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Failure of the structure can cause an accident.
2. Resin
You must use the correct quantity of mixed resin for the repair. Weigh all the cut cloth patches that you
will use for the repair. The ratio for glass cloth to mixed resin is 100 : 70. For example, 100 grams of
dry glass cloth require 70 grams of mixed resin. The ratio for carbon cloth to mixed resin is 100 : 85.
For example, 100 grams of dry carbon cloth require 85 grams of mixed resin.
Measure the quantities of resin and hardener accurately (± 0.5 % by weight). Mix the resin and
hardener thoroughly before laminating, or adding fillers or other additives.
Always use clean containers for mixing resin and only mix as much resin as you can use within its
“working life”.
When using a large quantity of resin put it into a shallow container. This will increase the ratio of
surface area to volume which will reduce the risk of an exothermic reaction.
% For parts made from self extinguishing resin use the same resin system for repair (refer to Section 51-
% 30).
% 3. Glass and Carbon Cloth
You must always use the correct cloth for the repair. Refer to the lay-up drawing of the repair area for
data about the type of cloths you must use. The lay-up drawing will tell you:
) The correct type of cloth.
) The fiber direction.
) The dimensions of the layer.
AIRCRAFT
Standard Practices and
Structures
DA 40 Series
AMM
Page 202
20 Sep 2007 51-20-00 Doc # 6.02.01
Rev. 5
Make sure that the fibers in each layer of cloth point in the direction given in the lay-up drawing. This
gives the correct strength to the laminate. Only use sharp shears or scissors to cut the cloth to size.
Make sure that the fibers in the cut cloth point in the correct relative direction. Make sure that the fiber
strands are not broken or damaged. The cloth must be free of any damage or contamination.
4. Core Material
You must always use the correct sandwich core for the repair. Refer to the lay-up drawing of the repair
area for data about the type of core you must use.
Make sure that the core material is not damaged or contaminated.
Use a sharp knife to cut the core to the exact size for the repair. The edges of the cut must be clean
so that the core will bond correctly. You can profile the core by cutting or sanding.
5. Laminating
A prescribed stack of resin impregnated cloth makes a laminate. A laminate which is used to repair
an airplane becomes an integral part of the airplane structure once the laminate is hardened and fully
cured.
You can make the laminate in place directly on the repair or you can make the laminate on a work
table and then apply the wet laminate to the repair. When you make the laminate on a table:
) It is easier to do.
) It is easier to control and correct the laminating process.
) You can make sure that the cloth layers in the stack are correct before you apply the resin.
) You can make the repair neater.
) You do not have to work upside down.
AIRCRAFT
DA 40 Series
AMM
Standard Practices and
Structures
Doc # 6.02.01
Rev. 5 51-20-00 Page 203
20 Sep 2007
A. Laminating in Place
Detail Steps/Work Items Key Items/References
(1) Prepare the damaged area for laminating. Make
sure that the repair is clean and free
contamination.
Refer to the relevant repair procedure in
this Section.
(2) Prepare the layers of cloth that you will use. Refer to the lay-up drawing.
(3) Protect the area of the structure around the repair
from contamination by the repair materials.
Use plastic/polythene sheet material
held in place by self adhesive tape.
WARNING: DO NOT GET RESIN ON YOUR SKIN. RESIN CAN CAUSE SKIN
DISEASE.
WARNING: DO NOT GET RESINS, HARDENERS OR SOLVENTS IN YOUR
MOUTH OR IN YOUR EYES. THESE CHEMICALS CAN CAUSE
DISEASE.
(4) Apply a thin coat of resin to the repair.
(5) Apply the first layer of cloth to the repair and trim
to the correct size.
Make sure that the fibers in the cloth
point in the correct direction.
(6) Use a roller, squeegee and a stipple brush to
remove all trapped air. Make sure that the cloth is
completely impregnated with resin. If necessary,
add more resin.
(7) When the excess resin has been brought to the
surface with the rolling and stippling process,
apply the next layer of cloth. Trim the cloth to the
correct size.
Make sure that the fibers in the cloth
point in the correct direction.
(8) Do steps 6 and 7 as necessary until all the layers
of cloth are in place.
(9) Use the roller and squeegee to remove the
excess resin.
(10) Put a layer of peel ply over the laminate.
　
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