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after a large repair and calculate the center of gravity. Refer to Section 08-10 for data about weighing
the airplane.
3. Control Surface Balancing
When you repair a control surface it becomes heavier. Make an estimate of the new weight of the
control surface after before you do a repair. If the control surface will be too heavy then do not repair
it. You must install a new item.
When you repair a control surface and/or apply a new paint coat you must weigh and balance the
control surface. Refer to Section 06-00 for data about weights and balance. Section 51-60 tells you
how to balance a control surface.
WARNING: YOU MUST WEIGH AND BALANCE A CONTROL SURFACE AFTER
REPAIR OR PAINTING. FAILURE TO BALANCE A CONTROL SURFACE
MAY CAUSE THE AIRPLANE TO FAIL IN FLIGHT.
4. Drain/Vent Holes
You must keep all drain and vent holes in the structure of the DA 40 open. If you close a drain or vent
hole doing a repair you must make a new hole in the same position.
AIRCRAFT
Standard Practices and
Structures
DA 40 Series
AMM
Page 2
20 Sep 2007 51-20-00 Doc # 6.02.01
Rev. 5
5. Holding the Component
You must hold a component in the correct position when you do a repair. If you do not hold a
component correctly it may move when you do the repair and cause further damage. It can also
change the airplane alignment.
Hold the component in a special device (jig/fixture) before you cut the repair area. If necessary, lift the
airplane on jacks and level the airplane. Refer to Section 07-10 for data about jacking and Section 08-
20 for data about levelling the airplane.
6. Safety Precautions
Most resins can cause skin disease. When you use resin/hardener use a protective barrier cream on
your hands and exposed skin. You must always wear plastic gloves.
WARNING: DO NOT GET RESIN ON YOUR SKIN. RESIN CAN CAUSE SKIN
DISEASE.
The resins, hardeners and solvents used for composite repairs are poisonous. You must not take food
into the work area. Use a mask to protect your face and use eye-protection.
WARNING: DO NOT GET RESINS, HARDENERS OR SOLVENTS IN YOUR MOUTH
OR IN YOUR EYES. THESE CHEMICALS CAN CAUSE DISEASE.
When you grind composites you make small particles of composite dust. These particles can irritate
the skin and eyes. If you breathe these composite particles, they can cause lung disease.
When you grind composite you must always use a protective cream on your hands and on all exposed
skin. Wear overalls which seal at the wrists, neck and ankles. You must always wear gloves and if
necessary, change them often. Use a suitable mask to protect you face and lungs. Always wear safety
goggles to protect your eyes.
If your skin comes into contact with composite dust, then wash it off with flowing water. Do not rub your
skin while it has dust on it.
WARNING: DO NOT GET COMPOSITE DUST PARTICLES IN YOUR EYES, OR IN
YOUR MOUTH, OR ON YOUR SKIN. THESE PARTICLES CAN CAUSE
DISEASE.
AIRCRAFT
DA 40 Series
AMM
Standard Practices and
Structures
Doc # 6.02.01
Rev. 5 51-20-00 Page 3
20 Sep 2007
7. Workshop Conditions
Keep the workshop clean and free from dust. Remove grinding dust as it occurs. The working area
must not be affected by draughts.
The temperature of the workshop should be maintained between 18 °C (65 °F) and 27 °C (77 °F) and
must not fall below 15 °C (59 °F). The relative humidity during mixing, applying or curing or resins must
not be allowed to rise above 80 %.
Maintain the workshop temperature as near to 25 °C (77 °F) as possible during curing.
AIRCRAFT
Standard Practices and
Structures
DA 40 Series
AMM
Page 4
20 Sep 2007 51-20-00 Doc # 6.02.01
Rev. 5
Intentionally left blank
AIRCRAFT
DA 40 Series
AMM
Standard Practices and
Structures
Doc # 6.02.01
Rev. 5 51-20-00 Page 201
20 Sep 2007
Maintenance Practices
1. General
These maintenance practices tell you about composite repair processes and how to repair Class 2,
3 and 4 damage to the composite structure. Refer to Section 51-10 for data about damage
classification. Class 1 damage may only be repaired in accordance with a repair scheme approved by
the manufacturer. All repairs must be carried out by approved persons.
You must only use the materials approved by the manufacturer when repairing the airplane. Refer to
Section 51-30 for data about approved materials.
Inspect the damaged area. Look specially at the adjacent structure. Damage can go a long way under
the surface. Use the techniques given in Section 51-10.
You must take care to do the repair correctly. The outer shell of a composite structure is stressed.
　
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