warp at zero degrees. Cut the ply
0.75 in. (19,0 mm) all around.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
E. Put another sheet of paring film above the repair ply. Use a
roller to force the resin fully into the ply.
(2) Press the ply into position and remove the wrinkles. Use a
roller if necessary.
(3) Remove the top sheet of the non-porous release film from
the ply.
G. Repeat steps D, E and F for the remaining repair plies and for
the fiberglass sanding ply.
NOTE: Make sure the repair plies are put together in the correct
warp direction. Make sure you remove the
non-porous release film from the plies.
11. Prepare A Vacuum Bag For the Repair (See Figure 204)
G. Put two plies of CoMat 02-166 breather cloth above the heat
blanket.
H. Put a sheet of CoMat 02-163 nylon bagging film above the repair
area. The sheet must be 2.0 in. (50,8 mm) larger than the repair
pieces all around.
I. Put the vacuum probe under the nylon bagging film. Seal the
thermocouples and vacuum probe. Use CoMat 12-024 sealant. Seal
the edges of the nylon bagging film to the skin. Use CoMat 12-
024 sealant.
J. Connect the vacuum pump hose the vacuum source. Connect the
heat blanket to an electrical source.
A. Cure the repair for 220 minutes at 190° to 210°F (88° to 99°C).
Keep a steady vacuum pressure of 22 inches of mercury during
the cure.
B. Disconnect the heat blanket and the pressure source. Remove the
bagging materials. Remove the teflon tape.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Remove sharp edges. Make the filler ply surface in the repair
area smooth with the adjacent surface. Use CoMat 05-020 and 05-
081 abrasive papers.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
B. Clean the surface with CoMat 02-099 lint free cloth made moist
with CoMat 01-438 solvent. Rub the surface dry before the
solvent evaporates.
Damage location
Figure 201 (Sheet 1 of 2)
Damage Location
Figure 201 (Sheet 2 of 2)
Repair Construction
Figure 202 (Sheet 1 of 2)
Repair Construction
Figure 202 (Sheet 2 of 2)
VACUUM BAG
REMOVE, TAPER 4:1 RATIO
(AFTER CURE)
BREATHER CLOTH
(2 PLIES) NON-POROUS RELEASE FILM
(1 PLY)
HEAT BLANKET
BLEEDER COTHER
(4 PLIES)
SILICONE RUBBER POROUS PARTING FILM
SHEET (1 SHEET) (1 SHEET)
CUTOUT
THERMOCOUPLE
(4 PL, MIN.)
SEALANT
FILL PLIES
BACKUP PLATE
VACUUM CONNECTOR
A5S543
REPAIR PLIES
NON-POROUS RELEASE
VACUUM BAG FILM (1 PLY
THERMOCOUPLE
(4 PL, MIN.)
SEALANT
SEALANT
VACUUM CONNECTOR
BACKUP PLATE
FILL PLIES
A5S544
REPAIR 017
OUTER BARREL COMPOSITE SKIN DELAMINATION REPAIR
LEFT OR RIGHT TRANSLATING SLEEVE
(VRS2037/2038)
1. General
2. Reference Information
VRS2037
VRS2038
A. Standard Tools
E. Component Materials
4. Prepare the Damaged Area for Repair, (See Figures 201 and 202)
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Clean the surface with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface clean before
the solvent dries.
B. Find the size of the delamination. Use the tap test method.
Make a border around the damage area. Use CoMat 02-160 teflon
tape.
CAUTION: DRILL THROUGH THE DAMAGED PLIES ONLY. DO NOT DRILL THROUGH
THE SKIN OR THROUGH THE PANEL.
C. Drill 0.125 in. (3,17 mm) diameter holes along one side of the
repair area at 1.00 in. (25,4 mm) intervals. Use drills and
drilling tools. Drill the holes through the damaged plies only.
Do not damage the adjacent structure. Remove the burrs.
D. Do the same procedure to drill vent holes along the other side
of the repair area. Remove the burrs.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
A. Clean the repair area with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Remove all debris. Rub the
surface clean before the solvent dries.
G. Cure the adhesive for one hour at 190 to 210ºF (88 to 99ºC). Use
an explosion proof heat lamp, as necessary.
H. Remove the pressure. Remove the non-porous films and the pieces
of teflon tape around the bonded panel.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Remove the sharp edges from the cured adhesive around the
injection holes. Make the surfaces smooth with the adjacent
surfaces. Use the CoMat 05-020 and CoMat 05-081 abrasive
papers.
B. Clean the repair area with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface clean before
the solvent dries.
A COMPOSITE SKIN
DELAMINATION
CORE
COMPOSITE
SKIN
ADHESIVE
13914A
REPAIR 020
TRANSLATING SLEEVE ACOUSTIC PANEL
PERFORATED INNER SKIN SMALL HOLE REPAIR
(VRS2043/VRS2044)
1. General
G. Damage must be located in field areas only. See Figure 201 for
areas where no damage is allowed.
(2) There must be a minimum distance of 2.0 in. (51,0 mm) from
the edge of the damage to fittings on the panel.
2. Reference information
A. Standard Equipment
E. Component Material
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Clean the damage area with CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface dry before
solvent becomes dry.
C. Mask off 1.5 in. (38,1 mm) around the damage area. Use CoMat 02-
161 Teflon tape.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
A. Cut and remove the damaged skins and core to the smallest
diameter and depth possible to remove damage. Use a drill or
hole saw. Remove the burrs.
B. Remove the sharp edges. Use the CoMat 05-020 and 05-081
abrasive papers.
C. Clean the repair area with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Clean the surface before the
solvent dries.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Make the surfaces in the repair area smooth with the adjacent
surfaces. Use the CoMat 05-020 and 05-081 abrasive papers.
B. Clean the surface with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Clean the surfaces before the
solvent dries.
A. Visually examine the repair area. Make sure the repair is even
with the adjacent skin surface.
REPAIR 021
TRANSLATING SLEEVE ACOUSTIC PANEL
BOND SEPARATION REPAIR
(VRS2045/VRS2046)
1. General
F. For Zone 1 damage larger than 3.0 in. (76.2 mm) and for Zone 2
damage larger than 1.0 in. (25,4 mm) contact Goodrich for
further disposition.
G. For damage to the blocker door cutout area see Repair 70.
2. Effectivity
A. Standard Equipment
CoMat 01-076
Methylethylketone; Alternative for CoMat 01-438
CoMat 01-438
Solvent Turco 6646
CoMat 02-097
Lint Free Gloves
CoMat 02-099
Lint Free Cloth
CoMat 02-160
Teflon tape
CoMat 02-162
Syringe
CoMat 02-168
Non-porous parting film
CoMat 05-020
Waterproof silicon carbide abrasive paper
CoMat 05-081
Waterproof silicon carbide abrasive paper
CoMat 06-131
Marking pen
CoMat 08-021
Epoxy Paste Adhesive, EA934NA (Alternate to
CoMat 08-078)
CoMat 08-078 Adhesive, EA9321
E. Component Material
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS
A. Clean the surface with CoMat 02-099 lint free cloth made moist
with CoMat 01-438 solvent. Rub the surface dry before solvent
becomes dry.
B. Find the size of the bond separation. Use the tap test method.
Refer to SRM 54-01-00.
C. Make a border around the damage area. Apply Comat 02-160 teflon
tape around all sides 0.5 in (13 mm) away from the border of the
damaged area. Refer to Figure 202.
CAUTION: WHEN YOU CUT THE WOVEN WIRE, OR REMOVE SHARP EDGES DO NOT
CUT INTO THE PERFORATED SKIN.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS CONTAMINATION
A. Clean the damage area with CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface dry before
solvent becomes dry.
C. Cover the perforated sheet holes within the damaged area with
CoMat 02-160 Teflon Tape. Keep the injection and vent holes
open.
NOTE: Every honeycomb cell under the damage are must be filled
with adhesive without any void area.
