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4) Sufficient material shall be applied to fill void and allow for a slight excess. 5) A piece of mylar film shall be placed over BMS 8-40 compound. Mylar film shall
extend about 1/2 inch around outer edge of the filled void area.
6)  Upper surface of mylar film shall be lubricated with light machine oil.
7)  Working from center of repair, BMS 8-40 shall be swept and faired to desired
contour, using a rigid squeegee.
8) Mylar film shall be attached to foam of hatrack nosing with masking tape.
9) Bullnose former shall be inserted in place and wrapped with masking tape
(Permacel No. 718) in order to maintain proper contour.
CAUTION:  IF PERMACEL NO. 718 MASKING TAPE IS NOT AVAILABLE, MASKING TAPE USED SHALL NOT BE APPLIED DIRECTLY TO BOLTARON COVER MATERIAL BECAUSE ADHESIVE ON TAPE WILL TEND TO DISCOLOR BOLTARON.
10)  BMS 8-40 compound shall then be cured for one hour at room temperature and five hours at 115°F.
11)  Bullnose former shall be removed and mylar film shall be carefully removed from repaired area.
(b) Repair with Stafoam P.E. 102 1) Follow steps (a) 1) and 2) of preceding (BMS 8-40) repair. 2) Thoroughly mix the following materials as described below: 50 grams P.E. 102 Component I (R) 2.8 grams P.E. 102 Component II (C) Add Component II to Component I. Mix slowly for 10 seconds and rapidly for 20 seconds or until mixture turns white.
3) Void area shall be filled approximately 3/4 full. 4) Immediately cover with mylar film and completely tape mylar in such a way as to restrain foam as it reacts. 5) If possible, hatrack nose former shall be inserted in place. If this is not possible, add weights.
559 
Aug 15/76  BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.  25-00-11 Page 221 

6)  Foam shall be cured 25 minutes at room temperature.
7)  Flex or knead foam area thoroughly and post cure for one (l) hour at 150°F.
(4)  Repair of foam after bonding Nose Former in place.
NOTE:  This includes completion of all bonding except Boltaron flap which is bonded to lower flange of nose former.
(a)  
Two openings shall be punched above void area through exposed foam adjacent to unbonded flap, using a probe approximately l/32 inch in diameter. By placing a finger on material (Boltaron) in void area, it is possible to feel when probing instrument has made contact.

(b)  
Areas around distorted area shall be protected with asbestos sheet and heat shall be applied with heat gun until the Boltaron snaps back into its original shape.

CAUTION: AVOID OVERHEATING.

(c)  
BMS 8-40 shall be mixed in accordance with paragraph (3) (a) and poured into a 6 ounce polyethylene cartridge with a #420 polyethylene nozzle and installed in a pressure gun. (Semco Sealant Gun No. 250)

(d)  
A hypodermic needle or similar type tube shall be inserted through foam into void area to allow air to escape.

(e)  
Nozzle shall be inserted into one of probed openings and BMS 8-40 material shall be forced into void until filled.

(f)  
A felt caul plate shall be placed over repaired area and secured with masking tape (Permacel No. 718).

NOTE:  Do not allow masking tape to come into direct contact with Boltaron unless it is Permacel No. 718 masking tape.
(5)  Repair after complete bonding of Nose Former.
NOTE:  This method includes foam repair after installation of hatrack bullnose into airplane.
(a)  
Cut hole in Boltaron cover material of 1/4 inch to 1/2 inch in diameter using a cork bore or other suitable tool.

(b)  
Repair foam in accordance with Repair Method 9 or with BMS 8-40, par. (3)(a).

(c)  
Boltaron cover material shall be repaired in accordance with Repair Method 5.

M.  Repair Method No. 11
(1) 
 General

(a)  This method is used to repair abrasions, scratches, mold lines, and sprue marks on nylon parts.

(2)  
Equipment and Material

(a)  
Learock--Type BS-30 and B815

(b)  
Disc Sander, with No. 400 Sandpaper

(c) 
 Spindle Shaper

(d)  
Sandpaper, No. 600 grit

(e)  
Buffing Wheel (4 inch)

 

(3)  
Repair: (for Abrasions and Scratches)

(a)  
Area adjacent to damage shall be sanded flush with abrasion or scratch, using 400 grit wet or dry sandpaper.

(b)  
Area surrounding damage shall also be sanded to feather in parts' surface.

(c)  
Damaged area shall then be sanded, using 600 grit wet or dry sandpaper.

(d)  
Surface gloss shall be restored by buffing with Learock, Type BS-30 or Type B815 buffing compound. Use standard 4 inch buffing wheel.
　
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