U900/000/TM/E/323

TECHNICAL MANUAL

B-HUNTER

UAV STRUCTURE REPAIR MANUAL

PROPRIETARY RIGHTS STATEMENT

THIS DOCUMENT CONTAINS INFORMATION WHICH IS PROPRIETARY TO EAGLE TEMPORARY AS-

SOCIATION, A BELGIAN TEMPORARY ASSOCIATION CONSTITUTED UNDER THE BELGIAN LAW, TO
ITS PARTNERS AND/OR ITS SUBCONTRACTORS. NEITHER THIS DOCUMENT NOR THE INFORMA-
TION CONTAINED HEREIN SHALL BE USED, DUPLICATED OR COMMUNICATED BY ANY MEANS TO
ANY THIRD PARTY, IN WHOLE OR PART, EXCEPT WITH THE PRIOR WRITTEN CONSENT OF EAGLE
TEMPORARY ASSOCIATION. THIS RESTRICTIVE LEGEND SHALL NOT BE ALTERED OR OBLITER-
ATED ON OR FROM THIS DOCUMENT.

SEPTEMBER 2002
U900/000/TM/E/323

EFFECTIVE PAGES

NOTE
The portion of text affected by the changes is indicated by a vertical line in the outer margins of the
page. Changes to illustrations are indicated by miniature pointing hands, shading or legend. Dates of
issue of original and changed pages are:

Original ......... 0 ........... September 2002

Total number of pages in this publications is 172, consisting of the following:

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* Zero in this column indicates an original page.

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TABLE OF CONTENTS

Chapter/Paragraph Page

INTRODUCTION ..................................................................................................... xv
1. PURPOSE OF USE AND SCOPE ................................................................ xv
2. ARRANGEMENT OF THIS MANUAL ........................................................... xv
3. USE OF THIS MANUAL .............................................................................. xvi
4. WARNINGS, CAUTIONS AND NOTES ...................................................... xvi
5. TECHNICAL TERMS .................................................................................. xvii
5. NON-STANDARD ABBREVIATIONS ......................................................... xvii
7 SAFETY SUMMARY ................................................................................. xviii
7-1 Keep Away From Live Circuits ...................................................... xviii
7-2 Do not Service or Adjust Alone ..................................................... xviii
7-3 Resuscitation ................................................................................ xviii
CHAPTER 1 - GENERAL ....................................................................................... 1-1
1-1 GENERAL DESCRIPTION ......................................................................... 1-1
1-1.1 Major Structural Group Breakdown ................................................ 1-1
1-1.2 Type of Construction ...................................................................... 1-1
1-2 CATEGORIES OF REPAIR CAPABILITIES ............................................... 1-1
1-2.1 Organizational (O) Level Repairs ................................................... 1-1
1-2.2 Depot Repairs ................................................................................ 1-2
1-3 CLASSIFICATION OF DAMAGE ................................................................ 1-2
1-3.1 Negligible Damage ......................................................................... 1-2
1-3.2 Repairable Damage ....................................................................... 1-3
1-3.3 Non-Repairable Damage ............................................................... 1-3
1-4 TYPES OF REPAIR .................................................................................... 1-3
1-4.1 Permanent Repair .......................................................................... 1-3
1-4.2 Temporary Repair .......................................................................... 1-3
1-5 PRINCIPAL DIMENSIONS AND STATION DIAGRAMS ............................. 1-4
1-6 AIRFRAME PREPARATION AND FINISHING ........................................... 1-4
1-7 CONTROL SURFACE REBALANCING ..................................................... 1-5
1-8 CRASH HANDLING AND SAFETY ............................................................ 1-5
1-9 SAFETY PRECAUTIONS ........................................................................... 1-6

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Chapter/Paragraph Page

CHAPTER 2 - SEALING AND BONDING REPAIR METHODS .............................. 2-1

2-1 INTEGRAL FUEL TANK SEALING ............................................................. 2-1
2-1.1 Definitions of Terms ....................................................................... 2-1
2-1.2 Safety Precautions ......................................................................... 2-1
2-1.3 Classification .................................................................................. 2-2
2-1.4 Materials ........................................................................................ 2-2
2-1.5 Tools and Equipment ..................................................................... 2-2
2-1.6 Sealing Area .................................................................................. 2-3
2-1.7 Cleaning and Surface Preparation Prior to Sealant Application ..... 2-3
2-1.8 Preparation of Surfaces ................................................................. 2-4
2-1.9 Preparation of Sealing Materials .................................................... 2-5
2-1.10 Application Time ............................................................................. 2-6
2-1.11 Curing of Sealant ........................................................................... 2-6
2-1.12 Sealing of Fairing Surfaces ............................................................ 2-7
2-2 ROOM TEMPERATURE MODERATE STRENGTH EPOXY BONDING .... 2-8
2-2.1 Classification .................................................................................. 2-8
2-2.2 Materials ........................................................................................ 2-8
2-2.3 Tools and Equipment ..................................................................... 2-8
2-2.4 General Requirements ................................................................... 2-8
2-2.5 Cleaning and Surface Preparation Prior to Bonding Application .... 2-9
2-2.6 Adhesive Preparation ................................................................... 2-10
2-2.7 Application of Adhesive ................................................................ 2-10
CHAPTER 3 - FINISH REPAIR PROCEDURES ..................................................... 3-1
3-1 INTRODUCTION ........................................................................................ 3-1
3-2 EXTERIOR FINISHES AND INTERNAL ACTUATOR SURFACES ............ 3-1
3-3 INTERIOR FINISHES ................................................................................. 3-2
3-4 GENERAL REQUIREMENTS..................................................................... 3-2
3-4.1 Process Specifications ................................................................... 3-2
3-4.2 Coating Appearance ...................................................................... 3-2
3-5 SAFETY PRECAUTIONS ........................................................................... 3-3
3-5.1 General Precautions ...................................................................... 3-3
3-5.2 Personnel Precautions ................................................................... 3-3
3-6 MATERIALS ............................................................................................... 3-4

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3-7 EQUIPMENT REQUIRED .......................................................................... 3-5

3-8 PROCEDURES .......................................................................................... 3-5
3-8.1 Preparation and Painting of Interior Surfaces ................................ 3-5
3-8.2 Preparation and Painting of Exterior Surfaces ............................... 3-8
CHAPTER 4 - REPAIR MATERIALS ...................................................................... 4-1
4-1 GENERAL .................................................................................................. 4-1
4-2 REPAIR MATERIALS ................................................................................. 4-1
4-3 MATERIAL CATEGORIES .......................................................................... 4-2
4-3.1 Part Materials Having Limited Self Life .......................................... 4-2
4-3.2 Part Materials Having Unlimited Shelf Life ..................................... 4-2
4-3.3 Auxiliary Materials .......................................................................... 4-2
4-4 MATERIALS GENERAL DESCRIPTION .................................................... 4-2
4-5 PART NUMBER AND SPECIFICATIONS ................................................... 4-3
4-6 MATERIALS AND PROCESSES USED IN THE MANUFACTURING
AND REPAIR OF THE STRUCTURE MAIN FRAME ................................. 4-5
4-6.1 Materials ........................................................................................ 4-5
4-6.2 Processes ...................................................................................... 4-5
4-6.3 General Safety Precautions ........................................................... 4-6
CHAPTER 5 - TYPICAL REPAIRS FOR FOAM CORE MATERIAL ....................... 5-1
5-1 GENERAL .................................................................................................. 5-1
5-1.1 Polystyrene Foam .......................................................................... 5-1
5-1.2 Polyurethane Foam........................................................................ 5-1
5-1.3 Polymethacrilimide Foam............................................................... 5-1
5-2 CONSUMABLE MATERIALS REQUIRED.................................................. 5-2
5-3 EQUIPMENT REQUIRED .......................................................................... 5-2
5-4 PROCESS STANDARD (PS) ..................................................................... 5-3
5-5 PROCEDURES .......................................................................................... 5-3
5-5.1 Hot Wire Cutting of Polystyrene Foam........................................... 5-3
5-5.2 Bonding Polystyrene Foam Blocks ................................................ 5-4
5-5.2.1 Bonding With Polyurethane Foam Mix .......................... 5-4
5-5.2.2 Bonding with Five Minute Epoxy ................................... 5-4
5-5.2.3 Bonding With Epoxy Resin/Micro Balloon Slurry ........... 5-5
5-5.3 Bonding Rohacell Foam................................................................. 5-6
5-5.4 Bonding a Block of Rohacell Foam Enclosed in Polystyrene Foam5-6

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5-5.5 Bonding a Block of Rohacell Foam to a Composite Surface/Detail 5-6

5-5.6 Bonding Metal Details to Rohacell Foam ....................................... 5-6
CHAPTER 6 - TYPICAL STRUCTURAL REPAIRS ................................................ 6-1
6-1 GENERAL INFORMATION ......................................................................... 6-1
6-2 DETERMINING APPLICABLE REPAIR...................................................... 6-1
6-3 NON-REPAIRABLE AREAS ....................................................................... 6-2
6-4 SAFETY PRECAUTIONS ........................................................................... 6-2
6-4.1 General Precautions ...................................................................... 6-2
6-4.2 Personal Precautions ..................................................................... 6-2
6-5 EVALUATION OF DAMAGE ....................................................................... 6-3
6-5.1 Evaluation of Repair ....................................................................... 6-3
6-5.2 Repair in Areas of Metal Brackets .................................................. 6-3
6-6 FUSELAGE LAMINATE STRUCTURE (OUT OF FUEL TANK AREA) ..... 6-10
6-6.1 General ........................................................................................ 6-10
6-6.2 Equipment .................................................................................... 6-10
6-6.3 Part Materials ............................................................................... 6-11
6-6.4 Auxiliary Materials and Disposable Items ..................................... 6-11
6-6.5 Safety Conditions: ........................................................................ 6-11
6-6.5 Repair Procedure ......................................................................... 6-11
6-7 FUSELAGE LAMINATE STRUCTURE - REPAIR OF A THROUGH
HOLE DAMAGE ....................................................................................... 6-13
6-7.1 Equipment .................................................................................... 6-13
6-7.2 Part Materials ............................................................................... 6-13
6-7.3 Auxiliary Materials and Disposable Items ..................................... 6-13
6-7.4 Safety Conditions ......................................................................... 6-14
6-7.5 Repair Procedure ......................................................................... 6-14
6-8 FUSELAGE LAMINATE STRUCTURE - REPAIR OF DAMAGE IN
LAMINATE AND STIFFENER .................................................................. 6-23
6-8.1 Equipment .................................................................................... 6-23
6-8.2 Part Materials ............................................................................... 6-23
6-8.3 Auxiliary Materials and Disposable Items ..................................... 6-23
6-8.4 Safety Conditions ......................................................................... 6-23
6-8.5 Repair Procedure ......................................................................... 6-23

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6-9 FUSELAGE LAMINATE STRUCTURE - REPAIR OF DAMAGE TO

STIFFENER SKIN WITH NO DAMAGE TO LAMINATE OUTER SKIN .... 6-31
6-9.1 Equipment .................................................................................... 6-31
6-9.2 Part Materials ............................................................................... 6-31
6-9.3 Auxiliary Materials and Disposable Items .................................... 6-31
6-9.4 Safety Conditions ......................................................................... 6-31
6-9.5 Repair Procedure ......................................................................... 6-31
6-10 FUSELAGE SANDWICH STRUCTURE - REPAIR OF DENTS AND
CAVITIES ................................................................................................. 6-35
6-10.1 Equipment .................................................................................... 6-35
6-10.2 Part Materials ............................................................................... 6-35
6-10.3 Auxiliary Materials and Disposable Items .................................... 6-35
6-10.4 Safety Conditions ......................................................................... 6-35
6-10.5 Repair Procedure ......................................................................... 6-35
6-11 DAMAGE TO PLANE SURFACE AREAS OF COWLINGS, FAIRING,
COVERS, DOORS AND ACCESS PANELS (DAMAGE TO LAMINATE
STRUCTURE - A THROUGH HOLE) ....................................................... 6-37
6-11.1 Equipment .................................................................................... 6-37
6-11.2 Part Materials ............................................................................... 6-37
6-11.3 Auxiliary Materials and Disposable Items .................................... 6-37
6-11.4 Safety Conditions ......................................................................... 6-37
6-11.5 Repair Procedure ......................................................................... 6-37
6-12 REPAIR OF DAMAGE TO CURVED LAMINATE STRUCTURE -
A THROUGH HOLE ................................................................................. 6-42
6-12.1 Equipment .................................................................................... 6-42
6-12.2 Part Materials ............................................................................... 6-42
6-12.3 Auxiliary Materials and Disposable Items .................................... 6-42
6-12.4 Safety Conditions ......................................................................... 6-42
6-12.5 Repair Procedure ......................................................................... 6-42
6-13 FUSELAGE LAMINATE STRUCTURE - REPAIR OF DAMAGE TO
EDGE ZONES OF SKIN, COVERS AND DOORS ................................... 6-46
6-13.1 Equipment .................................................................................... 6-46
6-13.2 Part Materials ............................................................................... 6-46
6-13.3 Auxiliary Materials and Disposable Items .................................... 6-46
6-13.4 Safety Conditions ......................................................................... 6-46
6-13.5 Repair Procedure ......................................................................... 6-46