J. Cure the adhesive for one hour at 180° to 200°F (82° to 93°C).
Use an explosion proof heat lamp.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Remove the sharp edges from the repair area, and make the
surface smooth with the adjacent surface. Use the CoMat
05-020 and 05-081 abrasive papers.
B. Clean the repair area with CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface dry before
solvent becomes dry.
COMPOSITE
OUTER SKIN
A5S369A
20.0 in.
(508 mm) 45.2 in.
13.0 in. (1148 mm)
(330 mm) 14.10 in.
(358,1 mm)
3.0 in.
(76 mm) 16.10 in.
(408,9 mm)
30.0 in.
5.52 in.
(762 mm)
(140,2 mm)
34.0 in. 7.0 in.
16.0 in.
(864 mm) (178 mm)
(406 mm) 11.35 in.
CONSTANT
(288,3 mm)
32.37 in.
(822,2 mm)
LATCH OR
PANEL
EOP
SEE REPAIR 70 7.0 in.
(178 mm)
CONSTANT
NO REPAIR
3.0 in.
ICN-V25-X-543000-01513-S-001
(76,2 mm)
ZONE 1
10.54in.
(267,7mm)
ZONE 2
14.23in.
(267,7mm)
NOTE: DIMENSIONS ARE MEASURED FROM 41.8 in.
THE TOP EDGE OF THE PANEL
(1062 mm)
CIRCUMFERENTIALLY AND FROM THE
AFT OR FORWARD EDGES OF THE 49.6in.
PANEL LINEARLY (1260 mm)
REPAIR 022
TRANSLATING SLEEVE WOVEN WIRE SCRATCH, RIP, OR TEAR REPAIR
(VRS2047/VRS2048)
1. General
2. Reference Information -
VRS2047
VRS2048
A. Standard Equipment
Explosion proof heat lamp
Plastic spatula
Knife
E. Component Material
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
B. Apply CoMat 02-160 teflon tape around the damage area. Add 0.4
in. (10 mm) around all sides of the damage. This makes an area
that is 0.8 in. (20 mm) wide.
C. Cut away all loose woven wire from the repair area. Use a sharp
knife. Do not cut into the perforated skin.
D. Remove the sharp edges from the cut wire and from the
perforated skin in the damaged area. Use the CoMat 05-020 and
05-081 abrasive papers.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
A. Clean the repair area with a CoMat 02-099 lint free cloth made
moist with coMat 01-438 solvent. Rub the surface dry before
solvent becomes gas.
D. Cure the adhesive for one hour at 180º to 200ºF (82º to 93ºC).
Use an explosion proof heat lamp.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
B. Remove the sharp edges from the stabilized area. Use the CoMat
05-020 and 05-081 abrasive papers.
C. Clean the repair area with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface dry before
solvent becomes gas.
REPAIR 023
TRANSLATING SLEEVE EXTERNAL PAINT REPLACEMENT REPAIR
(VRS2049/2058)
1. General
2. Reference Information -
VRS2049
VRS2058
PCI-V2500-1IA Overhaul Process
A. Standard Equipment
Explosion proof heat lamp
Spray tools for paint
E. Component Material
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
B. Apply CoMat 02-178 masking tape around the damage area. This
prevents unwanted spray damage to adjacent areas.
D. Apply a thin layer of the primer mixture to the repair area. Use
a spray gun or brush.
E. Cure the primer for one hour at 180º to 200ºF (82º to 93ºC). Use
an explosion-proof heat lamp.
A. Apply a 1.00 inch (25,4 mm) wide strip of CoMat 02-178 masking
tape to the primer surface. Pull the tape from the primer
surface in one sudden movement. If any of the primer is removed
by the tape, reject the primer layer and do Steps 4.A. through
4.E. again.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: 1. USE COMAT 02-097 LINT-FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
(1) For the area shown in Figure 201 use CoMat 07-148 mix,
apply, and cure per manufacture’s instructions.
A. Apply a 1.00 inch (25,4 mm) wide strip of CoMat 02-178 masking
tape to the external paint surface. Pull the tape from the
surface in one sudden movement. If the tape removes the paint,
reject the external paint and do the applicable steps again.
THRUST
REVERSER
EOP
2x 4.0
2x 12.0
ICN-V25-Z-543000-00263-S-001
2x 21.0
THRUST
RECOVERY
SCOOP
EOP
A-A
REPAIR 024
UPPER HOIST POINT NUTPLATE REPLACEMENT REPAIR
LEFT OR RIGHT THRUST REVERSER
(VRS2065/2085)
1. General
2. Reference Information -
VRS2065
VRS2085
A. Standard tools
Brush
Clamps
Drills and drilling tools
Hole finder
Riveting tools
Standard shop tools
Temporary fasteners
E. Component Material
F. Repair Parts
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Clean the repair area with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface dry before
solvent becomes dry.
C. Remove the primer from the attaching rivets for the damaged
nutplate. Use Comat 05-074 abrasive paper.
D. Remove the nutplates. Use drills and drilling tools. Remove the
burrs.
E. Cure the primer for one hour at 180 to 200ºF (82 to 93ºC). Use
an explosion-proof heat lamp.
5. Make the Patch and the Doubler, (See Figure 201 and 202)
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
B. Make the patch and the doubler to align with the contour of the
fairing in the repair area. The finished parts must align with
the contour with light finger pressure.
C. Make a mark of the holes around the outside edge of the cutout
and inside edge of the patch. Use a CoMat 06-131 marking pen.
F. Put the patch into position on the doubler. Repeat the same
procedure to drill the remaining holes. Remove the burrs.
G. Remove the doubler and the patch. Countersink the rivet holes
on the patch and the fairing as required.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: 1. USE COMAT 02-097 LINT-FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
B. Use a nylon brush or CoMat 02-099 lint free cloth to apply CoMat
07-106 conversion coating to the cleaned, bare aluminum
surfaces. Do not let the solution become dry on the surface.
Keep the surfaces wet with the solution for 2 to 5 minutes.
H. Air dry the primer for 30 minutes. Cure the primer for one hour
at 180º to 200ºF (82º to 93ºC). Use an explosion proof heat
lamp.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Apply pieces of the CoMat 02-178 masking tape to the two sides
of the space between the fairing and the patch all around.
E. Cure the adhesive for one hour at 190º to 210ºF (88º to 99ºC).
Remove the masking tape before the adhesive cures.
APPROX.
2.5 in.
(63 mm)
3.5 in.
(88,9 mm)
1.2 in.
(30 mm)
DETAIL AT A
FORWARD
CUTOUT
13918B
0.31 in.
(7,87 mm)
DOUBLER
1.25 in.
(31,75 mm)
PATCH
13919C
REPAIR 026
AFT LATCH FASTENER REPLACEMENT REPAIR
LEFT OR RIGHT TRANSLATING SLEEVE
(VRS2266/2267)
1. General
2. Reference Information -
VRS2267
VRS2266
A. Standard tools
Drills and drilling tools
Explosion proof heat lamp
Plastic spatula
Rivet installation tools
Rivet selector gage
Temporary fasteners
Standard shop tools
E. Component Material
F. Repair Parts
PART NO. PART IDENT Qty
ASPFF-DT06-14 Pin A/R
ASPFF-DT06-15NL Pin A/R
ASPFF-DT06-16 Pin A/R
ASPF-S-DT06-NL Sleeve A/R
ASP-LC-2AC-06 Collar A/R
4. Prepare the Damaged Area for Repair, (See Figures 201 and 202)
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Clean the repair area with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface dry before
solvent becomes dry.
B. Make a mark of the damage area to the smallest size that removes
all the damage. Apply Comat 02-160 Teflon tape around the
marked area.
C. Remove all adhesive filler from the area between the pieces of
Teflon tape. Use a plastic spatula and the CoMat 05-020 and 05-
081 abrasive papers.
E. Examine the repair area to make sure all damage has been
removed. Make sure the existing structure is not damaged.
F. Examine the holes to make sure they are not damaged. Remove the
burrs.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
A. Clean the repair area. Use dry air blast or vacuum as necessary
to remove sanding and drilling particles from the repair area.
