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Repair of Polycarbonate Composite Components Figure 802/TASK 25-00-00-991-012
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R R (6) Repair damage that is less than 10 mm (0.4 in.) in diameter at upper surface and at core material on flat and rounded components:
R (a) Apply the separating foil (1) to the front face of the component (5).
R (b) Put the component (5), front face down, on a PLATE - BASE, RUBBER (2).
(c) Fill the damaged area with BONDING AND ADHESIVE COMPOUNDS (Material No. 08-025).
R (d) Let the adhesive cure for 1 hour.
R (e) Remove the separating foil (1) from the component (5).
(f) Fill the areas that are not smooth with BONDING AND ADHESIVE COMPOUNDS (Material No. 08-025).
R R (g) If necessary, make the repair smooth with the emery cloth, 320-400 grade.
NOTE : Allow the bonding and adhesive compounds to harden before____ you use the emery cloth.
R R (7) Repair damage that is 10 mm (0.4 in.) or larger in diameter at upper surface and at core material on flat components:
NOTE : The minimum distance from the edge of the stiffener (7) to the____ damaged area must equal 20 times component thickness.
(a) Make a repair plug (3) from the applicable PC material.
(b) Make a stiffener (7) from the applicable PC material.
NOTE : Use stiffeners from SPECIAL MATERIALS (Material No. 05-____ 033) if the component is rounded.
(c) Make a stiffener (9) from SPECIAL MATERIALS (Material No. 05-033).
R NOTE : If the rear side of the component is made of PC material____ use a stiffener from the same material. Chamfer the edges of the PC stiffener to 45 degrees.
R R (d) Make an insert from rigid foam SPECIAL MATERIALS (Material No. 05-075) or alternative from NOMEX comb (8).
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R (e) Chamfer the edges of the PC surface layer (4) to 45 degrees.
R (f) Chamfer the edges of the repair plug (3) to 45 degrees.
R (g) Apply the separating foil (1) to the front face of the component (5).
R (h) Put the component (5), front face down, on a PLATE - BASE, RUBBER (2).
(i) Bond the repair plug (3) to the component (5) with BONDING AND ADHESIVE COMPOUNDS (Material No. 08-025).
(j) Apply BONDING AND ADHESIVE COMPOUNDS (Material No. 08-025) to the repair area.
(k) Apply BONDING AND ADHESIVE COMPOUNDS (Material No. 08-025) to the stiffener (7), the insert (8) and the honeycomb.
(l) Bond the stiffener (7) and the insert (8) with BONDING AND ADHESIVE COMPOUNDS (Material No. 08-025).
R (m) Let the adhesive cure for 1 hour.
R (n) Make the repair smooth with the emery cloth, 320-400 grade.
R R (o) Clean the repair area with CLEANING AGENTS (Material No. 11-010) and a lint-free cotton cloth MISCELLANEOUS (Material No. 19-003).
(p) Apply BONDING AND ADHESIVE COMPOUNDS (Material No. 08-025) to the repair area.
(q) Apply the stiffener (9) to the repair area.
NOTE : The total thickness of SPECIAL MATERIALS (Material No. 05-____ 033) (9) must equal the initial PC layer (6).The minimum distance from the edge of the stiffener (9) to the insert (8) must equal 40 times the thickness of the PC layer (6).
R (r) Remove the separating foil (1) from the component (5).
(s) Fill the areas that are not smooth with BONDING AND ADHESIVE COMPOUNDS (Material No. 08-025).
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R R (t) If necessary, make the area of the repair smooth with the emery cloth, 320-400 grade .
NOTE : Allow the bonding and adhesive compounds to harden before____ you use the emery cloth.
R (8) If necessary, apply a top layer (Ref. TASK 25-00-00-370-001).
Subtask 25-00-00-420-062
B. If you have removed the component to do the repair, install the component in the aircraft (refer to the related AMM chapter).
5. Close-up________
Subtask 25-00-00-942-068
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