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6-14 REPAIR OF DAMAGE TO DOORS AND ACCESS PANELS

INCLUDING DAMAGE TO CORE AREA ................................................. 6-51
6-14.1 Equipment .................................................................................... 6-51
6-14.2 Part Materials ............................................................................... 6-51
6-14.3 Auxiliary Materials and Disposable Items ..................................... 6-51
6-14.4 Safety Conditions ......................................................................... 6-51
6-14.5 Repair Procedure ......................................................................... 6-51
6-15 WING AND TAIL ASSEMBLIES - REPAIR OF DAMAGE TO
SURFACE CONTOUR WITH NO BROKEN SKIN ................................... 6-56
6-15.1 Equipment .................................................................................... 6-56
6-15.2 Part Materials ............................................................................... 6-56
6-15.3 Auxiliary Materials and Disposable Items ..................................... 6-56
6-15.4 Safety Conditions ......................................................................... 6-56
6-15.5 Repair Procedure ......................................................................... 6-56
6-16 WING AND TAIL ASSEMBLIES - DEBONDING BETWEEN SKIN
AND CORE ............................................................................................... 6-58
6-16.1 Equipment .................................................................................... 6-58
6-16.2 Part Materials ............................................................................... 6-58
6-16.3 Auxiliary Materials and Disposable Items ..................................... 6-58
6-16.4 Safety Conditions ......................................................................... 6-58
6-16.5 Repair Procedure ......................................................................... 6-58
6-17 WING AND TAIL ASSEMBLIES - REPAIR OF DAMAGE TO ONE
SKIN AND CORE WITHOUT DAMAGE TO OPPOSITE SKIN ................ 6-62
6-17.1 Equipment .................................................................................... 6-62
6-17.2 Part Materials ............................................................................... 6-62
6-17.3 Auxiliary Materials and Disposable Items ..................................... 6-62
6-17.4 Safety Conditions ......................................................................... 6-62
6-17.5 Repair Procedure ......................................................................... 6-62
6-18 WING AND TAIL ASSEMBLY - REPAIR OF DAMAGE TO BOTH
SKINS AND CORE (A THROUGH HOLE) ............................................... 6-67
6-18.1 Equipment .................................................................................... 6-67
6-18.2 Part Materials ............................................................................... 6-67
6-18.3 Auxiliary Materials and Disposable Items ..................................... 6-67
6-18.4 Safety Conditions ......................................................................... 6-67
6-18.5 Repair Procedure ......................................................................... 6-67

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Chapter/Paragraph Page

6-19 OUTBOARD WING - REPAIR OF DAMAGE IN TRAILING

EDGE ....................................................................................................... 6-72
6-19.1 Equipment .................................................................................... 6-72
6-19.2 Part Materials ............................................................................... 6-72
6-19.3 Auxiliary Materials and Disposable Items .................................... 6-72
6-19.4 Safety Conditions ......................................................................... 6-72
6-19.5 Repair Procedure ......................................................................... 6-72
6-20 CENTER WING - REPAIR OF DAMAGE IN TRAILING EDGE ................ 6-77
6-20.1 Equipment .................................................................................... 6-77
6-20.2 Part Materials ............................................................................... 6-77
6-20.3 Auxiliary Materials and Disposable Items .................................... 6-77
6-20.4 Safety Conditions ......................................................................... 6-77
6-20.5 Repair Procedure ......................................................................... 6-77
6-21 WING - REPAIR OF DAMAGE TO LEADING EDGE, NOT INCLUDING
ALUMINUM MESH ................................................................................... 6-83
6-21.1 Equipment .................................................................................... 6-83
6-21.2 Part Materials ............................................................................... 6-83
6-21.3 Auxiliary Materials and Disposable Items .................................... 6-83
6-21.4 Safety Conditions ......................................................................... 6-83
6-21.5 Repair Procedure ......................................................................... 6-83
6-22 WING - REPAIR OF DAMAGE TO LEADING EDGE INCLUDING
ALUMINUM MESH ................................................................................... 6-87
6-22.1 Equipment .................................................................................... 6-87
6-22.2 Part Materials ............................................................................... 6-87
6-22.3 Auxiliary Materials and Disposable items ..................................... 6-87
6-22.4 Safety Conditions ......................................................................... 6-87
6-22.5 Repair Procedure ......................................................................... 6-87
6-23 REPAIR IN SERVO-ACTUATOR PANEL ................................................. 6-91
6-23.1 Equipment .................................................................................... 6-91
6-23.2 Part Materials ............................................................................... 6-91
6-23.3 Auxiliary Materials and Disposable Items .................................... 6-91
6-23.4 Safety Conditions ......................................................................... 6-91
6-23.5 Repair Procedure ......................................................................... 6-91

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6-24 REPAIR OF DAMAGE IN ACTUATOR FAIRING ...................................... 6-96

6-24.1 Equipment .................................................................................... 6-96
6-24.2 Part Materials ............................................................................... 6-96
6-24.3 Auxiliary Materials and Disposable Items ..................................... 6-96
6-24.4 Safety Conditions ......................................................................... 6-96
6-24.5 Repair Procedure ......................................................................... 6-96
6-25 HINGE/LEVER ASSEMBLY - REPAIR OF MINOR DAMAGE TO
ROHACELL BLOCK ............................................................................... 6-100
6-25.1 Equipment .................................................................................. 6-100
6-25.2 Part Materials ............................................................................. 6-100
6-25.3 Auxiliary materials and Disposable Items .................................. 6-100
6-25.4 Safety Conditions ....................................................................... 6-100
6-25.5 Repair Procedure ....................................................................... 6-100
6-26 HINGE/LEVER ASSEMBLY - REPAIR OF MAJOR DAMAGE TO
ROHACELL BLOCK ............................................................................... 6-105
6-26.1 Equipment .................................................................................. 6-105
6-26.2 Part Materials ............................................................................. 6-105
6-26.3 Auxiliary Materials and Disposable Items ................................... 6-105
6-26.4 Safety Conditions ....................................................................... 6-105
6-26.5 Repair Procedure ....................................................................... 6-105

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LIST OF ILLUSTRATIONS

Figure Page

1-1 UAV Major Structural Groups ......................................................... 1-1

1-2 UAV Fuselage Major Dimensions .................................................. 1-4
6-1 Structural Damage in Fuselage, Wings or Tail Assembly (Sheet 1) ... 6-3
6-1 Structural Damage in Fuselage, Wings or Tail Assembly (Sheet 2) ... 6-4
6-1 Structural Damage in Fuselage, Wings or Tail Assembly (Sheet 3) ... 6-5
6-2 Fuselage Laminate structure (Out of Fuel Tank Area) - Repair
of Dents and Cavities ................................................................... 6-12
6-3 Fuselage Laminate Structure - Repair of Damage a Through
Hole (Sheet 1) .............................................................................. 6-18
6-3 Fuselage Laminate Structure - Repair of Damage a Through
Hole (Sheet 2) .............................................................................. 6-19
6-3 Fuselage Laminate Structure - Repair of Damage a Through
Hole (Sheet 3) .............................................................................. 6-20
6-3 Fuselage Laminate Structure - Repair of Damage a Through
Hole (Sheet 4) .............................................................................. 6-21
6-3 Fuselage Laminate Structure - Repair of Damage a Through
Hole (Sheet 5) .............................................................................. 6-22
6-4 Fuselage Laminate Structure - Repair of Damage in Laminate
and Stiffener (Sheet 1) ................................................................. 6-26
6-4 Fuselage Laminate Structure - Repair of Damage in Laminate
and Stiffener (Sheet 2) ................................................................. 6-27
6-4 Fuselage Laminate Structure - Repair of Damage in Laminate
and Stiffener (Sheet 3) ................................................................. 6-28
6-4 Fuselage Laminate Structure - Repair of Damage in Laminate
and Stiffener (Sheet 4) ................................................................. 6-29
6-4 Fuselage Laminate Structure - Repair of Damage in Laminate
and Stiffener (Sheet 5) ................................................................. 6-30
6-5 Fuselage Laminate Structure - Repair of Damage to Stiffener
Skin with no Damage to Laminate Outer Skin (Sheet 1) ............. 6-33
6-5 Fuselage Laminate Structure - Repair of Damage to Stiffener
Skin with no Damage to Laminate Outer Skin (Sheet 2) ............. 6-34
6-6 Fuselage Sandwich Structure - Repair of Dents and Cavities ..... 6-36
6-7 Damage to Plane Surface Areas of Cowlings, Fairing, Covers,
Doors and Access Panels (Damage to Laminate Structure -
a Through Hole) (Sheet 1) ........................................................... 6-40
6-7 Damage to Plane Surface Areas of Cowlings, Fairing, Covers,
Doors and Access Panels (Damage to Laminate Structure -
a Through Hole) (Sheet 2) ........................................................... 6-41

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LIST OF ILLUSTRATIONS (Cntd)

Figure Page

6-8 Repair of Damage to Curved Laminate Structure -

a Through Hole (Sheet 1) ............................................................. 6-44
6-8 Repair of Damage to Curved Laminate Structure -
a Through Hole (Sheet 2) ............................................................. 6-45
6-9 Fuselage Laminate Structure - Repair of Damage to Edge
Zones of Skin, Covers and Doors (Sheet 1) ............................... 6-49
6-9 Fuselage Laminate Structure - Repair of Damage to Edge
Zones of Skin, Covers and Doors (Sheet 2) ............................... 6-50
6-10 Repair of Damage to Doors and Access Panels Including
Damage to Core Area (Sheet 1) .................................................. 6-54
6-10 Repair of Damage to Doors and Access Panels Including
Damage to Core Area (Sheet 2) .................................................. 6-55
6-11 Wing and Tail Assembly - Repair of Damage to Surface
Contour with no Broken Skin ....................................................... 6-57
6-12 Wing and Tail Assembly - Debonding between Skin and
Core (Sheet 1) ............................................................................. 6-60
6-12 Wing and Tail Assembly - Debonding between Skin and
Core (Sheet 2) ............................................................................. 6-61
6-13 Wing and Tail Assembly - Repair of Damage to One Skin
and Core without Damage to Opposite Skin (Sheet 1) ............... 6-64
6-13 Wing and Tail Assembly - Repair of Damage to One Skin
and Core without Damage to Opposite Skin (Sheet 2) ............... 6-65
6-13 Wing and Tail Assembly - Repair of Damage to One Skin
and Core without Damage to Opposite Skin (Sheet 3) ............... 6-66
6-14 Wing and Tail Assembly - Repair of Damage to Both Skins
and Core (a Through Hole) (Sheet 1) ......................................... 6-70
6-14 Wing and Tail Assembly - Repair of Damage to Both Skins
and Core (a Through Hole) (Sheet 2) ......................................... 6-71
6-15 External Wing - Repair of Damage in Trailing Edge (Sheet 1) .... 6-75
6-15 External Wing - Repair of Damage in Trailing Edge (Sheet 2) .... 6-76
6-16 Central Wing - Repair of Damage in Trailing Edge (Sheet 1) ...... 6-80
6-16 Central Wing - Repair of Damage in Trailing Edge (Sheet 2) ...... 6-81
6-16 Central Wing - Repair of Damage in Trailing Edge (Sheet 3) ...... 6-82
6-17 Wing - Repair of Damage to Leading Edge, not including
Aluminum Mesh (Sheet 1) ........................................................... 6-85
6-17 Wing - Repair of Damage to Leading Edge, not including
Aluminum Mesh (Sheet 2) ........................................................... 6-86

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LIST OF ILLUSTRATIONS (Cntd)

Figure Page

6-18 Wing - Repair of Damage to Leading Edge including

Aluminum Mesh (Sheet 1) ........................................................... 6-89
6-18 Wing - Repair of Damage to Leading Edge including
Aluminum Mesh (Sheet 2) ........................................................... 6-90
6-19 Repair of Damage in Actuator Panel (Sheet 1) ............................ 6-94
6-19 Repair of Damage in Actuator Panel (Sheet 2) ............................ 6-95
6-20 Repair of Damage in Actuator Fairing (Sheet 1) .......................... 6-98
6-20 Repair of Damage in Actuator Fairing (Sheet 2) .......................... 6-99
6-21 Hinge/Lever Assembly - Repair of Minor Damage to
Rohacell Block (Sheet 1) ........................................................... 6-103
6-21 Hinge/Lever Assembly - Repair of Minor Damage to
Rohacell Block (Sheet 2) ........................................................... 6-104
6-22 Hinge/Lever Assembly - Repair of Major Damage to
Rohacell Block (Sheet 1) ........................................................... 6-108
6-22 Hinge/Lever Assembly - Repair of Major Damage to
Rohacell Block (Sheet 2) ........................................................... 6-109
6-22 Hinge/Lever Assembly - Repair of Major Damage to
Rohacell Block (Sheet 3) ........................................................... 6-110

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LIST OF TABLES

Table Page

2-1 Sealant Data .................................................................................. 2-6

4-1 Limited Shelf Life Part Materials .................................................... 4-3
4-2 Unlimited Shelf Life Part Material ................................................... 4-4
6-1 Evaluation of Damage .................................................................... 6-6
6-2 Filler Laminate Number of Plies ................................................... 6-17
6-3 Filler Laminate Number of Plies ................................................... 6-39
6-4 Repairable Damage Size ............................................................. 6-48
6-5 Filler Laminate Number of Plies and Orientation ......................... 6-49
6-6 Definition of Repair Patch Laminates ........................................... 6-93
6-7 Hinges and Levers Repair Limitations ....................................... 6-102

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INTRODUCTION

1. PURPOSE OF USE AND SCOPE

This manual provides structural repair personnel with information and instructions for evaluation
and repair of structural damage to the Unmanned Air Vehicle (UAV).
Reference is made in this structural repair manual to UAV Maintenance and operation technical
manuals for supplemental data, where applicable.
Tasks that can be performed at SFL maintenance level are listed in Table 6-1.