Clean with CoMat 02-099 lint free cloth made moist with CoMat
01-438 solvent. Wipe the surfaces dry before the solvent
becomes dry.
A. Visually examine the repair are to make sure that the fasteners
are installed correctly. If necessary, do the applicable steps
again.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Make the surface in the repair area smooth with the adjacent
surface. Use the CoMat 05-020 and 05-081 abrasive papers.
B. Clean the surface with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface dry before the
solvent becomes dry.
REPAIR 027
CASCADE ASSEMBLY - SURFACE DAMAGE BLEND REPAIR
(VRS2251)
1. General
A. You can blend out the damage and apply an adhesive or resin to
the damaged area to repair this type of minor surface damage to
the cascade.
(1) The maximum depth of the blended repair must not be more
than 0.50 in. (12,7 mm).
(2) Do not make repairs within 3.0-in. (76,2 mm) from the
forward and aft edge of the cascade in. Refer to Figure
201.
(3) Do not make repairs within 0.125 in. (3,175 mm) of any
vane/rail joint.
2. Reference Information -
VRS2251
A. Standard equipment
Explosion proof heat lamp
B. Consumable Materials
E. Component Material
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Use a CoMat 02-099 lint free cloth made moist with CoMat 01-438
solvent. Rub the surface clean before the solvent dries.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
NOTE: You can use CoMat 08-028 adhesive or CoMat 08-050 resin.
C. Use an explosion proof heat lamp. Cure the resin for 220
minutes at 200ºF (93ºC). If you use the adhesive, cure the
repair for 60 minutes at 180ºF (82ºC).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
3.0 in.
(76,2 mm)
3.0 in.
(76,2 mm)
3.0 in.
CASCADE (76,2 mm)
740-0105
740-0106
740-0107
740-0235
(Typical)
3.0 in.
(76,2 mm)
CASCADE
740-0184
NOTE: Do not make repairs (Typical)
in these areas
13931A
VANE
RAIL
GOUGE
0.125 in.
(3,175 mm)
MIN.
2xD
MINIMUM
D
2xD
TAPER
CRACK
NOTES: 2xD
TAPER
D = DEPTH OF DAMAGE
13932A
REPAIR 028
CASCADE ASSEMBLY - CRACKED VANE OR RAIL (BLADES) REMOVAL REPAIR
(VRS2253)
1. General
A. To repair this type of damage, you can remove the cracked blade
and seal the edges with resin or adhesive to prevent moisture
penetration into the exposed carbon.
2. Reference Information -
VRS2253
A. Standard equipment
Explosion proof heat lamp
Routing tool
B. Consumable Materials
E. Component Material
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
NOTE: You can use CoMat 08-050 resin or CoMat 08-028 adhesive.
C. Use an explosion proof heat lamp. Cure the resin for 220
minutes at 200ºF (93ºC). If adhesive is used, cure for 60
minutes at 180º to 200ºF (82º to 93ºC) or at 77ºF (25ºC) for 5
to 7 days.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
0.125 in.
(3,175 mm)
MINIMUM
0.125 in.
(3,175 mm)
MINIMUM
Notes:
1. Do not remove adjacent blades
2. Do not remove more than three
blades in each cascade 13934A
REPAIR 029
WOVEN WIRE REPLACEMENT DYNAPHOR™
R/H AND LH FIXED DUCT ASSEMBLIES
(VRS2262/2263)
1. General
B. Before you start the repair, find which peel test (Step 27)
will be used. Make sure the test panel configuration and the
subsequent test specimens will agree to the applicable peel
test. All bonding procedures from Step 13 and steps 15 through
26 (i.e. cleaning and priming through the inspection) must be
applied at the same time. The same way applies to both the TP140
test panel and to the repair area. At step 27 the test panel
will be destructively tested to verify the quality of the
repair bond. If the test specimens fail the peel test, do not
repeat the repair, contact a Goodrich Customer Support
Representative for evaluation and disposition.
2. Reference Information
VRS2262
VRS2263
Overhaul Processes Consumable Index
Standard Process and Procedure Manual
SAE ARP5143 Vacuum Bagging of Thermosetting Composite Repairs
A. Standard Equipment
Heat Blanket
Temperature Controller
Temperature Recorder
Thermocouples
Vacuum probes
Mechanics Tool Box
Analytical Balance
Router bit
18,000 -23,000 RPM drive motor
Heat Lamp (explosion proof)
Oven
Razor knife and scissors
B. Standard Equipment
Spray gun
Paint brush
Disposable brush
Standard Equipment
C. Consumable Materials
F. Component Material
G. Repair Parts
A. Use the tap test method to find size of the Disbond area.
NOTE: The woven wire used in this repair is different from the
original class of woven wire. The acoustic rayl values
are equivalent when this repair is done with the repair
woven wire.
C. Cut wire score the woven wire with a razor knife in 1.0 to 2.0
in. (25,4 to 50,8 mm) lengths.
CAUTION: USE EXTREME CARE TO MAKE SURE THAT ALL LOOSE WIRE MESH
PARTICLES ARE CLEANED AWAY. THE STAINLESS STEEL WIRE
HAS A STRONG ELECTROLYTIC REACTION WHEN IN CONTACT
WITH ALUMINUM ALLOYS. THIS CAUSES
GALVANIC CORROSION TO OCCUR.
B. Wire brush and sand existing adhesive and primer from the
exposed repair area surfaces of the perforated sheet. Use CoMat
05-128 (240 grit) or CoMat 05-129 (320 grit) aluminum oxide
abrasive paper. Avoid sanding through the bare metal.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Remove a 0.5 in (12,7 mm) diameter plug from the repair area
perforated sheet at the worst areas with corrosion with an
18,000 to 23,000 RPM motor and a router or equivalent. Sand any
residual adhesive from the honeycomb core side of the removed
plug and clean with a vacuum. Use CoMat 05-128 (240 grit) or
CoMat 05-129 (320 grit) aluminum oxide abrasive paper. Do not
removed parent material or perforated sheet plug. (Refer to Fig
203).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
Table 201
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Clean the repair area perforated sheet plug hole with CoMat 01-
438 MIBK/MEK and CoMat 02-091 cleaning cloth. Wipe the surfaces
dry with the second clean lint-free CoMat 02-091 wiping cloth
before the CoMat 01-438 MIBK/MEK dries. Force air dry for 30
minutes at 150° F to 180° F (66° C to 77° C).
B. Mask 0.06 to 0.12 in. (1,524 to 3,048 mm) from the perimeter of
perforated sheet plug hole with CoMat 02-161 Teflon tape (2
in./50,8 mm).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
B. Wipe the repair area perforated surface dry with a clean lint-
free CoMat 02-091 cleaning cloth before the CoMat
01-438 MIBK/MEK dries. Remove CoMat 02-161 teflon tape (2 in./
50,8 mm) and CoMat 02-107 plastic, kraft paper at the
perimeter of repair area. Force air dry for 30 minutes at 150°
F to 170° F (66° C to 77° C).
B. Cover the entire repair area with one layer of CoMat 02-167
fiberglass fabric type 181. Where possible, overlap the CoMat
02-167 fiberglass fabric 4.0 in. (101,6 mm) minimum from the
edges of repair area. Place one layer of CoMat
02-166 breather cloth RC3000-10 and one layer of CoMat
02-169 parting film to completely cover the CoMat 02-167
fiberglass cloth.
F. Weigh the test panel TP140. The test panel must increase in net
weight by 0.063 to 0.071 oz. (1,8 to 2,0 gm) when the coating
thickness is correct.
J. Lightly sand and repair area with CoMat 05-129 (320 grit)
aluminum oxide abrasive paper to remove any minor bumps in the
adhesive primer. Avoid sanding through to bare metal. Touch
application of adhesive primer is permitted for minor scratches
through the RMS058 adhesive primer. Allow 2 hours of air dry
following this type of application.
A. Prefit and cut new woven wire as necessary for the repair area.
Allow excess around perimeter (recommended 0.75 in. (18,0 mm),
trim before installation. (Refer to Fig. 205 to 206 and
reference Step 22).
