AI. Repair Method No. 33
(1)
General
(a) This method is for the repair of BAC5524 panels with D6-16056 Silkscreen Tedlar Decorative Facing.
(2)
Equipment and Materials
(a)
Artist brush
(b)
BAC5010, Type 38 Adhesive
(c)
BAC5010, Type 71 Adhesive
(d)
Decorative Tedlar Laminate BMS 8-98 Type II or III or BMS 8-143, Type 100 as appropriate
(e)
Double-backed tape 2 in. wide - Permacel No. 94
(f)
Abrasive paper, 240-320 grit
(g)
Foam, BMS 8-133 Type 1, Grade 20, Form A
(h)
Hole saw with 1/4-inch pilot
(i)
Masking tape
(j)
Scotchcast 5126 Adhesive
(k)
Silicone embossing pad
(l)
Silkscreen Ink BMS 10-73
(m)
TUF-ON P-24 Filler
(n)
Vacuum Pressure Source
(3)
Small Area Repair (During Overhaul)
NOTE: When damage effects one square inch or less of surface, small area repair shall be used. This method shall not be used when total damaged area exceeds 1% of total area of panel.
(a)
Cut a piece of foam to proper thickness.
NOTE: Thickness should be 0.010 inch less than the honeycomb core used in panel.
(b)
Bond a piece of decorative laminate of proper color, design and texture to the foam.
(c)
Using double-backed tape place a female template of proper hole diameter over damaged area of decorative surface.
(d)
Using a hole saw, cut out damaged area. Set cutter depth so fiberglass on back surface of panel is not cut.
(e)
Using double-backed tape, place a female template of the proper hole diameter on the foam plug prepared in steps (a) and (b).
(f)
Cut out a plug from the bonded foam of step (b).
NOTE: The outside diameter of the hole saw should be equal to the inside diameter of the cutter used to remove damaged section.
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(g) Sand lightly to remove burrs.
(h) Check plug for fit, alignment, design texture and depth. Adjust as necessary.
(i) Bond plug to panel with BAC 5010 type 38 adhesive.
(j) Fill any void space around circumference of plug with TUF-ON P-24. Fill to slight
excess.
WARNING: TUF-ON P-24 CONTAINS PHENOLIC RESINS. AVOID BREATHING
VAPORS AND MATERIAL CONTACT WITH SKIN AND EYES.
(k) Allow TUF-ON P-24 and adhesive to fully cure.
(l) Mask area around repair to within 0.125 inch.
(m)
Sand TUF-ON P-24 until smooth and even with surrounding area.
(n)
Color match BMS 10-73 ink and apply to repair with an artist's brush. Allow to dry for 15 minutes.
(o)
Apply a silicone embossing pad to repaired surface (pad to be embossed with proper texture and to be prepared per par. 3.H.(3)).
(p)
Apply vacuum pressure, approximately 10 inches of mercury. Cure repair for 15 minutes.
(4) Small Area Repair (During Overhaul) (Alternative to method in step (3))
NOTE: This method is recommended when damage occurs at a simple or compound curvature.
(a)
Using double-backed tape, place a proper size template over damaged area.
(b)
Cut a hole through entire panel (including nondecorative skin).
(c)
If use of template is not feasible, drill a 1/4-inch pilot hole through damaged area, and remove damaged area using proper size hole saw with a 1/4-inch pilot.
(d)
Place a silicone embossing pad over the hole on the decorative face (pad to be embossed with proper texture and to be prepared per par. 3.H.(3)). Pad must be held firmly in place using either weights or a vacuum bag.
NOTE: If silicone pad cannot be used because of compound curvature, tape shall be used to seal hole.
Feb 20/86 25-00-11
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BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.
(e)
Fill hole from the nondecorative face with Scotchcast 5126 adhesive.
WARNING: SCOTCHCAST 5126 CONTAINS EPOXY RESINS. AVOID BREATHING VAPORS AND MATERIAL CONTACT WITH SKIN AND EYES.
(f)
Cure at room temperature for 24 hours or at 140°F for 2 hours.
(g)
Remove silicone pad or tape and proceed using steps (n), (o), and (p) of par. AF.(3).
(5) Small Area Repair (Field, Quick Repairs)
(a)
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