2. ARRANGEMENT OF THIS MANUAL

This manual consists of an introduction and 6 chapters. Each chapter is divided into paragraphs
containing different subjects from general information related to the entire structure of the UAV to
a specific repair. The manual chapters are as follows:

CHAPTER 1 - GENERAL
This chapter contains the UAV general subjects such as type of construction,
material used, classification of damage, main dimensions, airframe cleaning and
finishing, general shop practices, damage evaluation, etc.

CHAPTER 2 - SEALING AND BONDING REPAIR METHODS

This chapter describes different Sealing and Bonding Methods

CHAPTER 3 - FINISH REPAIR PROCEDURES

This chapter details Finish Repair Procedures of the repaired area

CHAPTER 4 - REPAIR MATERIALS

This chapter provides a list of Repair Materials required for composite material
repairs.
CHAPTER 5 - TYPICAL REPAIR FOR FOAM CORE MATERIAL
This chapter provides information for Typical Repairs of Foam Core Material.

CHAPTER 6 - TYPICAL STRUCTURAL REPAIR

This chapter provides information for Typical Structural Repairs that are
authorized to be performed by the structural maintenance and repair technicians

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3. USE OF THIS MANUAL

NOTE
Prior to attempting any actual structural repair work, the user have to read the
information contained in this manual.

1. Determine the location and, if possible, the part number of the damaged part. Proceed as follows:

a. See Figure 1-1 and obtain the relevant chapter in which the structural repair procedures are
given.
b. Turn to the applicable chapter and obtain the required typical repair.
c. Prior to starting the repair, read the text material at the beginning of the repair chapter to
obtain any information which pertains to the repair of the damaged part.
d. Coordinate the information contained in the text and the repair illustration(s) to repair the
damaged part.
e. If more than one part is involved in the same damage, repeat the preceding procedure for
other part(s) and make repairs accordingly.
2. Following is a listing of information which will aid maintenance personnel in using these manuals:

a. Refer to the applicable UAV organizational maintenance manual(s) for removal instructions
for components necessary to gain access to structural area to be repaired.
b. Note all dimensions in this manual are in millimeters unless otherwise specified.
c. Remember how the UAV effectivity is displayed and what does it mean.
d. Refer to Chapter 2 of this manual for specification and manufacturer part number for materials
and special tools, and equipment for repairs.

4. WARNINGS, CAUTIONS AND NOTES

Warnings and cautions precede the text and follow the paragraph headings to which they apply.
Notes may precede or follow applicable text depending upon the material to be highlighted. When
a warning, caution or note consist of two or more paragraphs, the heading WARNING, CAUTION
or NOTE is not repeated above each paragraph. Warnings cautions or notes are short and concise
statement used to emphasize important or critical data. Warning and caution state the hazard, reason
and results unless obvious. Following are the definitions of a warning, caution and note.

WARNING
A warning is an operating or maintenance procedure, practice, condition, statement,
etc., which, if not strictly observed, may result in injury to, or death of personnel
and damage to, or destruction of equipment.

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CAUTION
A caution is an operating or maintenance procedure, practice, condition, statement,
etc., which, if not strictly observed, may result in damage to, or destruction of equipment.
NOTE
A note appears before or after an operating procedure or maintenance to emphasize
or clarify the operating procedure or maintenance.

5. TECHNICAL TERMS

The following technical terms, defined as follows, are used in the system maintenance manuals:

a. General Condition - Checkout of a system (assembly, part or mechanism) for missing part,
integrity and wear (cracks, fracture, visible damage, deformation, abrasion, rupture caused by
abrasion/damage, burn signs, disintegration or corrosion).

b. Proper Connection - Checkout of a system (assembly, part or mechanism) for connection

according to manufacturer or technical manual instructions and checkout for loose or missing
connecting bolts, tightening and safety.

c. Proper Installation (Safety) - Checkout of a system (assembly, part or mechanism) to be installed

according to manufacturer or technical manual instructions. The check will assure integrity and
check for abrasion, friction, contact, prevention of effects on other systems (heat, friction,
movement limit or capture); checkout for loose or missing connecting bolts.

d. Replacement - Removal of the item and installation of a serviceable item in its place.

5. NON-STANDARD ABBREVIATIONS

BIA - British Institute of Aeronautics

D - Depot
HVLP - High Volume Low Pressure
MSDS - Material Safety Data Sheets
NLG - Nose Landing Gear
O - Organizational
PMI - Polymethacrylimide Rigid Foam
PVA - Poly Vinyl Alcohol
PVC - Poly Vinyl Chloride
RTV - Room Temperature Vulcanizing Silicone
SFL - System Field Level
UAV - Unmanned Air Vehicle

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7 SAFETY SUMMARY

The following are general safety precautions that are not related to any specific procedures and
therefore do not appear elsewhere in this publication. These are recommended precautions that
personnel must understand and apply during many phases of operation and maintenance.

7-1 Keep Away From Live Circuits

Operating personnel must at all times observe all safety regulations. Do not replace components
or make adjustments inside the equipment with the high voltage supply turned on. Under certain
conditions, dangerous potentials may exist when the power control is in the off position, due to
charges retained by capacitors. To avoid casualties, always remove power and discharge and ground
a circuit before touching it.

7-2 Do not Service or Adjust Alone

Under no circumstances should any person reach into or enter the enclosure for the purpose of
servicing or adjusting the equipment except in the presence of someone who is capable of rendering
aid.

7-3 Resuscitation

Personnel working with or near high voltage should be familiar with modern methods of
resuscitation.

WARNING
. Heat resistant gloves shall be worn when handling hot equipment.
. High heat is used in maintenance. Serious burns may result if personnel fail to
observe safety precautions.
. High voltage is used in test procedures. Severe injury or death may result if
personnel fail to observe safety precautions.
. Hazardous chemicals are used during maintenance procedures. Explosions,
fire, damage to lungs, eye or skin, or death may result if personnel fail to
observe safety precautions.

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CHAPTER 1
GENERAL
1-1 GENERAL DESCRIPTION
1-1.1 Major Structural Group Breakdown
The major structural groups of the Unmanned
Air Vehicle (UAV) are shown in Figure 1-1.
1-1.2 Type of Construction
The UAV airframe is a modular assembly
consisting of the fuselage, wings, horizontal
stabiliser and elevators, vertical stabilisers and
rudders, booms and landing gear. Fuselage skin
and frames are made of Carbon/Epoxy moulded
into the autoclave. All doors, covers and fairing
are made of carbon fabric and epoxy resin by
wet lay-up moulding. Wing and tail surfaces are
full depth sandwich structures made of
polystyrene foam cone and wet laid carbon and
glass/epoxy skin.
1-2 CATEGORIES OF REPAIR CAPA-
BILITIES
Structural repair capabilities are divided into
the following categories:
1-2.1 Organizational (O) Level Repairs
Examples of structural repairs at the O level
are as follows:
1. Visual damage inspection
2. Touch up painting of nicks, scratches, small
parts, etc.
3. Repair of small dents
4. Replacement of major structural parts
5. Stripping and refinishing structural parts and
flight control surfaces
6. Repairs which may include replacing sections
of damaged Rohacell and polystyrene blocks,
forming and filling structural parts with light,
shop-type, equipment.
7. Repairs of cracked, dented, crushed,
punctured or delaminated composite
materials, sandwich or solid skin structures.

Actuator Panel (Typ)

Tail Assembly
Aft Engine
Recovery Compartment
Parachute

Forward Engine
Compartment
Boom

Arresting
Payload Hook Wing
Compartment
Main Landing
Gear
Figure 1-1. UAV Major Structural Groups

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U900/000/TM/E/323
1-2.2 Depot Repairs
Examples of structural repairs at the Depot
level are as follows:
1. Repair of large structural parts that require
major forming, bonding and laying of fiber
plies.
2. Major rebuilding and manufacture of
structural assemblies.
3. Replacement of parts that require
authorisation by a structural design engineer.
4. Structural repairs that require designs by a
structural design engineer.
1-2
1-3 CLASSIFICATION OF DAMAGE
Structural damages are divided into three
categories: negligible damage, repairable damage
and nonrepairable damage (damage which
requires design and authorisation by a structural
design engineer).
1-3.1 Negligible Damage
Negligible damage is a minor damage that is
allowable or can be corrected by simple repairs
methods. A damage that affects flight safety or
places flight restrictions on the UAV shall not
be classified as negligible. Parts damaged in
excess of the negligible damage limits (as defined
in this manual) shall be repaired or replaced.
NOTE
If in doubt as to whether the
damage is negligible or
repairable, classify the damage
as repairable.
The following paragraphs describe types of
minor damages which may be classified as
negligible, depending on location and
dimensions:
1. Dents: Small dents with no damage to the
structure nor any adverse effect on flight
operations may be permitted to remain. Larger
dents and those that show stretching or
wrinkling of the skin shall be treated as
repairable damage.
2. Scratches and Nicks: The severity of scratch
and nick damage varies greatly, depending on
length and depth of scratch or nick. No
specific negligible damage limit can be
established that would be suitable for all
structural components. For scratch and nick
damage limits and repair procedures, refer to
the applicable component figure in this
manual.
 U900/000/TM/E/323

1-3.2 Repairable Damage 1-4 TYPES OF REPAIR

Repairable damage is damage that exceeds
negligible damage limitations but is not big
enough to require replacement.
1-3.3 Non-Repairable Damage
There are two types of repairs: permanent and
temporary. The type repair to be made depends
upon availability of materials, tools and
equipment, time, and which maintenance level
is to accomplish the repair.

Non-repairable damage in this manual is 1-4.1 Permanent Repair

define as follows:
A permanent repair restores full load-carrying
1. Any damage which is not defined in this and damage tolerance requirements of the
manual as a repairable or a damage which is structural member satisfies aerodynamic,
defined by the structural design engineer as thermal, and interchangeability requirements and
non repairable. places the UAV in maximum operational and
maintenance status.
2. Damage that requires replacement of entire
part. Replacement of an entire part is to be 1-4.2 Temporary Repair
considered when one or more of the following
conditions exist: A temporary repair restores full load-carrying
of the structural parts but is deficient either from
a. When a complicated part has been the standpoint of aerodynamic smoothness or
extensively damaged. from the interchangeability aspects of the parts
involved.
b. When surrounding structure or
inaccessibility makes a repair impractical.
c. When damaged part is relatively easy to
replace and the replacement part is cheaper
than the repair.
d. When the structural design engineer has
defined the repair as impractical.
3. Flight Control Surfaces (flaps, ailerons,
rudders, elevators).

CAUTION
This manual contains
information for repairing
negligible and repairable
categories only. Any damage
which is not defined herein
should be referred to the
manufacturer or to a qualified
structural design engineer.
Failure to comply may result in
damage to the UAV structure.

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1-5 PRINCIPAL DIMENSIONS AND 1-6 AIRFRAME PREPARATION AND

STATION DIAGRAMS FINISHING

The major dimensions of the UAV are shown For airframe preparation and finishing, refer
in Figure 1-2. to Chapter 3.

