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2.0 REASSEMBLY:
2.1 Use the original stiffener as a template to cut a new stiffener [Figure B]. While many of the
older containers use HDPE or other materials, most of the newer designs use MDS nylon
because of its superior properties. Because of this, many riggers use MDS exclusively for
replacing any stiffeners.
2.1.1 Mark out the outline of the original stiffener on the MDS.
Mark the center of the hole for the grommet very precisely.
2.1.2 Use the basting tip to mark the center of the hole for the grommet.
Push the tip through the MDS until the shoulder of the tip
makes an indentation in the MDS [Figures C, D, E]. This
forms a pilot hole for the drill.
2.1.3 Using heavy shears or tin snips, cut the MDS nylon to shape.
Clip the corners to remove the sharp ends and if the edges are
sharp or rough, sand them with sandpaper.
2.1.4 Secure the MDS against a piece of wood and drill a 3/8" hole.
While this hole may seem big for the shank of the grommet,
when installed and the material is punched, it will be the right
size. A common mistake is to make the hole too small and
when the grommet is set, it cracks the plastic.
2.2 Insert the stiffener in between the layers of fabric of the bottom
flap and let it float inside.
2.3 Baste the two layers of fabric together with the single needle.
2.4 Restitch the binding to the bottom flap [Figure F].
2.5 Slide the stiffener to the edge of the flap and align the hole in
the stiffener with the hole in the fabric. Use an “O” grommet
to align the holes [Figure G].
2.6 Stitch the stiffener in place as per the original installation.
2.7 Insert the grommet with the correct orientation, and set with
the grommet set [Figure H]. Make sure that the grommet is
set sufficiently so there is no exposed edge to snag the lines
or material. Use the feeler gauge to check the gap under the
edge of the grommet [Figure J]. It should be no more than
.010". If more, hit the set again to tighten the grommet.
3.0 INSPECTION:
3.1 Verify the stiffener backing is resewn.
3.2 Check the grommet orientation.
3.3 The grommet must be set tightly and measured.
3.4 There should be no sharp edges on the inside of the grommet.
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7-51
Parachute Repair Procedure
TITLE: 7.2.5 Main Container Side Flap Replacement
NUMBER OF PAGES: 2
APPLICABLE PRODUCTS: Most modern container systems.
DESCRIPTION: Replacement of a main container side flap.
AUTHORIZED REPAIRMEN: FAA Senior or Master Parachute Rigger
MATERIALS: E thread—color to match
Ty-3 3/4" tape—color to match
Replacement flap
MACHINES: 301 Straight Stitch—Medium Duty 5-9 SPI
308 Zigzag—Medium Duty 7-11 SPI
301 Double needle with tape folder 5-9 SPI
1" x 42 stitch bar tack
EQUIPMENT:
Scissors
Seam ripper or scalpel
Marking pencil
6" ruler
Hot knife
PROCEDURE
Note: The following technique is typical of many modern container systems. This procedure
addresses only the disassembly of the container and replacement of the factory made part. It does not
address the manufacture of a replacement part.
1.0 DISASSEMBLY:
1.1 Remove all extraneous parts from the harness/container assembly.
1.2 Open the bottom corner of the main container on the appropriate side.
1.3 It will be necessary to remove the Ty-3 binding tape on the inside seam joining the main
body to the side flap. Depending on the container construction configuration, there are two
options how to do this.
1.3.1 Option 1, the salvage method. With this method, the binding tape is left undamaged and sewn
back in place after replacing the flap. A slower method, but good if the rigger doesn’t have
the necessary replacement tape.
1.3.2 Using a seam ripper, unpick the two rows of stitching
that holds the side flap to the main container
[Figure A]. Start at the lower corner and continue
until approximately 2" past where the side flap joins
the riser cover.
1.3.3 Remove the side flap.
1.4 Option 2, the replacement tape method. With this
method, the binding tape is destroyed during the
removal process and replaced with new. A faster
method, but new tape is required.
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1.4.1 Use a hot knife to melt the stitching that holds the binding tape that attaches the side flap to
the main container [Figure B]. When doing this, have the side of the tape that faces the damaged
side flap facing up in case you slip so the wrong flap won't be damaged. Proceed to the
point where the side flap stops. Trim the melted tape at this point.
1.4.2 Using a seam ripper,
unpick the tape approximately
　
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