(a) This method is for the repair of perforated acoustical panel having damage that penetrates the decorative surface and the fiberglass fly screen. This repair is limited to damage greater than . inch in diameter and less than 1.5 inch in diameter.
(2)
Equipment and Materials
(a)
Female routing template (Dia. 1.5 to 4”)
(b)
Tape (double-back)
(c)
Mylar tape
(d)
Male routing template
(e)
Epibond 126
(f)
Hardener - Furane #9812
(g)
Plexiglas(6” X 6” X 8” X .”)
(h)
Fabric -BMS 8-64
(3)
Repair: (Patch)
(a)
A femal routing template with a hole diameter of 1.5 to 4 inches shall be centered over damage and held in place with double-back tape. A Formica repair kit has such a template.
(b)
Rout out damaged area. Set router depth so that fiberglass fly screen beneath decorative face is not cut. Remove flow-resistant fabric.
NOTE: On Tedlar-covered laminates, butt several pieces of Mylar tape over damaged area and matching perforated decorative sheets to keep Tedlar film from fraying during routing.
(c)
Using a male template (Formica repair kit), rout out a matching patch from a piece of perforated decorative sheet material. Prefit patch by light sanding high points. Patch should require only light hand pressure to insert. Index patch by marking two places on patch and on surface being repaired. Marking shall be capable of being removed after bonding.
(d)
cut a piece of BMS 8-64 flow-resistant fabric to same size as patch
NOTE: This may be done by bonding fabric to decorative material per Item (g) and then cut patch and fabric together per Item (c).
(e)
Insert flow-resistant fabric and patch in cutout area of panel and adjust for a flush fit of patch to surrounding surface.
(f)
Mask decorative side of patch and area surrounding cutout in panel. Clean faying surfaces with naptha.
(g)
Spray heavy coat of the following adhesive on faying surface of patch and cutout area. Epibond 126 - 100 parts by weight Furane Hardener 9812 - 60-65 parts by weight Blend together above adhesive and hardener. Dilute with one volume of methyl ethyl ketone and one volume of toluene to one volume of adhesive plus hardener. Allow 10 minutes for air drying after spraying prior to bonding. bond within 30 minutes after spraying.
(h)
Remove masking from patch and panel. Apply double-back (thin as possible) tape to decorative side of patch and to area around cutout in panel. Do not cover up patch index markings.
(i)
Stick patch to 6 X 6 inch or 8 X . inch piece of Plexiglas. Insert flow-resistant fabric before patch so that it is between patch and flyscreen. Insert patch in cutout area, looking through Plexiglas to line up index markings.
(j)
Apply enough pressure to Plexiglas to assure flush fit. cure for 24 hours at room temperature or 3 hours at 120 ±5°F.
(k)
Fill any visible cracks in decorative surface.
(l)
Perforations may be restored by drilling. Use a piece of perforated material as a
559
Aug 15/76 BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. 25-00-11 Page 233
NOTE: A “cupcake” patch per Fig. 203 may be used instead of above circular patch.
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25-00-11 Page 234 BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. Aug 15/76
drilling template. AA. Repair Method No. 25
(1) General
(a) This method is for the repair of Textured Finishes.
CAUTION: THIS PROCEDURE IS NOT TO BE USED ON POLYCARBONATE OR POLYSULFONE PARTS.
(2)
Equipment and Materials
(a)
Spray Gun (DeVilbiss JGA502)
(b)
Spray Gun Head (AV-15-E, 402E Needle)
(c)
Spray Gun Air Cap (765)
(d)
Scotch brite pads
(e)
Lacquer - hi-speed
(f)
Aliphatic Naptha - TT-N-95A
(g)
Snowite Plastic Mender or Ditzler - DX-888 Mender
(h)
Duratite surfacing putty
(i)
Toluene
(j)
Adhesive - Eastman 910
(k)
Solvent - BMS 3-2
(3)
Repair: (Textured Finish)
(a)
Minor Repair of Coating (Scratches, gouges, etc.) 1) Solvent clean area to be repaired using BMS 3-2 solvent or naptha. 2) Apply coating (Hi-Speed Lacquer, Sherwin-Williams Paint Company) to area to
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