Figure 1-2. UAV Fuselage Major Dimensions

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1-7 CONTROL SURFACE 1-8 CRASH HANDLING AND SAFETY

REBALANCING
Rebalancing of control surfaces is very critical
in order to maintain static balance around axis
of articulation.
CAUTION
It is strictly prohibited to repair
control surfaces before the
requirements are defined.
Failure to comply may result
in UAV loss.
This paragraph contains general instructions
for recovery and safety when handling a crashed,
damaged UAV. The instructions include safety
precautions to be observed prior and during crash
handling.
The most common method for recovering
crashed or damaged UAV is hoisting the entire
UAV using a sling or straps and cranes. In the
event of minor damage resulting from a runway
overrun landing or a damage requiring repair of
a UAV lifted from the ground, circumstances may
permit towing the UAV to the repair facility. In
some cases, some disassembly of the UAV may
be required at the crash site to permit safe
recovery and prevent further damage during
transport to the repair facility.

1. The method of recovery to be used depends

on various conditions. As different conditions
can be encountered, or a combination of these
conditions, it is not practical to establish a
fixed procedure for every incident. The basic
conditions to be considered are as follows:

a. Type and Extent of Damage: If the UAV

has sustained minor damage or is a
complete loss.
b. Position of UAV: If it is tilted or at right
angle to a hard surface.
c. Condition of Terrain where UAV has Come
to Rest: If it has landed in mud or snow,
on rough ground in a hilly area or in an
area covered by brush or growth.
d. Accessibility of Rescue Vehicles to Crash
Site: Whether roads lead to the crash site,
condition of roads, narrow bridges or other
obstacles along recovery route.
e. Time permitted for recovery of UAV: At
times in the event of crash landing on the
runway, it is necessary to clear the runway
immediately.
f. Equipment available.

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U900/000/TM/E/323

2. There are preliminary survey steps to be taken 1-9 SAFETY PRECAUTIONS

in any type of ground incident. The steps are
as follows: Accidents are usually a result of improper
procedures and unsafe equipment or conditions.
a. Survey damage to determine structural All personnel involved in UAV recovery
condition of UAV. This is important from operations shall be thoroughly familiar with
a stand point of safety to personnel to recovery procedures and applicable UAV safety
prevent additional damage to UAV, precautions.
determine equipment required and
ascertain limitations of available
equipment.
b. Check access to crash site so that passage
to recovery vehicles can be planned.
c. Take into consideration wind and weather
conditions which can create unstable
conditions during UAV lifting and moving
operations.
d. Before attempting any lifting operations,
several recovery methods should be
analysed and judged by steps a and b.

1-6

CHAPTER 2
SEALING AND BONDING REPAIR METHODS
2-1 INTEGRAL FUEL TANK SEALING
MIL-S-83430 sealant (PR-1750 or equivalent)
is used in all Unmanned Air Vehicle (UAV)
integral fuel tank sealing applications. The fuel
system consists of single tank and internal
collector box. The fuel tank is located in the
fuselage under the wing between stations 652
and 1600.
The fuel is 95 octane gasoline.
2-1.1 Definitions of Terms
Some of the terms used in sealing integral fuel
tanks are defined as follows:
1. Integral fuel tank: A fuel tank in which
the primary airframe structure is designed
to contain fuel.
2. Fairing surface: The common surface or
seam between mating parts such as fitting
and skin panel.
3. Void: An opening within the structure
formed by the assembly of parts which
overlap where they join together. On the
boundary structure of an integral fuel tank,
this opening leads to the fuel tank exterior.
4. Accelerated cure: The application of heat
(50 °C maximum) on repair sealant which
results in a faster curing cycle for the
material.
2-1.2 Safety Precautions
Most materials used in sealing operations are
toxic and/or flammable. Care shall be taken in
the use of these materials.
U900/000/TM/E/323
The following safety precautions shall be
observed when performing fuel tank sealing
operations:
1. A fuel tank shall be purged and rinsed with
test liquid (MIL-F-38299) before tank is
entered.
2. The UAV shall be grounded before starting
sealing operations.
3. All areas involved in sealing operations shall
be well ventilated, particularly those which
are partially or completely enclosed.
Breathing air line respirators shall be worn
while using sealers and solvents in confined
areas.
4. Only approved explosion-proof electrical
equipment shall be used. Pneumatic
equipment shall be used whenever possible.
5. Electrical equipment shall be grounded while
in operation.
6. Fire fighting equipment shall be available
during sealing operations.
7. Solvents and cleaners in minimum quantities
shall be kept in safety cans or special
polyethylene bottles.
8. Cleaners and solvents shall be handled
carefully to avoid spilling.
9. Excessive breathing of fumes shall be
avoided.
10. Protective clothing, approved for the
material in use, shall be worn.
11. Sealant, MIL-S-83430, may irritate the skin
and cause a rash on some persons. Cleaning
solvents will dry the skin by removing the
natural fats and oils.
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U900/000/TM/E/323
The following precautions should be taken
prior to, during and after use of these materials.
a. Prior to using sealant, MIL-S-83430, and/
or cleaning solvent, maintenance personnel
shall proceed as follows:
1) Apply antiseptic hand cream to hands
and all skin surfaces not covered by
clothing.
2) Wear cotton gloves on hands.
3) Put rubber gloves over cotton gloves.
WARNING
Ethyl alcohol is poisonous if taken
internally. Do not use cleaning
solvent to clean the skin. Failure to
observe this warning may result in
injury to personnel.
b. During sealing operations, if any sealant
comes in contact with bare skin,
immediately remove sealant with ethyl
alcohol or soap and water. If sealant enters
eyes, flush immediately with large
quantities of warm water.
c. During break time (breakfast, launch, etc.)
remove gloves and wash hands with soap
and water. After break time and prior to
resuming sealing operation, perform steps
1) and 2).
d. At end of shift or upon completion of
sealing operations, remove gloves and
clean hands and skin with rubbing alcohol
or soap and water.
e. If dryness of skin is observed when off the
job, use hand lotions or mineral oil on the
skin.
f. If a skin rash develops, seek medical
attention.
2-2
2-1.3 Classification
Integral fuel tanks will be sealed either by
brushing with MIL-S-83430, class A materials,
or by injection or spreading with MIL-S-83430,
class B materials.
2-1.4 Materials
The most common and primary materials for
integral fuel tank sealing are MIL-S-83430
sealing compounds. Product Research Co.,
manufacturer part number PR-1750, sealing
compound will be used for integral fuel tank
sealing by brush or spatula application.
1. PR-1750 sealing compound. A two-
component, polysulfide material is used in
all sealing operations of the integral fuel
tanks and airframe. Also it is used as an
aerodynamic smoother on exterior surfaces
to produce an aerodynamically smooth
contour. Class A material is a low viscosity
material suitable only for brushing fuel tanks.
Class B material is a thicker, higher viscosity
material suitable for gun or spatula
application.
2. Cleaning Solvent MIL-C-38436 is used to
remove markings such as stencil and grease
pencil and for all cleaning operations prior
to application of sealant.
3. Lint-free cloth or equivalent is used in
cleaning and drying.
2-1.5 Tools and Equipment
Tools and equipment used for sealing
operations are as follows:
1. Brush, high quality commercial grade,
unpainted handle - used when required for
sealant application or cleaning.
2. Spatula (steel, aluminium, or plastic),
smooth and free of rough edges - used for
smoothing fairing surface or fillet sealant.

3. Scraper, non-metallic (hardwood, plastic or
phenolic laminates) - used for removal of
sealant. Chemical desealing or stripping
compounds shall not be used.
4. Rubber wheel, commercial grade - a rubber
wheel mounted in an air motor may be used
to remove or trim sealant. Care shall be
exercised to ensure adjacent surfaces are not
abraded to the extent they become damaged.
5. Safety containers - used to contain cleaning
solvent.
6. Gloves (commercial grade, lightweight,
rubber and cotton) - used for cleaning and
sealing.
7. Breathing air line respirator - to be worn
while using sealers and solvents in confined
areas.
8. Face shield or chemical goggles - to be worn
during cleaning and sealing operations.
2-1.6 Sealing Area
All phases of the cleaning process such as
surface preparation, application and curing shall
take place in a clean area meeting the following
conditions:
1. The area shall be enclosed and essentially
dust free.
2. The temperature at the sealing work area
shall be maintained at 18 to 25 °C and the
relative humidity shall be 40 to 70%.
3. The area shall have controlled access and
cleanliness shall be assured by continuous
maintenance.
4. Smoking, eating, drinking, grinding,
sanding, sawing or other operations that
could adversely affect the quality of the
sealant shall not be permitted.
U900/000/TM/E/323
5. Application of any sprayable mould releases
or lubricants within the controlled area is
prohibited. All materials, tools, parts or
equipment taken into the controlled area
shall be free of dirt, oil or dust.
6. All air lines or ducts used for spraying,
drying of parts or for operation of air motors
shall contain filters for airborne dust and
traps for moisture and oils. Internal
combustion engines shall not be used in the
controlled areas.
7. The controlled room shall be well ventilated
in order to maintain the concentration of
solvent and toxic materials below the
permitted level.
2-1.7 Cleaning and Surface Prepara-
tion Prior to Sealant Application
Preparation of surfaces to be sealed is
important, as sealant depend on good adhesion
to perform sealing function effectively. The best
sealant applied perfectly to an improperly
prepared surface will not provide a tight seal.
Strict adherence to the specified preparation
procedures is mandatory. The following general
cleaning procedures shall be performed prior to
sealing operations.
WARNING
Use of compressed air for cleaning
can create an environment of
propelled foreign particles which
may enter the eyes and cause serious
injury. Carbon dust may short circuit
electrical equipment. Always use
vacuum cleaners to remove dust and
particles. Failure to comply may
result in injury to personnel.
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U900/000/TM/E/323
1. Remove all dust, chips and other foreign
particles with a brush or vacuum cleaner.
WARNING
MEK is flammable. Avoid eye and
skin contact or breathing of vapours.
Protective equipment consisting of
goggles and gloves is required.
Failure to comply may result in
injury to personnel and/or damage to
aircraft or equipment.
NOTE
Dispense cleaning solvent into a rag/
towel. Do not dip Lint-free cloth into
solvent containers. Replace Lint-free
cloth frequently, as soon as shows
signs of becoming soiled. MEK, may
be used to remove stencil and grease
pencil marks, provided surfaces are
recleaned with cleaning solvent.
2. Remove all stencil, grease pencil, layout dye,
etc., with a rag/towel dampened with
cleaning solvent. Wipe dry with clean, dry
rag/towel. All solvent shall be wiped off
while wet, with a clean rag/towel. Rag/towel
shall be made off oil-free, lint-free paper or
cotton cloth such as lint-free cloth.
CAUTION
Wear clean gloves when handling
cleaned surfaces. Personal contact
with cleaned surfaces can destroy the
adhesion of sealant applied to these
surfaces. If personal contact is made
accidentally, the surface shall be
recleaned.
2-4
3. When required, remove existing sealant with
a nonmetallic scraper or rubber wheel. Clean
surface with lint-free cloth dampened with
cleaning solvent. Wipe surface dry with
clean, dry lint-free cloth.
4. Always clean an area larger than the final
sealant area.
2-1.8 Preparation of Surfaces
Prepare surfaces to be sealed as follows:
1. Verify area has been cleaned per paragraph
2-1.7.
2. Allow treated surface to air-dry
approximately 15 minutes but not more than
24 hours before applying sealant.
3. If sealant application is to be delayed more
than two hours, protect surface from
contamination by covering with clean wax-
free wrapping paper or cloth.
4. If cleaned surface becomes contaminated,
reclean surface with cleaning solvent.
WARNING
MIL-S-83430 general purpose
sealant is toxic. Avoid eye and skin
contact or breathing of vapors.
Protective equipment consisting of
goggles and gloves is required.
Failure to comply may result in
injury to personnel.
5. If an additional amount of general purpose
sealant must be applied over an existing
application, cleaning is not required if
existing sealant has not exceeded its
application time and has not become
contaminated.