NOTE: Repair woven wire warp and weft directions shall be cut
to conform with existing wire cloth orientation.
NOTE: Repair woven wire may be cut and spliced in order to fit
the contour without wrinking. (See Figure 206).
NOTE: Each woven wire splice must have an adhesive film barrier
strip. If the area of barrier strips reduce the total
acoustic area below the approved limit per SRM section
54-01-00, rearrange the woven wire splices to minimize
the use of barrier strips in an effort to minimize the
use of barrier strips hence reducing acoustic loss to
acceptable limits. Ideally, the barrier strips should be
placed over non-acoustic areas.
NOTE: For the adhesive film barrier strips, use RMS042, Type 2,
Grade B adhesive film. If grade B is not available, Grade
A film can be used as an alternative. If the adhesive
film barrier strips are made from Grade B film, two
layers will be needed; if made from the alternative Grade
A, use only one layer.
NOTE: The RMS042 adhesive film can be used after the adhesive
film reaches room temperature. Use the adhesive film
within 14 days after reaching room temperature.
A. Cut the RMS042 adhesive film into barrier strips to fit along
all cut edges of the woven wire, including under any splices.
(Refer to Fig. 207).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS
F. Air dry test panel for 120 minutes at room temperature before
weighing. Weigh test panel to find the coating thickness. The
coating thickness is correct when the weight of the 12 X 12 in.
(300 X 300 mm) test panel has increased 0.15 to 0.16 oz/ft²
(51,67 to54,90 grams/m²). Continue to apply equal coats of
RMS070/MIBK/MEK adhesive on test panel and repair area until
the correct thickness, by weight, is achieved.
NOTE: Protect repair area surface from dust and debris during
air dry period. If repair area is covered, do not allow
cover to make contact with adhesive.
G. Allow the repair area surface to air dry for 120 minutes at
room temperature.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Remove CoMat 02-161 Teflon tape (2 in./ 50,8 mm) and CoMat 02-
107 plastic, kraft paper at perimeter of repair area. Use a
brush to wet perimeter of repair area (and splice joints, if
used) with CoMat 01-438 MIBK/MEK to provide a tacky
surface for the adhesive film barrier strips. The CoMat
01-438 MIBK/MEK application width should match that of the
adhesive film barrier strips. Do not soak with excessive
quantities of CoMat 01-438 MIBK/MEK.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: IT IS ESSENTIAL THAT THE PRECUT WOVEN WIRE AND TEST PANEL
WOVEN WIRE BE CLEAN AND REMAIN CONTAMINANT FREE DURING THE
REPAIR.
A. Solvent flush precut repair woven wire and the test panel woven
wire TP738-70 with CoMat 01-438 MIBK/MEK. Repeat flushing until
all visual traces of oil, water or dirt are removed.
B. Roll the precut repair woven wire inward from each end to the
centerline, in the form of a scroll.
D. Lay the precut repair woven wire with the marked centerline on
the repair area and line up the centerline of woven wire with
centerline marks on masking tape.
A. Use the heat gun to apply the repair woven wire to the repair
area and the test panel woven wire TP738-70 to the TP140 test
panel. Work the woven wire from the center to the radial ends.
NOTE: Woven wire can be moved for proper positioning before the
next step. Woven wire shall be located so that there is
excess material around the repair area that extends over
the existing woven wire and/or existing solid barrier.
NOTE: The following two steps (23 and 24) should be performed
simultaneously.
A. Mark around the perimeter where repair woven wire overlays the
existing woven wire, or where the repair woven wire goes over
existing fasteners. Use a CoMat 06-131 marking pen of different
color.
B. Mark excess repair woven wire where splice joints are needed to
avoid wrinkling using a CoMat 06-131 marking pen of contrasting
color.
CAUTION: DO NOT USE A RAZOR TO CUT WOVEN. USING A RAZOR CAN DAMAGE
THE EXISTING LAYER OF WOVEN WIRE.
NOTE: The test panel (TP140 with TP738-70 shall be bagged and
cured using equivalent bagging, heating and pressure
application procedures as are used on the repair.
B. Position CoMat 02-169 porous parting film over the repair area.
Where possible, overlap the CoMat 02-169 porous
parting film 4.0 in. (101,6 mm) minimum from the edges of
repair area. Put one layer of CoMat 02-166 breather cloth
RC3000-10 over the CoMat 02-169 parting film.
A. Peel test panel using bating Roller Test Arrangement per ASTM-
D-3167-76 (Reapproved 1986). Test speed is 3 in. (76 mm) per
minute. The minimum acceptable peel strength is 6 lbs/in. (1050
nm) width; minimum of 3 specimens.
(OPTIONAL METHOD)
A. Mask with CoMat 02-1178 masking tape the repair woven wire to
the original barrier dimension and mask woven wire splice
joints to a width of 5.0 in. (12,7 mm), centered on the splice.
(Refer to Fig. 211 and 212).
B. Sand the masked off area until smooth. Use CoMat 05-128 (240
grit) and the CoMat 05-129 (320 grit) aluminum oxide
abrasive paper.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
C. Clean repair area woven wire CoMat 01-438 MIBK/MEK and CoMat
02-091 wiping cloth. Wipe the surfaces dry with second clean
lint-free CoMat 02-091 cleaning cloth before the CoMat
01-438 MIBK/MEK dries. Force air dry for 30 minutes at 150°F to
170° F (66° C to 77° C).
29. Apply RMS078 Liquid Barrier (See Figures 211 and 212)
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
B. Air dry for 45 minutes. Immediately after air dry, remove CoMat
02-178 masking tape. Dry an additional one hour at 190° F to
210° F (87,4°C to 98,6°C).
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Apply a Proseal 899 B-2 aerodynamic sealant 0.10 in. (2,5 mm)
wide around perimeter of repair and the butt splice area.
(Refer to Fig. 213 and 214)
A. Visually examine the repair. Make sure that there are no loose
ends of the woven wire mesh strands. Do a check to make sure
that all exposed surfaces of the repair are prepared and that
the edges of the faying surfaces have an adhesive coat. Check
sealant and woven wire interfaces to make sure it is
smooth.
Bagging Arrangement
Figure 210
REPAIR 031
EDGE SEALANT REPLACEMENT REPAIR
FOR THE 7TH AND 10TH STAGE BLEED VALVE CUTOUTS
RIGHT FIXED DUCT ACOUSTIC PANEL
(VRS2083)
1. General
2. Reference Information -
VRS2083
A. Standard equipment
Explosion proof heat lamp
Heat blankets
Heat gun
Plastic spatula
Standard shop tools
Temperature controllers
Temperature recorder
Thermocouples
E. Component Material
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
A. Clean the damage area with a CoMat 02-099 lint-free cloth made
moist with CoMat 01-438 solvent. Rub the surface dry before
solvent becomes dry.
D. Remove the sharp edges. Remove the cured bonding material from
the exposed edges of the honeycomb cells. Use the CoMat 05-020
and 05-081 abrasive papers. Do not damage the skin.
E. Use clean air blast to remove the sanding debris. Clean the
repair area with a CoMat 02-099 lint-free cloth made moist with
CoMat 01-438 solvent. Rub the surface clean before solvent
becomes dry.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT-FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
B. Make a border around the repair area. Use CoMat 02-161 teflon
tape.
NOTE: You must use the potting compound within 8 hours after
it reaches the room temperature.
K. Let the repair area cool down to room temperature. Then remove
the curing materials.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Visually examine the repair area and check records to make sure
that procedures in this repair were done. If necessary, do the
applicable steps again.
REPAIR 032
FIXED STRUCTURES TORQUE RING METALLIC ONE-PIECE INNER FAIRING PATCH REPAIR
AND FORWARD FRAME REPAIR (VRS2362/VRS2363)
1. Effectivity
2. General
(2) Only to Pre SB78-230 Torque Rings. The inner fairing and
forward frame of these Torque Rings are mechanically
fastened by countersunk or flush rivets.
