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(3)  Put a layer of clean transparent plastic/polythene sheet over the repair and hold it in place with self adhesive tape. 
(4)  Use an indelible felt marker to: S Trace onto the plastic sheet the extreme outline of the repair. S Trace onto the plastic sheet the contour lines of each layer of cloth in the structure.  The outer layer of the structure must be tapered to avoid stress risers and to give a good finish. 
(5)  Remove the transparent sheet from the structure and place it upside down on a work table. 
Note: The cloth layers are laid in reverse order when you laminate on a table. You must take care to put the cut cloth layers in the correct order and that the fibers in each cloth layer point in the correct direction. 
(6)  Cut the layers of cloth to fit the contour lines that you traced onto the transparent sheet. 
WARNING: DO NOT GET RESIN ON YOUR SKIN. RESIN CAN CAUSE SKIN DISEASE. WARNING: DO NOT GET RESINS, HARDENERS OR SOLVENTS IN YOUR MOUTH OR IN YOUR EYES. THESE CHEMICALS CAN CAUSE DISEASE. 
(7)  Apply a thin coat of resin to the transparent sheet. 
(8)  Apply the first inner layer of cloth to the transparent sheet and trim to the correct size.  Make sure that the fibers in the cloth point in the correct direction. 
(9)  Use a roller, squeegee and a stipple brush to remove all trapped air. Make sure that the cloth is completely impregnated with resin. If necessary, add more resin. 

Page 204 Doc # 6.02.01 09 Jan 2003 Rev. 4
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Structures

DA 40 Series

Detail Steps/Work Items  Key Items/References 
(10)  When the excess resin has been brought to the surface with the rolling and stippling process, apply the next layer of cloth. Trim the cloth to the correct size.  Make sure that the fibers in the cloth point in the correct direction. 
(11)  Do steps 9 and 10 as necessary until all the layers of cloth are in place. 
(12)  Apply a thin coat of resin to the area of the repair on the structure where you will attach the laminate patch. 
(13)  Put the laminate patch carefully into position on the structure using the transparent sheet.  Make sure that the fibers in the cloths point in the correct direction. 
(14)  Carefully remove the transparent sheet from the laminate patch. 
(15)  Use a roller to make sure that the laminate patch is firmly in position and that any excess resin is removed from the repair laminate. 
(15)  Put a layer of peel ply over the laminate. 
(16)  If necessary, apply a vacuum bag to the laminate.  Refer to the lay-up drawing and/or repair drawing. 

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AMM

Table 1 - Bonding Paste Mixing Table
Material  Weight in Grams 
Mixed Resin  50  100  150  200  250  300  350  400  450 
Cotton Flocks  6  11.5  17  23  29  34.5  40  46  52 
Aerosil  1.4  2.8  4.2  5.5  6.9  8.3  9.7  11.1  12.5 

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Structures

6. Bonding Paste (Thickened Resin)
Use bonding paste to bond GFRP/CFRP components together and in the repair of sandwich cores. Resin and thickening fillers make bonding paste. Table 1 gives you the proportions by weight of resin to thickening fillers. You can change the proportions of Aerosil and Microballoons relative to each other but you must keep the total weight of the Aerosil/Microballoon mix constant.
7. Curing
You must cure a composite structure to make it strong. If you do not cure a composite structure correctly it may fail. Curing is a 2 part process, pre-curing and post-curing. The following procedure gives a typical curing process.
　
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