1. General purpose sealant consists of two
CAUTION
Do not apply additional sealant to
existing sealant if existing sealant
has exceeded application time or is
still tacky to the touch. Failure to
comply may result in damage to
aircraft or equipment.
6. If conditions in step 5 cannot be met, prepare
sealant surface as follows:
WARNING
Cleaning solvents are flammable.
Avoid eye and skin contact or
breathing of vapors. Protective
equipment consisting of goggles,
gloves and respiratory protection is
required. Failure to comply may
result in injury to personnel and/or
damage to aircraft.
a. When sealant is tack-free and firm to the
touch, clean surface with a brush or clean
rag/towel dampened with cleaning solvent.
b. Wipe with clean, dry rag/towel.
2-1.9 Preparation of Sealing Materials
General purpose sealant shall be prepared for
use as follows:
WARNING
PR-1750 general purpose sealant is
toxic. Avoid eye and skin contact or
breathing of vapors. Protective
equipment consisting of goggles and
gloves is required. Failure to comply
may result in injury to personnel and/
or damage to aircraft.
U900/000/TM/E/323
parts, a base material and curing agent which
require mixing:
a. Mix the two-part sealant in accordance
with manufacturer instructions; then
carefully fold the material upon itself and
mix for a period of at least five minutes.
Mix slowly to keep compound free of
trapped air.
WARNING
A mixture of dry ice and alcohol
creates cold liquid capable of
burning the skin and eyes. Protective
equipment consisting of face shield,
rubber gloves and rubber apron is
required. Failure to comply may
result in injury to personnel.
NOTE
Class B-1/2 and B-1/4 sealant must
be used immediately after mixing
due to short application time.
b. If mixed general purpose sealant, except
Class B-1/2, is not used immediately, it
may be stored in a hermetically sealed
container at a temperature of -20 °C or
below for a maximum of 30 days. Prior to
storing sealant under refrigeration, quick
freeze sealant by placing sealant in suitable
container and immersing in a mixture of
alcohol and dry ice or equivalent at -65 °C
or cooler for 12 to 15 minutes.
c. After removal from refrigerated storage,
sealant shall be used before the end of its
application time (Table 2-1). Sealant has
to thaw until no further condensation is
observed, before opening the container.
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U900/000/TM/E/323

2-1.10 Application Time 4. Cure time is defined as the maximum time

interval between the mixing or thawing and
Application time, squeeze-out shelf life, tack- the time sealant reaches a Shore A durometer
free time and cure time for the sealant are given hardness of 30.
in Table 2-1. User shall select sealant having the
proper application time or squeeze-out life 2-1.11 Curing of Sealant
needed for each particular application. The times
given in Table 2-1 are measured from the mixing General purpose sealant shall be cured to a
of the sealant. For sealant stored in a freezer after firm rubbery condition prior to pressure testing
mixing, the time of freezing and thawing has to and fueling the tank. The application, tack-free,
be subtracted from the values. and firm and rubbery cure times are shown in
Table 2-1. Curing of general purpose sealant may
1. The application time of the sealant is defined be accelerated by applying heat not to exceed 50
as the maximum time interval allowed °C, using one of the following methods:
between the mixing (or thawing) of the
sealant and the completion of its application 1. Circulating warm air over sealant.
to the structure.
2. Pre-warming of structure.
2. Squeeze-out life is defined as the maximum
time interval allowed between the mixing
3. Combination of step 1 and 2.
(or thawing) of the sealant and the final
fastening of fairing surfaces.
3. Tack-free time is defined as the maximum
time interval between the mixing or thawing
and the time the surface of the sealant is no
longer tacky to a polyethylene film.

Table 2-1. Sealant Data

MATERIAL MIL. SPEC. APPLICATION TACK-FREE CURE

TIME (hours) TIME (hours) TIME (hours)
(see notes) (see notes)
A B A B
General PR-1750, 1/2 10 10 30 30
purpose MIL-S-83430
sealant class A1/2 or B1/2

General PR 1750 2 24 24 48 48
purpose Class A2 or B2
sealant
1. Application time, tack-free time and cure time are based upon testing at 25±1 °C and a
relative humidity of 50 % . Variations above or below these points will affect the time.

2. All sealant shall be cured to a firm rubbery condition prior to pressure testing and fuelling
the fuel tank.

2-6

CAUTION
High humidity accelerates curing.
Humidity can be increased by the
presence of moist towels near the
assembly in sealing. Do not heat
above 50 °C. Overheating may
reduce relative humidity thus
slowing down the curing process.
2-1.12 Sealing of Fairing Surfaces
Apply PR-1750, class B (MIL-S-83430)
sealing compound to form fairing surface seals
as follows:
WARNING
PR-1750 sealing compound is
flammable and toxic. Avoid contact
with spark or flame. Avoid eye and
skin contact or breathing of vapors.
Protective equipment consisting of
industrial goggles, rubber gloves and
respirator is required. Irritation to eyes,
skin, lungs, nose and throat or death
may result if personnel fail to comply.
1. If possible, complete all drilling and
deburring operations prior to sealing
compound application.
NOTE
If holes must be drilled or reamed
through sealed fairing surfaces, set-
up bolts or equivalent shall be used
to pull parts into close contact to
avoid depositing chips or burrs in
fairing surface.
2. Ensure that areas to which PR-1750 sealing
compound is to be applied are clean and dry
(paragraph 2-1.7).
3. Spread a heavy coat of PR-1750-B sealing
compound in a way that prevents formation
of bubbles and air pockets on one of the
mating surfaces.
U900/000/TM/E/323
4. Spread PR-1750-B sealing compound with
a spatula over all areas of the fairing surfaces
in an amount sufficient to provide a
continuous bead of PR-1750-B sealing
compound along edges of flange after parts
are assembled.
5. Clamp sealed fairing surfaces together
within the application time of the PR-1750-
B as follows:
a. At least two permanent fasteners must be
installed through or immediately adjacent
to the fairing surface seal, prior to the end
of the sealant application time. Remaining
temporary or permanent fasteners through
and adjacent to the fairing surface seal
must be installed prior to the expiration of
sealing compound application time.
6. Extruded fairing surface sealant shall be
removed as follows:
a. Before sealant cures, form extruded sealant
into a partial fillet, if all surfaces to which
fillet is to adhere were cleaned at the time
fairing surfaces were prepared for sealing.
WARNING
Cleaning solvent, MIL-C-38736 is
flammable. Avoid eye and skin
contact or breathing of vapors.
Protective equipment consisting of
goggles, gloves and respiratory
protection is required. Failure to
comply may result in injury to
personnel and/or damage to aircraft.
b. Remove extruded sealant with lint-free
cloth saturated with cleaning solvent
before sealant cures. If sealant has cured,
remove extruded sealant with a
nonmetallic scraper, taking care to avoid
damage to corrosion protection coating.
2-7
U900/000/TM/E/323
2-2 ROOM TEMPERATURE MODER-
ATE STRENGTH EPOXY BONDING
The following paragraphs cover all
requirements for processing and inspection of
room temperature epoxy bonding. It is used for
moderate-stressed applications where shear
strengths and temperature limitations do not
require testing.
2-2.1 Classification
Room temperature epoxy bonding will be
used for repair of reinforced plastics and rigid
foams requiring moderate peel strength. The
maximum allowed working temperature is 70 °C.
Aluminium parts may be bonded with room
temperature epoxy adhesive after an appropriate
surface treatment.
2-2.2 Materials
Materials for room temperature epoxy
bonding are divided into adhesives and auxiliary
materials as described below:
1. Medium strength adhesive EA9309.1NA -
It is a two component material mixed in a
ratio of 100 parts by weight (Part A) and 20
parts by weight (Part B).
2. Grade 220-280 abrasive paper - used for
sanding or abrading surface areas during
repair procedures.
2-2.3 Tools and Equipment
Miscellaneous tools and equipment are used
for room temperature bonding:
1. Spatula - wood, plastic or aluminium spatula.
2. Safety containers - used to contain cleaning
solvent.
2-8
3. Gloves (commercial grade, lightweight,
rubber and cotton) - used for cleaning and
bonding operations.
4. Breathing air line respirator - to be worn
while using adhesive and solvent in confined
areas.
5. Face shield or chemical goggles - to be worn
during cleaning and bonding operations.
6. Mixing cup - Disposable polyethylene or
wax-free paper cup used for mixing
adhesives.
7. High sped hand router with solid carbide or
diamond grit router bit - to remove all
damaged skin and excess cured adhesive.
8. Vacuum cleaner - to remove all dust from
sand area.
2-2.4 General Requirements
All phases of bonding such as surface
preparation, application and curing shall take
place in a clean area meeting the following
conditions:
1. The area shall be enclosed. Bonding work
areas shall be kept clean. Oil, grease and dust
particles shall be removed.
2. The bonding area shall have controlled
access and cleanliness shall be assured by
continuous maintenance.
3. The temperature at the bonding work area
shall be maintained at 15 to 30 °C unless
otherwise specified (preferably 18 to 22 °C).
4. Smoking, eating, drinking, grinding,
sanding, sawing or other operations that
could adversely affect the quality of the
bonding shall not be permitted.

5. Application of any sprayable mould releases
or lubricants within the controlled area is
prohibited. All materials, tools, parts or
equipment taken into the controlled are shall
be free of dirt, oil or dust.
6. All air lines or ducts used for spraying,
drying of parts or for operation of air motors
shall contain filters for airborne dust and
traps for moisture and oils. Internal
combustion engines shall not be used in the
controlled areas.
7. The controlled room shall be well ventilated
in to maintain the concentration of solvent
and toxic materials below the permitted
level.
2-2.5 Cleaning and Surface Prepara-
tion Prior to Bonding Application
Preparation of surface to be bonded is
important as good bonding depends on
cleanliness and proper preparation of area to be
bonded.
WARNING
Use of compressed air for cleaning
can create an environment of
propelled foreign particles which
may enter the eyes and cause serious
injury. Carbon dust may short circuit
electrical equipment. Always use
vacuum cleaners to remove dust and
particles. Failure to comply may
result in injury to personnel and
damage to equipment.
U900/000/TM/E/323
WARNING
· Ethanol and MEK are flammable.
Avoid eye and skin contact or
breathing of vapors. Protective
equipment consisting of goggles
and gloves is required. Do not use
any flame or electrical equipment
near area in which those solvents
are used. Failure to comply may
result in injury to personnel and/
or damage to aircraft or
equipment.
· MEK attacks polystyrene foam.
Do not use it to clean wing and
tail components.
NOTE
Dispense cleaning solvent into rag/
towel. Do not dip lint-free cloth into
solvent containers. Replace lint-free
cloth frequently, as soon as they
show signs of becoming soiled
MEK, may be used to remove stencil
and grease pencil marks, provided
surfaces are recleaned with cleaning
solvent.
1. Remove all oil, grease, pencil, layout dye,
etc., with rag/towel dampened with cleaning
solvent. Wipe dry with clean, dry rag/towel.
All solvent shall be wiped off while wet, with
a clean rag/towel. Rag/towel shall be made
of oil-free, lint-free paper or cotton cloth,
such as lint-free cloth.
2. Abrade surface as required using grade 220
to 280 grit abrasive paper.
3. Repeat step 1.
2-9
U900/000/TM/E/323
2-2.6 Adhesive Preparation
Adhesive mixing and preparation conform to
the following instructions:
WARNING
EA 9309.1 NA epoxy adhesives, and
especially hardeners, are toxic. Use
in a well-ventilated area only. Avoid
eye and skin contact or breathing of
vapors. Protective equipment
consisting of goggles and gloves and
respiratory protection is required.
Failure to comply may result in
injury to personnel.
NOTE
· Mixing the adhesives shall be
carried out in disposable
polyethylene or wax-free paper
cups. Wooden or metal spatulas
are aids in mixing.
· Slow long strokes are
recommended to achieve best
mixing results. Manufacturer
instructions shall be followed.
· If adhesive components have
been stored in a refrigerator, they
should reach room temperature
prior to opening the containers of
the components and mixing.
Mixing containers shall remain at
room temperature at least four
hours prior to opening. Frozen
containers shall remain at room
temperature for at least eight
hours.
1. Mix adhesive components in batches of up
to 100 g.
2. Mix thoroughly until a homogeneous mass
of uniform viscosity is obtained.
2-10
2-2.7 Application of Adhesive
WARNING
· EA 9309.1 NA epoxy adhesives,
especially hardeners are toxic.
Use in well-ventilated area only.
Avoid eye and skin contact or
breathing of vapors. Protective
equipment consisting of goggles
and gloves and respiratory
protection is required. Failure to
comply may result in injury to
personnel.
· MEK is flammable. Avoid eye
and skin contact or breathing of
vapors. Protective equipment
consisting of goggles and gloves
is required. Do not use any flame
or electrical equipment near area
in which those solvents are used.
Failure to comply may result in
injury to personnel and/or
damage to aircraft or equipment.
1. Verify areas to which the epoxy adhesive is
to be applied are clean and dry.
2. Apply a layer of approximately 0.25 mm of
mixed adhesive to each fairing surface.
Spread with spatula, glue spreader or brush
with short bristles.
3. Remove excess adhesive with a spatula/
brush.
CAUTION
Application of high pressure to
bonded parts shall be avoided.
Failure to comply may degrade
quality of bonding by totally
squeezing out the adhesive from the
bond line.