(3) If the width of the inner fairing cutout is less than 6.0
in. (152 mm). Refer to Figure 202.
(1) 0.056 in. (1,42 mm) chem-milled to 0.036 in. (0,91 mm)
F. The location of the cut lines for the inner fairing and forward
frame should be established only within area 2 as shown in
Figure 201. They should be no less than 2.0 in. (50,8 mm) from
the edge of the actuator fitting. The exact location of cut
lines shall be established in such a way that the final
installation of the repair pieces will not interfere with the
production hardware.
3. Referenced Information
A. Standard Equipment
Clamps
Cutting tools
Drilling tools
Grinding tools
Nylon brush
Palette knife
Rivet tools
Standard shop tools
B. Consumable Materials
E. Component Material
G. Repair Parts
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Remove the torque ring seal. Pull the seal from the retainer.
Cut if necessary.
B. Remove the sharp edges from the damaged area using CoMat 05-128
Aluminum oxide abrasive paper.
C. Clean the repair area using CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface clean before
the solvent becomes dry.
6. Cut the Inner Fairing, Refer to Figure 202, Figure 203 and Table 1
A. Stop drill the crack ends if there are cracks on the inner
fairing. Use a hole between 0.125 and 0.150 in. (3,17 and 3,81
mm) in diameter. Use drills and drilling tools. Remove the
burrs.
NOTE: The cutout must be a minimum of 0.50 in. (12,7 mm) more
than the edge of damage or stop drill holes, if any.
D. Cut the damaged fairing. Cut the inner fairing as marked. Use
cutting and grinding tools. Remove burrs.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Clean the repair area using CoMat 02-099 Lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface clean before
the solvent becomes dry.
8. Cut the Forward Frame, Refer to Figure 202, Figure 205 and Table 1
A. Stop drill the crack ends if there are cracks in the forward
frame. Use a hole between 0.125 and 0.150 in. (3,17 and 3,81 mm
in diameter. Use drills and drilling tools. Do not drill into
the existing structure. Remove the burrs.
B. Make a mark of the cutout on the forward frame. Use a CoMat 06-
131 marking pen.
9. Make the Repair Parts, Refer to Figure 203, 205 and Table 1
NOTE: The inner fairing and the forward frame have complex
shapes. It is recommended to make the fairing patch
and frame segment from a spare fairing and spare
forward frame.
E. Heat treat the parts that are made from 2024-T0 aluminum alloy
to the T62 condition. Be careful not to heat treat parts that
are already in the 2024-T3 condition.
G. Make a mark of the holes on the repair parts and the structure.
Refer to Figure 208 for spacing requirements.
H. Drill the pilot holes at the marked locations. Use drill and
drilling tools. Remove the burrs.
J. Countersink the holes. Use drills and drilling tools. Drill the
pilot holes at the marked locations. Remove the burrs. See
Table 1.
10. Prepare the Repair Parts for Installation, Refer to Figure 203, 205
and Table 1
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
A. Clean the repair area. Use a palette knife and CoMat 05-126
Scotch brite pads made moist with CoMat 01-438 solvent.
Carefully remove the bulk of the existing sealant and adhesive
from the repair area and from the inside of the retainer. Use
CoMat 02-099 lint free cloth. Rub the surfaces clean before the
solvent becomes dry.
C. Clean the tested surfaces. Use CoMat 02-099 lint free cloth
made moist with CoMat 01-438 solvent. Rub the surfaces clean
before the solvent becomes dry.
11. Install the Repair Parts, Refer to Figure 203, 205 and Table 1
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CAUTION: 1. USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
(3) Cure the adhesive/liquid shim for one hour between 190°
and 210°F (88° and 99°C). Use an explosion proof heat
lamp. Go to step 10.D.
(2) Apply the release agent to the other mating surface. Use
CoMat 02-099 lint free cloth made moist with CoMat 02-158
release agent.
CAUTION: YOU WILL FORCE THE UNCURED LIQUID SHIM OUT OF THE JOINT IF
YOU APPLY TOO MUCH PRESSURE.
(5) Cure the adhesive/liquid shim at 190° and 210°F (88 and
99°C) for one hour. Use an explosion proof heat lamp
Remove the parts before the adhesive cures.
E. Clean the repair area. Use CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface clean before
the solvent becomes dry.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
A. Abrade the mating surfaces of the seal and the seal retainer.
Use CoMat 05-128 aluminum oxide abrasive paper.
B. Use a CoMat 02-099 lint free cloth made moist with CoMat 01-438
solvent. Clean the mating surfaces of the seal and retainer.
Rub the surfaces clean before the solvent becomes dry.
E. Insert the seal into the retainer. Use a CoMat 02-099 lint free
cloth to remove the unwanted adhesive from the area.
13. Apply the Sealant to the Spaces, Refer to Figure 203, 205 and Table 1
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS CONTAMINATION
A. Clean the repair area. Use CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface clean before
the solvent becomes dry.
B. Use CoMat 02-178 masking tape. Make a border along the edges of
the spaces between the fairing patch and existing fairing.Do
the same along the edges of open spaces.
E. Remove the unwanted sealant using CoMat 02-099 lint free cloth.
On the air wetted surfaces, the sealant must not be above the
surface, and must not be more than 0.010 in. (0,25 mm) below the
surface.
Torque Ring Inner Fairing Patch Repair and Forward Frame Repair
Left & Right C-Duct Fixed Structure
Figure 201
Torque Ring Inner Fairing Patch Repair and Forward Frame Repair
Left & Right C-Duct Fixed Structure
Figure 202
FAIRING
PATCH
2 (Ref)
EXISTING
FAIRING
FRAME
3
3 RIVET
2 RIVET
SEE VIEW G
FORWARD FRAME FAIRING
(Ref) PATCH
Torque Ring Inner Fairing Patch Repair and Forward Frame Repair
Left & Right C-Duct Fixed Structure
Figure 203
Torque Ring Inner Fairing Patch Repair and Forward Frame Repair
Left & Right C-Duct Fixed Structure
Figure 204
Torque Ring Inner Fairing Patch Repair and Forward Frame Repair
Left & Right C-Duct Fixed Structure
Figure 205
Torque Ring Inner Fairing Patch Repair and Forward Frame Repair
Left & Right C-Duct Fixed Structure
Figure 206
REPAIR 033
FIXED STRUCTURE, TORQUE RING METALLIC ONE-PIECE INNER
FAIRING REPLACEMENT REPAIR (VRS2179/VRS2180)
1. Effectivity
2. General
B. This repair requires that the C-Duct is removed from the wing,
and the cascades have been removed from the structure per the
applicable procedures.
(2) Only to Pre SB78-230 Torque Rings. The inner fairing and
forward frame of these Torque Rings are mechanically
fastened by countersunk or flush rivets.
(1) 0.056 in. (1,42 mm) chem-milled to 0.036 in. (0,91 mm)
3. Referenced Information
A. Standard Equipment
Clamps
Cutting tools
Drilling tools
Grinding tools
Nylon brush
Palette knife
Rivet tools
Standard shop tools
Heat lamp (explosion proof)
Temporary fasteners
B. Consumable Materials
C. Special Tools
E. Component Material
G. Repair Parts
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
B. Remove the fasteners that attach the upper track and lower
track block seals to the structure. Remove the seals to the
structure. Remove the seals and keep for reinstallation.
C. Remove the fitting fasteners that are common to the upper end
fitting and the inner fairing. Do the same for the lower end
fitting.
D. Remove the fasteners that are common to the upper end fitting
and the adjacent bracket. Do the same for the lower end fitting
and the adjacent bracket.
G. Remove the rivets and the nutplates common to the inner fairing
and the torque ring cone.
H. Remove the fasteners that are common to the forward frame and
the inner fairing.
L. Use CoMat 02-099 lint free cloth made moist with CoMat 01-438
solvent to clean the area. Rub the surface clean until the
solvent becomes dry.
