Doc # 6.02.01 Page 201
Rev. 4 09 Jan 2003

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AMM

DA 40 Series

Detail Steps/Work Items  Key Items/References 
(6)  Carefully remove the protective coating from the new window only where it will bond to the frame. 
(7)  Grind the bonding surface of the window.  Use 120 grade abrasive paper. 
(8)  Make sure that the viewing area of the window is protected.  Use masking tape with paper. 
(9)  Apply adhesive to the frame.  Use Terostat 9380. 
(10)  Put the window in position in the frame. Hold the window with 3 mm pins through the 2 holes in the canopy. 
(11)  Removed unwanted adhesive. 
(12)  Allow the adhesive to cure for 24 hours. 
(13)  Remove the 2 pins. 
(14)  Apply a bead of white sealant to the gap between the edge of the window and the frame.  Use Terostat 9380. 
(15)  Allow the sealant to cure.  Follow the manufacturer’s instructions. 
(16)  Remove the protective covering from the window. 
(17)  Install the canopy or door.  Only if you have replaced the canopy or door window. Refer to Section 52-10. 

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Windows
AMM

3. Window Repairs
A. Damage Limits
Maximum crack length: 150 mm (6 in).
Do not repair cracks which are more than 150 mm (6 in) from the edge of the window.

B. Equipment
Item  Quantity  Part Number 
Small high-speed rotary grinder.  1  Commercial 
Filler: Acryfix 92 or Tensol cement No. 70.  A/R  Commercial 
Masking tape.  A/R  Commercial 
Plastic adhesive tape.  A/R  Commercial 
Cold ultra-violet light source (only for Acryfix 92).  A/R  Commercial 

Note:  Fillers become smaller when they cure. Apply enough filler to be above the level of the window surface. Cut the filler back when it has cured.
If you repair a vertical crack, keep the filler in place with plastic adhesive tape. Apply a second coat of filler after the first coat has cured.
C. Temporary Repairs to Windows
Stop-drill the ends of short cracks. Use a 2.5 mm (3/32 in) drill. Refer to Figure 2.
Doc # 6.02.01 Page 203
Rev. 4 09 Jan 2003

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AMM

MaskingCrack Window

  Tape 60-90° Outer Surface
 Inner SurfaceSTEP 1
Cold UV Light
Filler
(Acryfix Filler Only)

STEP 2
Stop-drill 2.5 mm (3/32 in)
Outer
>1/3 Thickness
STEP 3
  Tape

Cold UV Light (Acryfix Filler Only) STEP 4
Grind to Contour and Polish with Fine Abrasive Paper

STEP 5
Figure 2: Window Repairs
Page 204 Doc # 6.02.01 09 Jan 2003 Rev. 4
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Windows
AMM

D. Permanent Repairs to Windows
DA 40 Series

Detail Steps/Work Items  Key Items/References 
(1)  Remove the canopy or door. Put the canopy or door on a firm working surface with the crack horizontal.  Only if you will repair the canopy or door window. Refer to Section 52-10. 
(2)  Put protective covers over the inside of the cockpit.  Only if you will repair the right fuselage window. 
(3)  Mask the area around the crack on both inner and outer surfaces. 
(4)  Cut a groove along the crack in the outer surface of the window.  Refer to Figure 2, step 1. 
(5)  Countersink temporary stop-drill holes. 
(6)  Seal the stop-drill holes on the inner surface.  Use plastic adhesive tape. 
　
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