4. Assemble parts immediately in proper
alignment, and apply only sufficient pressure
to allow close contact and maintain
approximately 0.2 to 0.4 mm layer of
adhesive in the joint. A layer of thin glass
scrim in the bond line can control the layer
thickness.
5. Wipe off squeezed out adhesive before it is
cured, using a clean lint-free cloth slightly
dampened with solvent. Do not allow the
solvent to flow into the bond line. Leave a
fillet of adhesive at the edge of the bonded
components.
CAUTION
6. Cure at 20 to 30 °C for 8 hours to attain
Lint-free cloth shall not be soaked
in MEK. It shall only be dampened.
Failure to comply may degrade
quality of bonding.
U900/000/TM/E/323
CAUTION
Pot of EA 9309.1 NA epoxy
adhesive mixture is 30 to 45 minutes
at room temperature, for a batch of
100 g or less. Do not use adhesive
after adhesive becomes very viscous
or starts warming.
NOTE
Appropriate bond strength is reached
after seven days of curing at
temperature higher than 20 °C or two
hours at 50 °C.
adequate bond strength before removing
clamping or releasing from jig assembly.
2-11/(2-12 Blank)
2-11
 U900/000/TM/E/323

CHAPTER 3

FINISH REPAIR PROCEDURES

3-1 INTRODUCTION 3-2 EXTERIOR FINISHES AND
INTERNAL ACTUATOR SURFACES
This chapter provides detailed procedures for
restoration and touch-up of damaged finishes of Exterior surfaces are defined as all surfaces
the Unmanned Air Vehicle (UAV), and to the normally exposed to exterior environment during
finishing of repaired zones. It covers surface flight or on ground and internal actuator surfaces
preparation prior to painting, paint preparation and of servo actuator boxes in the wings and tail
application to the UAV. Procedures are presented assembly. All exterior and internal actuator
in two groups, exterior finishes and interior finishes. surfaces shall be painted with polyurethane paint
MIL-C-83286 color per FED-STD-595, upper
1. Finishing of all surfaces includes the surface blue 35237 and lower surface gray 36495
following steps: per FED-STD-595.
a. Priming with light colored epoxy primer,
such as chromate primer or high build primer
surfaces. The functions of this primer are:
1) Improving the adhesion of the top coat
to the composite substrate.
2) Helping to reveal the surface defects.
Defects can be detected on a light colored
surface better than on a black one.
b. Filling deep dents with epoxy filling
compound.
c. Filling the surface small pores with an acrylic
filler or a mixture of epoxy resin and micro
balloons. (For external surfaces only.)
NOTE
All metal surfaces must be primed
with chromate primer MIL-P-23377.
Non-metallic surfaces, such as high
build surfaces should be primed with
non-chromate primer.
d. Reapplying of primer.
e. Top coating with polyurethane paint.
2. Two different colors of the polyurethane top
coat are used for the UAV:
a. Glossy white for the interior surfaces.
b. Flat gray shade for the exterior surfaces.
3. A conductive paint is used for the radome
only. This paint is applied under the top coat.

3-1
U900/000/TM/E/323
3-3 INTERIOR FINISHES
Interior surfaces are defined as all surfaces
not classified as exterior surfaces. All interior
surfaces shall be painted with polyurethane paint
MIL-C-83286, color white-glossy, FED-STD-
595, No. 17875. Surfaces included are:
1. Fuselage interior except fuel tanks
2. Inside surface of cowlings, aerodynamic
fairing, covers and doors (except the three
fuel tank covers).
3-2
3-4 GENERAL REQUIREMENTS
The following requirements define the
applicable process specifications referenced for
painting of various sections of the UAV and
general requirements that pertain to the painting
procedure.
3-4.1 Process Specifications
Painting of the UAV exterior and interior
surfaces shall meet the requirements of the IAI
P.S. 24.9160 and the specifications referred to
in this specification.
3-4.2 Coating Appearance
Paint appearance shall be smooth, uniform
and flawless. The presence of bare spots,
embodiments of debris, runs, sags, crates,
pinholes, bubbles and over-spray or other
blemishes that detract from the overall
appearance of the coated area shall be cause for
rejection.

3-5 SAFETY PRECAUTIONS
Precautions for finishing are divided into
general and personnel precautions.
3-5.1 General Precautions
The following general precaution shall be
followed during finish and paint repairs:
1. Repair area shall be well-ventilated.
2. Only approved explosion-proof equipment
shall be used.
3. All non-repaired areas shall be masked prior
to painting neighbouring areas.
4. Solvents and cleaners shall be kept in safety
containers.
5. Soiled rags and cloth shall be discarded in
safety cans.
6. Any liquid spilled in repair area shall be
cleaned immediately.
7. All step-by-step procedures shall be
performed sequentially.
8. No other repair work or installation shall be
performed on surface during paint repair.
9. Suitable fire extinguishing equipment, ready
for use must be positioned near the repair
area.
3-5.2 Personnel Precautions
The following personnel precaution shall be
taken during finishing and paint repairs.
U900/000/TM/E/323
1. Some of the materials are toxic and
flammable. Precaution shall be exercised to
avoid health hazards.
CAUTION
Chromate pigment MIL-P-23377
primer is extremely toxic. Precaution
shall be exercised to protect
personnel during application and
sanding of this primer.
2. Skin contact with paint shall be avoided.
Care shall be exercised to prevent paint from
coming in contact with the eyes. Should such
contact occur, thoroughly rinse with large
amounts of water and seek immediate
medical treatment.
3. Workers shall refrain from inhaling vapors
of thinners and paints or paint dust generated
in sanding.
4. No source of flame, heat or flammable
material shall be allowed in the vicinity of
work area.
5. Rubber gloves, suitable respirator and safety
garments and equipment shall be worn when
handling paints and other finishing materials.
6. Personnel not essential to operation shall be
kept clear of the area.
7. Material Safety Data Sheets (MSDS) of all
hazardous materials (paints thinners, fillers)
shall be present in the repair and painting
shops. In case of injury, requiring medical
treatment, the relevant MSDS. shall be
attached to injured person when sent to the
hospital or clinic.
3-3
U900/000/TM/E/323

3-6 MATERIALS e. Acrylic filler, body fine, standox 1k,

1. Part materials having limited shelf life (paint
components storage time before mix).
NOTE
The following materials (sub-
paragraphs a to g are kits of two
components:
Herberts GMBH
f. Epoxy resin, LY564-1 or LY564, Ciba-
Geigy Co.
g. Hardener for epoxy, HY560, Ciba-Geigy
Co.
2. Part materials, unlimited shelf life:
a. Micro balloons, eccospheres 1G101 per

· Component A is defined in the

relevant technical literature and
MS050016, Emmerson Cummings
b. Thinner for epoxy paints, MIL-T-81772,
on the cans as base material. Type II

· Component B is defined under

various terms, curing agent,
hardener, catalyst or activator. In
this chapter, this component is
defined as part B.
c. Thinner for polyurethane paints, MIL-T-
81772, Type I
d. Antifoam agent, BYK 500A.
3. Auxiliary materials

a. High build epoxy surface, code 464-3-1/
CA142, AKZO MFG, Sikkens Co, USA
b. Fairing compound, RP-1257-3, Ren
Plastics
c. Epoxy primer, per MIL-P-23377, Type I
d. Polyurethane paint, per MIL-C-83286 or
MIL-C-85285:
1) Color, gray flat of various shades:
FED-STD-595, No. 35237 for
exterior upper surfaces or army
aircraft
a. Masking tape, 3M-250, 1", for adhesion
testing
b. Masking tape, per A-A-883
c. Plastic plugs for plugging precision holes
and threads
d. Ethyl alcohol, technical grade, per FED
spec O-E-760
e. Abrasive paper. (Wet-and-Dry), 180, 240,
320 and 400 grit
f. Scotch brite pads, Jupe A.

FED-STD-595, No. 36495 for

exterior lower surfaces or army
aircraft

FED-STD-595, No. 36375 for all

exterior upper surfaces or navy
aircraft.

2) Color, white, glossy, FED-STD-595,

No. 17875 for all interior surfaces of
all short range UAV configuration.

3-4
 U900/000/TM/E/323

3-7 EQUIPMENT REQUIRED 3-8 PROCEDURES

1. Water and oil filter for compressed air line 3-8.1 Preparation and Painting of
Interior Surfaces
2. Pressure gauge and regulator

3. Spray gun, Devillbis, Type MBC or CAUTION

equivalent, with #E needle and nozzle and
air cup #30 if spraying is performed by · This procedure requires sanding
of carbon fiber components.
siphon cup gun, or HVLP (High Volume
Resultant dust is an electrical
Low Pressure) gun such as accuspray series
conducting material which may
10 with #36 nozzle
cause electrical short circuits.
Protect all electrical equipment
4. Thermometer and hygrometer
and components against dust.
Failure to comply may result in
5. Mechanical paint mixer or shaker
damage to equipment.
6. Zahn cup No. 2

7. Stopwatch
· During sanding, exercise care not
to damage fabric plies of
component or metal part of
8. Putty applicator structure. Failure to comply may
result in damage to structure.
9. Vacuum cleaner
1. Using masking tape and/or plastic plugs, tape
or plug all surfaces and openings that are
10. Balance ±1 g
not to be painted, such as threads, tube
opening, bores for joining units, grounding
11. Window screen.
receptacles, nut plates etc.

2. Sand off any excess adhesive or cloth and

sand surface, smooth to touch, using 180 grit
abrasive.

3. Roughen surfaces which were not cured

against peel-ply prior to painting by one of
the following methods. The wet method is
preferred.

a. Wet Method
1) Wet surface with water and then sand
by applying abrasive paper #240 to
#320 with a light circular motion and
constant wetting until a dull surface
appearance is obtained.

3-5
U900/000/TM/E/323
2) For sanding minor depressions,
particularly in the case of sandwiches,
use Scotch Brite pads, very fine, Type
A instead of #320 abrasive paper.
3) After sanding, flush the surface with
clean running water.
4) Check completion of sanding
operation by spraying sanded surface
with distilled water. If a water break-
free surface is maintained for 30
seconds, the sanding operation has
been completed. Otherwise, sanding
operations must be repeated until
satisfactory results are obtained.
WARNING
Technical grade ethyl alcohol is
flammable and toxic. Use in well-
ventilated area only. Avoid eye and
skin contact or breathing of vapors.
Protective equipment consisting of
goggles, gloves and respiratory
protection is required. Failure to
comply may result in injury or health
problems to personnel.
5) Dry surface by wiping with dry lint-
free rags and then wipe with alcohol
saturated towels.
b. Dry Method
1) Sand surface with #240 to #320
abrasive paper using a light circular
motion.
CAUTION
Avoid excessive sanding. Be careful
not to damage and expose the fabric
plies.
2) For sanding minor depressions, use
Scotch Brite pads, very fine, Type A,
instead.
3-6
3) An uniformly dull lustreless surface
indicates completion of sanding
operations.
4) Wipe accumulated dust, generated by
sanding operation, with dry towels or
vacuum clean it. Clean by wiping with
alcohol saturated towels.
WARNING
· Epoxy primer and thinner are
flammable and toxic. Use in well-
ventilated area only. Avoid eye
and skin contact or breathing of
vapors. Protective equipment
consisting of goggles, gloves and
respiratory protection is required.
Failure to comply may result in
injury or health problems to
personnel.
· Chromate pigment MIL-P-23377
primer is toxic. Precaution shall
be exercised to protect personnel
during application and sanding of
this primer.
CAUTION
When spraying, avoid wet spots in
paint. Failure to comply may result
in poor painting quality.
NOTE
· Primer coating does not have to
hide completely the substrate.
· Nonmetallic surfaces should be
primed with high build surfaces
as specified in paragraph 3-8.2.
MIL-P-23377 primer should not
be used.