6. Remove the Forward Frame, Refer to Figure 201 thru Figure 208 and
Table 1
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Pull the seal from the seal retainer. Cut the seal if
necessary. Remove the fasteners that attach the retainer to the
forward frame. Remove the retainer. Keep the retainer for
reinstallation, if serviceable.
NOTE: You can remove the seal retainer. Keep the retainer
for reinstallation, if serviceable.
NOTE: The two Hi-lok pins at the lower end of the assembly
are difficult to remove. It is recommended that you
cut off these pins.
H. Use CoMat 02-099 lint free cloth made moist with CoMat 01-438
solvent to clean the area. Rub the surface clean before the
solvent becomes dry.
7. Examine the Repair Area, Refer to Figure 201 thru Figure 208 and
Table 1
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
8. Locate the New Forward Frame, Refer to Figure 202 and Figure 208
NOTE: You must use the forward frame locating tools at five
locations along V-blades.
B. Put the new forward frame into position on the tools. At each of
the tool locations install the clamp. Make sure the tool and
the forward frame are in contact along the D and E surfaces.
Tighten the clamp.
D. Remove the repair parts. Remove the sharp edges. Use CoMat
05-128 aluminum oxide abrasive paper.
9. Prepare the Repair Area and the Adjacent Parts for Forward Frame
Installation, Refer to Figure 201 thru Figure 208 and Table 1
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
A. Clean the repair area and the repair part. Use CoMat 02-099
lint free cloth made moist with CoMat 01-438 solvent. Use a
palette knife and CoMat 05-126 Scotch brite pads made moist
with CoMat 01-438 solvent. Carefully remove the loose liquid
shim from the repair area. Rub the surface clean before the
solvent becomes dry.
NOTE: If you use the existing seal retainer, you must clean
the inside of the retainer at this time.
C. Clean the tested surface. Use CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent to clean the area. Rub the
surface clean before the solvent becomes dry.
D. Use a nylon brush or CoMat 02-099 lint free cloth. Apply CoMat
07-106 conversion coating to the tested surfaces. Do not let
the solution dry on the surface. Keep the surfaces wet with
fresh solution for 2 to 5 minutes.
NOTE: The CoMat 08-093 I primer class M must be used with the
CoMat 07-115 I Primer Class M and the CoMat 07-116
Thinner. The alternative CoMat 07-126 Water soluble
primer must be used with CoMat 07-127 Water soluble
primer converter and the CoMat 07-128 Water soluble
primer thinner. Do not mix the two primer systems.
H. Use and explosion proof heat lamp. Cure the primer for one hour
at 190° to 210° F (88 to 99°C).
10. Install the New Forward Frame, Refer to Figure 203 and Figure 205
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: 1. USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
C. Cure the adhesive. Use an explosion proof heat lamp. Cure the
adhesive for one hour at 190° to 210°F (88 to 99° C). As an
alternative, you can cure the adhesive for eight hours at room
temperature.
D. Drill the holes. Use the existing holes common to the V-blade
and the torque ring cone to drill holes in the forward frame. Do
not damage the existing holes. Use temporary fasteners as
necessary to keep the holes aligned.
NOTE: If you must move the tools to drill more holes, remove
and reinstall only one tool at a time.
E. Clean the repair area. Remove the drilling pieces. Use dry air
blast and CoMat 02-099 lint free cloth made moist with CoMat
01-438 solvent. Rub the surfaces clean before the solvent
becomes dry.
F. Install the forward frame fasteners. Wet install with CoMat 08-
021 the fasteners that attach the forward frame to the V-blade
and torque ring cone.
NOTE: In place of the two Hi-lok pins at the lower end that
were cut off, install the bolts. Refer to Figure 207,
View N, Flag note 4, for fastener callout.
I. Cure the primer for one hour between 190° and 210°F (88° and 99°
C). Use an explosion proof heat lamp.
11. Prepare the New Inner Fairing and the Adjacent Parts for
Installation, Refer to Figure 203 and Figure 205
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
C. Drill some of the holes in the new inner fairing. Use clamps and
temporary fasteners as necessary to keep the holes aligned.
Drill the remaining holes. These include holes for the
nutplates attach rivets Do not damage the existing holes in the
structure. Remove the burrs.
D. Use drills and drilling tools. Countersink the holes on the air
wetted surfaces. Remove the burrs. See Table 1.
F. Clean the repair area. Use a palette knife and CoMat 05-126
Scotch brite pads made moist with CoMat 01-438 solvent.
Carefully remove the loose liquid shim from the repair area.
Use CoMat 02-099 lint free cloth. Rub surfaces clean before the
solvent becomes dry.
H. Clean the tested surfaces. Use a CoMat 02-099 lint free cloth
made moist with CoMat 01-438 solvent. Rub the surface clean
before the solvent becomes dry.
I. Use a nylon brush or CoMat 02-099 lint free cloth. Apply CoMat
07-106 conversion coating to the tested surfaces. Do not let
the solution dry on the surface. Keep the surfaces wet with
fresh solutions for 2 to 5 minutes.
NOTE: The CoMat 08-093 I Primer class M must be used with the
CoMat 07-115 I Primer class M and the CoMat 07-116
Thinner. The alternative CoMat 07-126 Water soluble
primer must be used with CoMat 07-127 Water soluble
primer converter and CoMat 07-128 Water soluble primer
thinner. Do not mix two primer systems.
M. Cure the primer. Use an explosion proof heat lamp. Cure the
primer for one hour at 190° to 210°F (88° to 99°C).
12. Install the New Inner Fairing, Refer to Figure 201 thru Figure 208
and Table 1
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: 1. USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
B. Clean the repair area. Use Comat 08-021 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface dry before the
solvent becomes dry.
G. Cure the adhesive. Use an explosion proof heat lamp. Cure for
one hour at 190° to 210°F (88° to 99°C)
13. Apply the Sealant to the Spaces, Refer to Figure 203 and 205
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS CONTAMINATION
B. Clean the repair area. Use CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Clean the mating surface of
the seal and the retainer. Rub the surface clean before the
solvent becomes dry.
E. Install the seal. Insert the seal into the retainer. Use a
CoMat 02-099 lint free cloth to remove the unwanted adhesive
compound from the area.
F. Cure the adhesive. Air cure for 8 hours at not less than 59°F
(15°C) before you handle the parts.
G. Clean the areas around the joints and the spaces between the
adjacent parts before you do the next step. Use CoMat 02-099
lint free cloth made moist with CoMat 01-438 solvent. Rub the
surfaces clean before the solvent becomes dry.
14. Apply the Sealant to the Spaces, Refer to Figure 201 thru Figure 208
and Table 1
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
C. Cure the sealant primer. Let the primer dry at room temperature
for one hour. If the primer forms a dull finish or dusty chalk
on the surface, remove it with a CoMat 02-099 lint free cloth.
Torque Ring Inner Fairing Patch Repair and Forward Frame Repair
Left & Right C-Duct Fixed Structure
Figure 207
5. Not to Scale.
REPAIR 034
FIXED STRUCTURE, TORQUE RING METALLIC ONE-PIECE INNER FAIRING
AND FORWARD FRAME SEGMENT REPAIR (VRS2181/VRS2182)
1. Effectivity
2. General
(1) 0.056 in. (1,42 mm) chem-milled to 0.036 in. (0,91 mm)
G. The location of the cut lines for the inner fairing and
forward frame should be established only within area 2 as shown
in Figure 201. It should be no less than 2.0 in. (50,8 mm) from
the edge of the actuator fitting. The exact location of cut
lines shall be established in such a way that the final
installation of the repair pieces will not interfere with the
production hardware.
3. Referenced Information
A. Standard Equipment
Clamps
Cutting tools
Drilling tools
Grinding tools
Nylon brush
Palette knife
Rivet tools
Standard shop tools
Heat lamp (explosion proof)
Temporary fasteners
B. Consumable Materials
C. Special Tools-None
E. Component Material
G. Repair Parts
5. Examine the Damaged Area, See Figure 201 and Figure 202
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Remove the torque ring seal. Pull the seal from the retainer.
