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Look specially at the area around the damage for secondary damage, which can remain undetected.
5. Further Inspection
If you find paint damage when you examine a composite structure then do this further inspection.
Find a way to see the inside of a structure or a component. If necessary, remove panels (or other components), or you can use remote viewing equipment. For example, remove the wing tip assembly to see inside the wing. If you can see damage inside the component or structure you must do a repair.
Remove the paint coat in the area that you think is damaged. Remove the paint coat carefully, you must not damage the cloth under the paint coat.
Look carefully at the surface. If you find cracks in the composite you must repair the structure.
If you do not find cracks in the composite then do this test. Push the middle of the area to be tested with your thumb. If you can feel the skin hitting the core of a sandwich (or other layer/component), then the skin is disbonded and you must repair the structure.
In some cases you must cut inspection holes in the structure to do the test correctly. If you must cut inspection holes you must seek advice from Diamond Aircraft Industries.
Doc # 6.02.01 Page 3
Rev. 4 09 Jan 2003

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Structures
AMM

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51-10-00
AMM
Structures

Section 51-20
Repair Processes

1. General
This Section tells you how to repair composite structures. Repairs must be carried out by approved persons. Refer to Section 51-00 for data about the types of structures. Refer to Section 51-10 for data about the classification of damage and inspection techniques. Refer to Section 51-30 for data about approved repair materials.
2. Center of Gravity Limits
When you repair an airplane, you can change the weight of the airplane. If you change the weight of an airplane, you can change the center of gravity. The further the distance of a repair from the center of gravity, the greater the effect will be on the center of gravity. You must always weigh the airplane after a large repair and calculate the center of gravity. Refer to Section 08-10 for data about weighing the airplane.
3. Control Surface Balancing
When you repair a control surface it becomes heavier. Make an estimate of the new weight of the control surface after before you do a repair. If the control surface will be too heavy then do not repair it. You must install a new item.
When you repair a control surface and/or apply a new paint coat you must weigh and balance the control surface. Refer to Section 06-00 for data about weights and balance. Section 51-60 tells you how to balance a control surface.
WARNING:  YOU MUST WEIGH AND BALANCE A CONTROL SURFACE AFTER REPAIR OR PAINTING. FAILURE TO BALANCE A CONTROL SURFACE MAY CAUSE THE AIRPLANE TO FAIL IN FLIGHT.
4. Drain/Vent Holes
You must keep all drain and vent holes in the structure of the DA 40 open. If you close a drain or vent hole doing a repair you must make a new hole in the same position.
Doc # 6.02.01 Page 1
Rev. 4 09 Jan 2003

51-20-00
Structures
AMM

5. Holding the Component
You must hold a component in the correct position when you do a repair. If you do not hold a component correctly it may move when you do the repair and cause further damage. It can also change the airplane alignment.
Hold the component in a special device (jig/fixture) before you cut the repair area. If necessary, lift the airplane on jacks and level the airplane. Refer to Section 07-10 for data about jacking and Section 08-20 for data about levelling the airplane.
6. Safety Precautions
Most resins can cause skin disease. When you use resin/hardener use a protective barrier cream on your hands and exposed skin. You must always wear plastic gloves.
WARNING:  DO NOT GET RESIN ON YOUR SKIN. RESIN CAN CAUSE SKIN DISEASE.
　
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