4. Prepare epoxy primer, MIL-P-23377, as
follows:
a. Mix each of the components thoroughly
in its own container.
b. Slowly add a quantity of part B according
to the manufacturer instructions.
c. Allow the mixture to stand for 30 to 60
minutes before thinning.
d. Thin with epoxy thinner to a viscosity of
18 to 22 seconds in a Zahn cup No. 2.
Thin the paint to the required viscosity as
follows: add small quantities of thinner
slowly to the mixed base paint and
accelerator while constantly stirring to
provide a uniform mixture. Do not add the
entire amount of thinner at once. Do not
add paint to thinner. Mechanical mixing
with an air-propelled paddle is preferred.
After paint material is thinned, use it as
soon as possible or keep it under constant
agitation.
e. Strain the prepared paint through a fine
window screen, or several layers of
cheesecloth. Check the viscosity.
NOTE
The maximum pot life at room
temperature is eight hours after
adding part B.
5. Apply the primer as follows:
6. Mix 100 parts by weight of LY564-1 epoxy
a. Paint may be applied by spraying using
airless or siphon equipment.
b. The coatings shall be applied at a
temperature between 15 to 28 °C and a
relative humidity of 45 to 75%.
7. Fill deep surface defects with the epoxy/
U900/000/TM/E/323
c. Spray epoxy primer with a regular spray
gun (or with HLVP gun) at a pressure of
50 psi. Apply a single wet film of primer
(the drying time between the coats of wash
primer and primer shall be 30 minutes
minimum up to 2 hours maximum). Since
the epoxy primer has a high solids content,
a cross coat is not required and spray gun
movement shall be maintained so as to
prevent excessive film build-up with
subsequent reduction in adhesion.
d. Allow the primer to air dry for a minimum
of one hour (depending on the temperature
and humidity of the area) before any further
operation. Next application shall be
accomplished within 24 hours after
application of the primer. If more than 24
hours have elapsed between application of
primer and next coat, sand with fine
abrasive paper, wipe with alcohol and
reapply primer.
e. Dry coating thickness of the primer shall
be 15 to 22 m (0.6 to 0.9 mil) for top coated
parts. Primary parts without topcoat the
thickness of the primer shall be 22 to 40 m
(0.9 to 1.5 mil).
NOTE
Clean tools with toluene, MEK or
thinner immediately after use, as the
cured material is difficult to remove.
resin and 27 parts of HY560 hardener. Add
glass micro balloons to the epoxy mixture,
at a ratio of 3 to 4 parts by volume micro
balloons to 1 part of epoxy. Continue mixing
until a homogenous thick mixture, free of
lumps is obtained.
micro balloons mix. Cure for at least six
hours at room temperature.
3-7
U900/000/TM/E/323
8. Prepare polyurethane paint, glossy white as
follows:
a. Mix each of the components in its own
container.
b. Add small quantities of part B according
to the manufacturer instructions and stir
continuously.
c. Allow the mixture to stand for 30 minutes
before thinning.
d. Thin with polyuethare paint thinner to a
viscosity of 18 to 22 seconds in a Zahn
cup No. 2. Thin the paint to the required
viscosity as follows: add small quantities
of thinner slowly to the mixed base paint
and accelerator while constantly stirring to
provide a uniform mixture. Do not add the
entire amount of thinner at once.
Do not add paint to thinner. Mechanical
mixing with an air-propelled paddle is
preferred. After paint material is thinned,
use it as soon as possible or keep it under
constant agitation.
e. Strain the prepared paint through a fine
window screen, or several layers of
cheesecloth. Check the viscosity.
NOTE
· The maximum application time
(time between the mixing and the
application of the paint) at room
temperature is eight hours after
adding part B.
· Paint may be applied by spraying
using airless or siphon
equipment, HVLP gun is
preferable.
· The coatings shall be applied at a
temperature between 15 to 28 °C
and a relative humidity of 45 to
75%.
3-8
9. Apply the paint as follows:
a. Spray coat, at 50 psi with a regular gun,
(or with HVLP gun) a thin wet layer of
top coat. The top coat shall be wet and
uniform throughout without indication of
orange peel formation.
b. Allow 20 to 30 minutes for drying before
spraying a second full wet cross-layer of
top coat.
3-8.2 Preparation and Painting of
Exterior Surfaces
CAUTION
· This procedure requires sanding
of carbon fiber components.
Resultant dust is an electrical
conducting material which may
cause electrical short circuits.
Protect all electrical equipment
and components against dust.
Failure to comply may result in
damage to equipment.
· During sanding, exercise care not
to damage cloth plies of
component or metal part of
structure. Failure to comply may
result in damage to structure.
1. Using masking tape and/or plastic plugs, tape
or plug all surfaces and openings that are
not to be painted, such as threads, tube
opening, bores for joining units, grounding
receptacles, nut plates etc.
CAUTION
Sanding wing and tail assembly shall
be carried out using circular strokes
with a general inclination of 45° to
the longitudinal axis of the aircraft.
Sanding shall be manual or with a
vibrating sander. No other
mechanical tools shall be used.
Failure to comply may result in
damage to structure.

NOTE
A vibrating sander may be used for
sanding fuselage.
2. Sand off any excess adhesive or cloth and
sand surface, smooth to touch, using 180 to
400 grit abrasive paper.
3. Roughen surfaces which were not cured
against peel-ply prior to painting by one of
the methods in paragraph 3-8.1 step 3. The
wet method is preferable.
WARNING
· Epoxy resin is toxic and
flammable. Use in well-ventilated
area only. Avoid eye and skin
contact or breathing of vapors.
Protective equipment consisting
of goggles, gloves and respiratory
protection is required. Failure to
comply may result in injury or
health problems to personnel.
· Chromate pigment MIL-P-23377
primer is extremely toxic.
Precaution shall be exercised to
protect personnel during
application and sanding of this
primer.
CAUTION
When spraying, avoid wet spots in
paint. Failure to comply may result
in poor painting quality.
NOTE
Primer coating does not have to hide
completely the substrate.
U900/000/TM/E/323
4. Prepare epoxy primer, MIL-P-23377, as per
paragraph 3-8.1 step 4.
NOTE
The maximum application time at
room temperature is eight hours after
adding part B.
5. Apply the primer as per paragraph 3-8.1. step 5.
6. Mix 100 parts by weight of LY564-1 epoxy
resin and 27 parts of HY560 hardener.Add
glass micro balloons to the epoxy mixture,
at a rate of 3 to 4 parts by volume micro
balloons to 1 part of epoxy. Continue mixing
until homogenous mixture, free of lumps is
obtained.
7. Fill deep surface defects with the epoxy/
micro balloons mix. Cure for at least 6 hours
at room temperature.
8. Small defects may be repaint with fairing
compound REN RP-1257-3, according to the
manufacturer’s instructions.
WARNING
Hi-build epoxy surface, code 464-3-
1/CA142 and thinner are flammable
and toxic. Use in a well-ventilated
area only. Avoid eye and skin contact
or breathing of vapors. Protective
equipment consisting of goggles,
gloves and respiratory protection is
required. Failure to comply may
result in injury or health problems
to personnel.
CAUTION
When spraying, avoid wet spots in
paint. Failure to comply may result
in poor painting quality
3-9
U900/000/TM/E/323

NOTE 14. Clean surfaces with clean dry air, then wipe
off surface to be painted using technical
· Spray should reach surface in an
almost dry state.
grade ethyl alcohol.

15. Verify surfaces finish meets requirements

· Two coats of acrylic filler can be
used instead of the high build
primer.
9. Dilute primer, Hi-build epoxy surface, code
464-3-1/CA142 with thinner MIL-T-81772
and apply by spraying, building up a minimal
number of layers until all exterior UAV
surface pin holes are completely filled.
10. Allow a minimum of four hours for drying
at room temperature.
11. Using 200 to 400 grit wet sandpaper, sand
off excesses and smooth out surfaces until
an uniformly smooth surface is obtained.
12. Clean surface with dry air and visually
inspect surface for pin holes and smoothness.
13. Repeat steps14 to 16, as necessary.
and check surfaces readiness for painting
with top coat.
16. Prepare and apply (for army aircraft) two
layers of polyurethane paint MIL-C-83286
or MIL-C-85285, color gray/blue, FED-
STD-595 No. 35237 to the top as specified
in paragraph 3-8.1h and 3-8.1i.
17. Prepare and apply (for army aircraft) two
layers of polyurethane paint MIL-C-83286,
color gray, FED-STD-595 No. 36495 to the
bottom as specified in paragraph 3-8.1h and
3-8.1i.
18. Prepare and apply (for navy aircraft) two
layers of polyurethane paint MIL-C-83286,
or MIL-85285 color gray, FED-STD-595
No. 36375 to all external surfaces, as
specified in paragraph 3-8.1h and 3-8.1i.

WARNING
Ethyl alcohol is flammable and
toxic. Use in well-ventilated area
only. Avoid eye and skin contact or
breathing of vapors. Protective
equipment consisting of goggles,
gloves and respiratory protection is
required. Failure to comply may
result in injury or health problems
to personnel.

3-10
 U900/000/TM/E/323

CHAPTER 4

REPAIR MATERIALS
4-1 GENERAL 4-2 REPAIR MATERIALS

This section provides a listing of the materials
required for repair of composite structures at the
SFL maintenance level.
The repair materials are specified in Tables
4-1 to 4-2, which provide general description of
the material, manufacturer part number, name
and address of manufacturer, and general
remarks.
To ensure procurement of the proper material,
when ordering materials or when checking stock
lists for a material, only manufacturer part
number shall be used. Deviation from the
material listed herein are allowed only with the
approval of a structural design engineer. For any
“approved source” material, only applicable
specification (MIL, FED, IAI, MS etc.) or
chemical composition (MEK, Ethyl, Alcohol,
PVC, etc.) shall be used.

4-1
U900/000/TM/E/323

4-3 MATERIAL CATEGORIES 4-4 MATERIALS GENERAL DE-

Structural repair materials consist of three
different categories:
4-3.1 Part Materials Having Limited
Self Life
SCRIPTION
When possible, material description shall be
identical to nomenclature in the applicable
specifications.

Part materials having limited shelf life must

be stored under controlled temperature
conditions (Table 4-1).

4-3.2 Part Materials Having Unlimited

Shelf Life

Part materials having unlimited shelf life do

not need to be stored under controlled
temperature conditions (Table 4-2).

4-2
 U900/000/TM/E/323

4-5 PART NUMBER AND SPECIFICA-

TIONS

When both part number and specification

appear for a given material, the specific material
meets the requirements of the specification. Any
other equivalent material which meets these
requirement can also be used.

Table 4-1. Limited Shelf Life Part Material

GENERAL C.A.G.E. No. MANUFACTURER GENERAL

DESCRIPTION AND/OR
REMARKS
SPECIFICATION No.
Two part epoxy adhesive EA9309.1NA Hysol-Dexter Two components
ambient temperature high mixed at a ratio of
IAI-MS 05.0007
peel strength -30 to 80 °C use 100 pbw of part A
and 20 pbw of part B.
Wet lay-up, low viscosity, low LY564-1 or LY564 Ciba-Geigy Co. Used for:
temperature cure, epoxy 1. Impregnation of
HY560
system: fibers.
a. Resin IAI-MS 05.0023
2. Preparation of
b. Hardener filling and low
strength adhesives
by adding filler.
Non-structural, two part rapid DP100 3M Co. Duo pack syringe
RT cure epoxy adhesive used for bonding
IAI-MS 05.0019
polystyrene foam
blocks.
Polyurethane system for rigid IN2340A/B Polyurethane Co., Used for bonding
foam in-place applications Haifa, Israel polystyrene foam to
IAI-MS 50.70007
Rohacell or other
polystyrene foam
block.
Two parts epoxy adhesive EA934 NA Hysd-Dexter Two components
ambient temperature cure, IAI-MS 05.0006 mixed at a ratio of
-55 to 130° C cure. 100:33. Used as a
liquid shim.
Carbon fiber woven fabric IAI-MS 09.0005, Any approved source Plane weave, style
Type 2, Grade 3, 3k-70 p
Style 1
Glass fiber fabrics MIL-C-9084, Class 2 Any approved source
a. Style 1581
b. Style 120

4-3
U900/000/TM/E/323

Table 4-2. Unlimited Shelf Life Part Material

GENERAL C.A.G.E. No. MANUFACTURER GENERAL

DESCRIPTION AND/OR REMARKS
SPECIFICATION No.
Glass micro balloons Eccospheres-G101, MS Emmerson &
050015 Cummings
Polystyrene foam F-15 Polybead Co., Israel
IAI-MS 08.0008
Polymethacrylimide foam Rohacell 71A Rohm GMBH
Aluminum mesh Astrostrike 16AL Astroseal Products
Mfg. Co.
Anti-foam agent BYK-A500 BYK-Chemie GMBH Additive to LY564
resin
Ethyl alcohol (ethanol), Any approved source Cleaning solvent
technical grade
MEK Federal Spec. Any approved source Cleaning solvent; is
TT-M-26D not used for wing
and tail repair.
Nylon fabric peel IAI-PS 32.1700 Any approved source
(para 6.2.3.5) per
ply, 0.004”
PS 32.1700
Abrasive cloth/paper, water Any approved source
resistance (wet and dry),
80, 120 and 280 grit
Tape, masking, nylon or Any approved source
polyester base, 0.002” or
thicker
Plastic sheet: nylon 6, nylon Any approved source Used as vacuum
6/6, polyethylene, PVC or bags or separating
PVA sheets.
Release agent F-57LC “Axel” Plastics May be replaced by
any non-silicon
release agent.