Cut if necessary.
C. Clean the repair area with CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface clean before
the solvent becomes dry.
6. Cut the Inner Fairing, See Figure 202 and Figure 203
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Stop drill the crack ends if there are cracks on the inner
fairing. Use a hole between 0.125 and 0.150 in. (3,17 and 3,81
mm) in diameter. Use drills and drilling tools. Remove the
burrs.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
A. Clean the repair area with CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface clean before
the solvent becomes dry.
8. Cut the Forward Frame, Refer to Figure 202 and Figure 207
A. Stop drill the crack ends if there are cracks in the forward
frame. Use a hole between 0.125 and 0.150 in. (3,17 and 3,81 mm)
in diameter. Use drill sand drilling tools. Do not drill into
the existing structure. Remove the burrs.
B. Make a mark of the cutout on the forward frame. Use a CoMat 06-
131 marking pen.
C. Cut the damage frame as marked. Use cutting and grinding tools.
Do not cut into the existing structure. Remove the burrs.
9. Make the Repair Parts, See Figure 203 and Figure 207
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
NOTE: Because the inner fairing and the forward frame have
complex shapes, it is recommended to make the fairing
segment and frame segment from a spare fairing and a
spare forward frame, respectively. This is not
required if the repair is contained only within Area
2. However, if damage is contained in Area 1 or Area 1
and 2 simultaneously it is necessary to make these
from spare components. Use laminated shim if necessary
to fill the spaces. Refer to VRS2179/VRS2180 for
removal and installation information of the forward
frame and inner fairing.
E. Heat treat the parts that are made from 2024-T aluminum alloy
to the T62 condition. Be careful not to heat treat parts that
are already in the 2024-T3 condition.
NOTE: You can use liquid shim and/or laminated shims to fill
the spaces between the matting parts. See Figure 210,
Note 3, for the limits.
G. Make a mark of the holes on the repair parts and the structure.
Refer to Figure 210 for spacing requirements.
H. Use drill and drilling tools. Drill the pilot holes at the
marked locations. Remove the burrs.
J. Use Drills and drilling tools. Countersink the holes on the air
wetted surfaces. Remove the burrs.
10. Prepare the Repair Parts for Installation, Refer to Figure 203 and
Figure 207
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
A. Clean the repair area. Use a palette knife and CoMat 05-126
Scotch brite pads made moist with CoMat 01-438 solvent.
Carefully remove the bulk of the existing sealant and adhesive
from the repair area and from the inside of the retainer. Use
CoMat 02-099 Lint free cloth. Rub the surface clean before the
solvent becomes dry.
C. Clean the tested surfaces. Use CoMat 02-099 Lint free cloth
made moist with CoMat 01-438 solvent. Rub the surfaces clean
before the solvent becomes dry.
11. Install the Repair Parts, See Figure 203 and Figure 205
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: 1. USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
(3) Cure the adhesive at 190° and 210°F (88° and 99°C) for one
hour. Use an explosion heat lamp. Go to step 10.D
(2) Use CoMat 02-099 lint free cloth made moist with CoMat 02-
158 release agent. Apply the release agent to the other
mating surface.
CAUTION: IF YOU APPLY TOO MUCH PRESSURE, YOU WILL FORCE THE UNCURED
LIQUID SHIM OUT OF THE JOINT.
(5) Cure the adhesive/liquid shim at 190° and 210°F (88° and
99°C) for one hour. Use an explosion proof heat lamp.
Remove the parts before the adhesive cures.
E. Clean the repair area. Use CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surfaces clean before
the solvent becomes dry.
I. Cure the adhesive/liquid shim at 190° and 210°F (88° and 99°C)
for one hour. Use an explosion proof heat lamp.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
A. Abrade the mating surfaces of the seal and the seal retainer.
Use CoMat 05-128 aluminum oxide abrasive paper.
B. Clean the repair area. Use Comat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Clean the mating surface of
the seal and retainer. Rub the surface dry before the solvent
becomes dry.
E. Insert the seal into the retainer. Use a CoMat 02-099 lint free
cloth to remove the unwanted adhesive from the area.
13. Apply the Sealant to the Spaces, Refer to Figure 203 and 205
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS CONTAMINATION
A. Clean the repair area. Use CoMat lint free cloth made moist
with CoMat 01-438 solvent. Rub the surface clean before the
solvent becomes dry.
B. Apply CoMat 02-178 masking tape. Make a border along the edges
of the spaces between the fairing patch and the existing
fairing. Do the same along the edges of the open space.
Torque Ring Inner Fairing Patch Repair and Forward Frame Repair
Left & Right C-Duct Fixed Structure
Figure 201
Torque Ring Inner Fairing Patch Repair and Forward Frame Repair
Left & Right C-Duct Fixed Structure
Figure 202
Torque Ring Inner Fairing Patch Repair and Forward Frame Repair
Left & Right C-Duct Fixed Structure
Figure 203
Torque Ring Inner Fairing Patch Repair and Forward Frame Repair
Left & Right C-Duct Fixed Structure
Figure 204
Torque Ring Inner Fairing Patch Repair and Forward Frame Repair
Left & Right C-Duct Fixed Structure
Figure 205
Torque Ring Inner Fairing Patch Repair and Forward Frame Repair
Left & Right C-Duct Fixed Structure
Figure 206
Torque Ring Inner Fairing Patch Repair and Forward Frame Repair
Left & Right C-Duct Fixed Structure
Figure 207
Torque Ring Inner Fairing Patch Repair and Forward Frame Repair
Left & Right C-Duct Fixed Structure
Figure 208
Torque Ring Inner Fairing Patch Repair and Forward Frame Repair
Left & Right C-Duct Fixed Structure
Figure 209
Torque Ring Inner Fairing Patch Repair and Forward Frame Repair
Left & Right C-Duct Fixed Structure
Figure 210
REPAIR 035
LEFT & RIGHT C-DUCT HEAT SHIELD WELD PATCH REPAIR
(VRS2003/2004)
1. General
2. Effectivity
V2500-A1/A5
3. Reference Information
VRS2003
VRS2004
V2500 Thrust reverser Component Maintenance Manual
Overhaul Processes Consumable Index
Standard Process and Procedure Manual
A. Standard Equipment
Fine wire stainless steel brush
Hand held probe
Hand punch, 0.250 in. (6,35 mm) diameter
Power supply
Palette knife
Stored energy spot welder
Standard shop tools
B. Consumable Materials
CoMat 01-438 Solvent
CoMat 01-457 Methylisobutylketone (alternative for
CoMat 01-438)
CoMat 02-097 Lint-free gloves
CoMat 02-099 Lint-free cloth
CoMat 02-134 Masking tape
CoMat 06-153D Felt Tip Marker, Rapid Dying
CoMat 08-030 Sealant
Primer, adhesion/promoter, PR-1200
CoMat 12-028 Thermal insulating material
CoMat 12-030 Foil (plain)
E. Component Material
5. Repair Instructions
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
B. Prepare the Patch, Figure 201 through Figure 204 and Tables 1
and 2
C. Make and Install the Vent Shield, Figures 201 through 204 and
Tables 1 and 2
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
(a) Use CoMat 02-030 foil (plain). Cut the vent shield
1.0 in. (25,4 mm) by 2.25 in. (57,15 mm). Fold back
one of the longer edges 0.25 in. (57,15 mm). Fold
back one of the longer edges 0.25 in. (6,35 mm) to
prevent a sharp edge. This edge will become the open
side of the vent.
(a) Clean the repair area with CoMat 02-099 lint free
cloth made moist with CoMat 01-438 solvent. Rub the
surface clean before the solvent becomes dry.
(a) Center the shield over the hole. point the open side
of the shield down towards the lower edge of the
heat shield, except in area 6. In area 6, point the
open side of the heat shield towards the aft edge.
WELD DATA
Type of Stored energy spot weld (poke)
weld with power supply.
Materials CoMat 12-030 foil (plain).
WELD DATA
Weld Do a test of the weld procedure
setting for good welds. Join a patch and
two pieces of repair foil the
same as the part to be repaired.
Pull apart the pieces. Weld is
good if portions of the weld
nugget are torn out when pulled
apart.
Weld Start the weld at one of the two
sequence tack welds. Continue at
intervals of 0.063 in. (1,60
mm). Keep the probe of the
welder on the edge of the part.
Do the same procedure on the
second and third sides.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
(1) Clean the faying surface of the patch and the repair area
of the heat shield
(a) Clean the repair area with Comat 02-099 lint free
cloth made moist with CoMat 01-438 solvent. Rub the
surface clean before the solvent becomes dry.
(2) Put the patch in position on the damaged area of the heat
shield
(a) Center the patch over the damaged area. Point the
open end of the vent shield toward the open end of
the heat shield.
WELD DATA
Type of weld Stored energy spot weld (poke)
with power supply.
Materials CoMat 12-030 foil (plain).
Weld setting Do a test of the weld procedure
for good welds. Join a patch and
two pieces of repair foil the same
as the part to be repaired. Pull
apart the pieces. Weld is good if
portions of the weld nugget are
torn out when pulled apart.
Weld sequence Start the weld at one of the two
edges of the patch that have no
tape. Weld from the center of this
edge to a corner. Poke wield at
0.063 to 0.125 in. (1,60 to 3,18
mm) intervals. Keep the probe of
the welder on the edge of the
patch. Finish the first edge by a
start at the center and poke weld
to the other corner with the same
intervals. Do the same procedure
on the second and third sides.
Before the weld procedure of the
tape edge is started, carefully
remove the hold down tape. Start
from the folded corner of the tape
and peel gradually with a pull
away from the patch.
(a) Clean the repair area with CoMat 02-099 lint free
cloth made moist with CoMat 01-438 solvent. Rub the
surface clean before the solvent becomes dry.
EDGE OF DAMAGE
PATCH TO CONFORM
TO REPAIR SURFACES
APPROX. 0.50 in. (12,7 mm)
ALL AROUND
CLEAN AREA
ALL AROUND
1.0 in. (25,4 mm)
PATCH (Foil)
PREPARATION STRAIGHTEN OR
REMOVE TORN FOIL
HEAT SHIELD
SECOND EDGE START HERE-
WELD TO CORNERS
START WELD HERE-
AFTER REMOVAL OF
MASKING TAPE MASKING TAPE
(2 off)
(TO HOLD PATCH IN
PLACE FOR WELDING)
NOTE: A CORNER IS
TO BE TURNED UNDER
FOR EASY REMOVAL
FIRST EDGE
START HERE-
WELD TO CORNERS
WELDING
PATCH (Foil)
A5S120A
FOLD BACK
(Open edge) VENT SHIELD
REPAIR PATCH
1.00 in.
0.125 in. (3,18 mm) (25.4 mm)
2.00 in.
(50.8 mm)
SEAL
(3 sides only)
POKE WELD
(3 sides)
POKE TACKWELD
(2 places)
A5S121
1 2 8
3
6
5 4
VENT LOCATIONS 7 10
(OPEN SIDE DOWN)
A5S122
8 2 12 2 1
11
3
6
VENT LOCATION
5
4 (OPEN SIDE AFT)
9 7 VENT LOCATIONS
10 (OPEN SIDE DOWN)
A5S123
REPAIR 036
FULL PENETRATION DAMAGE REPAIR OF COMPOSITE CONE AND OUTER FAIRING
C-DUCT FIXED STRUCTURE - LEFT AND RIGHT TORQUE RING ASSEMBLIES
(REPAIR WITH M20 PREIMPREGNATED FABRIC)
(VRS2176)
1. General
2. Reference Information
A. Standard Tools
E. Component Material
4. Prepare the damaged area for repair (See Figures 202 thru 204)
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH
PREIMPREGNATED FABRICS, FILM ADHESIVES OR CLEANED
SURFACES. THIS PREVENTS CONTAMINATION.
B. Use a CoMat 02-099 lint free cloth made moist with CoMat
01-438 solvent to clean the damaged area. Rub the surface dry
before the solvent evaporates.
C. Find the type of repair that you will do. (See Note 1 below.)
Make a mark of the cutouts (stepped or tapered) on the surface,
as applicable. Use a CoMat 06-131 marking pen.
(2) The steps or tapers must be 0.5 in. (13 mm) wide for each
graphite ply.
D. Cut the damage out in a geometric shape. Cut and remove the
plies of graphite from the repair area in a stepped or scarf
(tapered) shape, as applicable. Remove the minimum amount of
material that will remove the damage completely. Use cutters or
routers, and CoMat 05-020 and CoMat 05-021 waterproof silicon
carbide abrasive papers. Do not damage the adjacent structure.
Remove sharp edges.
E. Make a border for the repair area with CoMat 02-161 teflon
tape. Apply the tape 1.5 in. (38 mm) from the mark of the
largest cutout all around.
F. Remove the surface finish and lightly make the surface rough in
the repair area within the border. Use CoMat 05-020 and 05-021
waterproof silicon carbide abrasive papers. Do not damage the
graphite fibers.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
H. Use dry air blast to remove the sanding particles. Clean the
two surfaces in the repair area. Use a CoMat 02-099 lint free
cloth made moist with CoMat 01-438 solvent. Rub surfaces dry
before the solvent evaporates.
CAUTION: DO NOT TOUCH THE HOT PARTS WITHOUT PROTECTIVE GLOVES. HOT
PARTS CAN CAUSE REDDENING AND BLISTERING OF THE SKIN IF
THE HANDS ARE NOT PROTECTED. PUT THE CONTACTED AREA IN
COLD WATER FOR 10 MINUTES IF THE SKIN IS BURNED. GET
MEDICAL AID IF PAIN OR BLISTERING CONTINUES.
K. Let the area cool down to room temperature. Cover the repair
area to prevent contamination.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH
PREIMPREGNATED FABRICS, FILM ADHESIVES OR CLEANED
SURFACES. THIS PREVENTS CONTAMINATION.
A. Cut the repair and doubler plies from CoMat 08-138 graphite
prepreg fabric. The repair plies must have the same warp
directions as the removed plies. Refer to SRM 54-30-00 Thrust
Reverser Structural Identification for warp directions.
(1) For each graphite ply of the original skin that was cut
out, you must make two plies. The size of the repair plies
is different for the step repair and the taper repair.
Refer to applicable illustrations.
(2) Make two more plies to use as doubler. Each ply must be
0.5 in. (13 mm) larger that the previous ply all around.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH
PREIMPREGNATED FABRICS, FILM ADHESIVES OR CLEANED
SURFACES. THIS PREVENTS CONTAMINATION.
A. Cut a piece of the CoMat 08-136 film adhesive. Remove one of the
protective parting films from the piece and apply the film
adhesive top the repair area. Press into position and remove
the wrinkles. Use the roller if necessary.
NOTE: 1. Make sure the repair and doubler plies have the same
warp directions ad the original.
CAUTION: DO NOT TOUCH THE HOT PARTS WITHOUT PROTECTIVE GLOVES. HOT
PARTS CAN CAUSE REDDENING AND BLISTERING OF THE SKIN IF
THE HANDS ARE NOT PROTECTED. PUT THE CONTACTED AREA IN
COLD WATER FOR 10 MINUTES IF THE SKIN IS BURNED. GET
MEDICAL AID IF PAIN OR BLISTERING CONTINUES.
A. Remove the sharp edges. Make the surface ion the repair area
smooth with the adjacent surfaces. Use CoMat 05-020 and 05-021
waterproof silicon carbide abrasive papers.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
B. Use dry air blast to remove the sanding particles. Clean the
repair area. Use a CoMat 02-099 lint free cloth made moist with
CoMat 01-438 solvent. Rub surface dry before the solvent
evaporates.
REPAIR 037
DOUBLER REPAIR AROUND RH C-DUCT 7TH AND 10TH-STAGE BLEED VALVES
(VRS2338)
1. General