4-4

4-6 MATERIALS AND PROCESSES
USED IN THE MANUFACTURING
AND REPAIR OF THE STRUC-
TURE MAIN FRAME
4-6.1 Materials (Tables 4-1 to 4-2)
NOTE
· Rohacell is a trade name of the
Rohm Co., Germany
· Machining: Any metal or wood
machining methods and
equipment can be used. Can be
hot formed at 180 °C after a very
long drying process. Hot wire
cutting not recommended.
· Rohacell is specified by nominal
density in kg/m3: 51,71, etc. and
by Type: A, WF or HF.
1. Fibers and fillers
2. Resins and adhesives
3. Foams
4. Paints
5. Sealant
6. Auxiliary materials.
4-6.2 Processes
1. Lay-up
a. Lay-up requirements are specified in basic
specification PS 32.1700 and
supplementary specification PS 32.17.03.
U900/000/TM/E/323
b. All SFL level repairs per PS 32.1703 are
Type 2, no vacuum applied (contact
molded). Most parts are manufactured per
PS 32.1703 and are Type 1, vacuum
molded. Assembly by wet lay-up, i.e.
bonding of frames to skin - is by contact
molding.
c. All repairs and most manufactured parts
are Grade 1, overlap joints in plies.
2. Curing
a. Curing begins at the moment the liquid
resin and hardener are mixed, and ends
when the solid epoxy polymer reaches its
required strength.
b. Parts made per PS 32.17.03 are fully cured
by post-curing at an elevated temperature.
c. SFL level repairs per PS 32.17.03 are only
partially cured at ambient temperature. No
post-curing is required. If ambient
temperature is below 20 °C (68 °F), heating
(overall or local) is required.
3. Adhesive Bonding
a. Structural bonding requirements are
specified in PS 37.0200. EA9309.INA
adhesive is classified as Type F in this
specification.
b. Composite parts are prepared for bonding
by sanding and wiping with alcohol and
can be done at SFL level.
c. Aluminum parts are prepared for bonding
by sulphochromic etching and coating with
a special bonding primer. This process
must be carried out in a properly equipped
facility and not at SFL level. Etched and
primed aluminum details can be kept
bondable for two years.
d. Foam details are bonded per PS 33.0600.
4-5
U900/000/TM/E/323

4. Hot Wire Cutting - Polystyrene cutting by 4-6.3 General Safety Precautions

hot wire shall be as specified in PS 33.0600.
It is advisable to prepare a portable small
hot wire device, for on place cutting.
5. Filling of Polystyrene Foam Surface -
Filling of polystyrene foam surface is before
lay-up on polystyrene and avoids excess
resin to being absorbed by the foam. The
surface is filled with a mixture of LY564-1/
HY560 resin and glass micro balloons, as
specified in PS 32.1703.
6. In Place Foaming - In place foaming is to
fill gaps between foam details. The process
shall be per PS 33.0300.
Epoxy hardeners, resin/hardener mixtures and
polyurethane foam may cause skin and eye
irritation, or allergic reactions to some workers.
The shop should be well ventilated, workers
shall wear protective gloves, goggles, etc.
Carbon dust is harmful if inhaled. It is also
an electrically conductive material and may cause
short circuits.
Paints and thinners are flammable material.
Keep away from open fire, sparks and sources
of concentrated heat (e.g., hot wire) sparks.

7. Painting - Painting includes the following

steps:

a. Application of epoxy primer. After this

step, all surface defects can be easily
detected.
b. Filling of surface defects by filler and/or
high build primers.
8. Machining of composites: Routing,
sanding, cutting and drilling of fiber
composites shall be per PS 32.7002.

4-6
 U900/000/TM/E/323

CHAPTER 5

TYPICAL REPAIRS FOR FOAM CORE MATERIAL

5-1 GENERAL
Three types of foams are used in repairing
Unmanned Air Vehicle (UAV) structures:
- Polystyrene foam
- Polyurethane foam
- Polymethacrilimide foam (Rohacell).
5-1.1 Polystyrene Foam
Polystyrene foam is supplied in blocks. It can
be cut by hot wire. At elevated temperatures the
polystyrene foam distorts or can melt. This foam
is attacked by most organic solvents (except
ethanol and isopropanol).
Rohacell is much stronger and heat resistance
than polystyrene. For bonding PMI to polystyrene
foam, a strong epoxy/micro balloon adhesive is
used. For bonding foam to metal, the strongest
EA 9309.1 NA adhesive is used.
Rohacell natural colour is white and consists
of the following main features:
1. High dimensional stability under heat
2. Solvent resistance, particularly at low
temperatures
3. A low coefficient of heat conductivity
4. High strength to weight ratio

5-1.2 Polyurethane Foam 5. High elongation.

Polyurethane foam is supplied as a kit of two

liquids, A and B. When mixed together, they
react and expand into a hard, low density solid
material. During this process it strongly adheres
to most material surface; other foams,
composites and metals and can be used as a rapid,
low density gap filling adhesive for low strength
materials such as polystyrene foam. This material
is thermosetting, stable at elevated temperatures,
cannot be cut by hot wire and is slowly attacked
by solvents. it can only be formed by cutting,
routing or sanding.

5-1.3 Polymethacrilimide Foam

Polymethacrylimide foam (“Rohacell”) is a

closed-cell rigid expanded plastic material. This
material is supplied in plates and cannot be cut
by hot wire. Forming of Rohacell is by cutting,
routing and sanding. There are many types and
grades defined by type symbol and nominal
density (in kg/m3).

5-1
U900/000/TM/E/323
5-2 CONSUMABLE MATERIALS
REQUIRED
The following consumable materials are
required during repair of foam cores:
1. Epoxy adhesive, two part, rapid cure, per MS
05.0019
2. Epoxy adhesive, two part, room temperature
cure. per MS 05.0007
3. Epoxy resin/hardener system, low viscosity,
per MS 05.0023
4. Glass micro balloons per MS 05.015
5. Ethanol, cleaning solvent
6. Polystyrene foam per MS 08.0008
7. Polymethacrylimide foam per MS 08.0015
8. Short glass fibers, 1/16 to 1/8 in epoxy
compatible.
5-2
5-3 EQUIPMENT REQUIRED
The following equipment is required during
repair of polystyrene core material:
1. Hot wire cutting device consisting of the
following:
a. Frame with adjustable tension screws for
wire
b. Cutting wire. type 302, stainless steel, 0.8
to 1.2 mm
c. Dc voltage regulator, range from 12 to 21
Vdc, current of 3 A
2. Clamps for joining foam blocks
3. Spatula for application of adhesives and
mixes
4. Weights for joining foam blocks.
 U900/000/TM/E/323

5-4 PROCESS STANDARD (PS) 5-5 PROCEDURES

The following PS are referenced in this 5-5.1 Hot Wire Cutting of Polystyrene
section: Foam
1. PS 33.0300 - Rigid Urethane Foam-in-place
NOTE
Application

2. PS 21.3100 - Preparation of Aluminium for

Bonding
· Correct hot wire adjustment is
when the wire cuts approximately
25 mm of foam in 5±1 seconds,
3. PS 23.3200 - Chemical Conversion Coatings using light hand pressure.
for Aluminium Alloys

4. PS 37.4203 - Structural Adhesive Bonding

· A light fuzz of solidified
polystyrene strands on the cut
of Metal, Composite and Sandwich Parts. surface indicates correct wire
temperature. A pitted or rutted
surface indicates the wire is too
hot.

1. Adjust the correct wire temperature.

CAUTION
Excessive pressure shall not be
applied to the hot wire cutter. Failure
to comply may result in bowing and
deviation from the required cut
profile.

NOTE

· Wire shall be moved smoothly

along the cutting template with
minimum stops and starts.

· Hot wire cannot cut through

epoxy or polyurethane bond line.

2. Check template to ensure it meets the

dimensional requirements for the cutting
wire thickness.

3. Using hot wire, cut polystyrene foam block

to the required dimension by applying light
and even side pressure and maintaining
continuous contact between wire and cutting
template.

5-3
U900/000/TM/E/323
5-5.2 Bonding Polystyrene Foam
Blocks
The following three applicable methods may
be used for bonding polystyrene foam blocks.
NOTE
When repairing with polystyrene foam, do not
cut foam to its final form by using templates.
Polystyrene foam is generally cut to exceed
dimensions and then reworked by sanding or
cutting after bonding.
5-5.2.1 Bonding With Polyurethane
Foam Mix
WARNING
Polyurethane foam mix is flammable
and toxic. Use in well-ventilated area
only. Avoid eye and skin contact or
breathing of vapors. Protective
equipment consisting of goggles,
gloves and respiratory protection is
required. Failure to comply may
result in injury or health problems
to personnel.
1. Mix equal quantities of component A and
B for 10 to 30 seconds.
2. Immediately apply a thin coat of
polyurethane foam mix to faring surfaces of
the blocks to be joined (refer to PS 33.0300).
3. Bring polystyrene foam block faring surfaces
into contact and hold under pressure using
clamps or weights for 10 minutes, minimum.
Carefully apply pressure on foam. Do not
crush it.
NOTE
Cured thickness shall not exceed 3
mm.
5-4
4. Inspect bond line of joined polystyrene
blocks to ensure cure thickness does not
exceed 3 mm.
5. Using 180 grit abrasive paper, sand off
excess and smooth surfaces until a uniformly
smooth surface is obtained.
5-5.2.2 Bonding with Five Minute
Epoxy
WARNING
· Micro balloons are a serious
health hazard. Dispersing of
micro balloons during weighing
and mixing shall be avoided.
Failure to comply may result in
injury or health problems to
personnel.
· Epoxy adhesive is harmful and
toxic. Use in well-ventilated area
only. Avoid eye and skin contact
or breathing of vapors. Protective
equipment consisting of goggles,
gloves and respiratory protection
is required. Failure to comply
may result in injury or health
problems to personnel.
CAUTION
Adhesive shall not be used in foam
areas requiring subsequent hot wire
cutting. Failure to comply may result
in inadequate joining of polystyrene
blocks.
NOTE
Hot wire cannot cut through epoxy
bond line

1. Prepare a two part rapid cure epoxy adhesive
(per MS 05.0019) mixed with up to 20% by
weight of glass micro balloons per MS
05.0015. Continue mixing until a
homogenous mass of uniform viscosity is
obtained, free of lumps.
2. Apply a thin coat of mix to faring surfaces
of the blocks to be joined.
3. Bring polystyrene foam block faring surfaces
together within three minutes after starting
the mixing, ensuring good contact exists
between surfaces. Hold surfaces under
pressure using clamps or weights for 30
minutes, minimum.
NOTE
Cured thickness of bond line shall
not exceed 1 mm.
4. Inspect bond line of joined polystyrene
blocks to ensure cure thickness does not
exceed 1 mm.
5. Using 180 grit sandpaper, sand off excesses
and smooth out surfaces until a uniformly
smooth surface is obtained.
5-5.2.3 Bonding With Epoxy Resin/
Micro Balloon Slurry
WARNING
Micro balloons are a serious health
hazard. Dispersing of micro balloons
during weighing and mixing shall be
avoided. Failure to comply may
result in injury or health problems
to personnel.
U900/000/TM/E/323
WARNING
Epoxy resin is flammable and toxic.
Use in well-ventilated area only.
Avoid eye and skin contact or
breathing of vapors. Protective
equipment consisting of goggles,
gloves and respiratory protection is
required. Failure to comply may
result in injury or health problems
to personnel.
NOTE
A thick slurry layer may result in an
exothermic reaction generating heat
that may melt the polystyrene foam.
Thickness shall be kept as low as
possible.
1. Prepare an epoxy resin/micro balloon slurry
by adding up to 30% by weight a glass micro
balloon per MS 05.0015 to fresh mix resin
MS 05.0023. Continue mixing until a
homogenous mass of uniform viscosity is
obtained.
2. Apply a thin coat of mix to faring surfaces
of the blocks to be joined.
3. Bring polystyrene foam block faring surfaces
together, ensuring good contact exists
between surfaces. Hold surfaces under
pressure using clamps or weights for four
hours, minimum.
NOTE
Cured thickness of bond line shall
not exceed 1 mm. It is recommended
to add 2 to 3% of pigmenting epoxy
compatible paste, to facilitate bond
line thickness control.
4. Inspect bond line of joined polystyrene
blocks to ensure cure thickness does not
exceed 1 mm.
5-5
U900/000/TM/E/323
5. Using 180 grit sandpaper, sand off excess
and smooth out surfaces until a uniformly
smooth surface is obtained.
5-5.3 Bonding Rohacell Foam
Rohacell foam bonding may be to a block of
Rohacell bonded within polystyrene foam or
bonded to a solid composite surface.
5-5.4 Bonding a Block of Rohacell
Foam Enclosed in Polystyrene
Foam
This is identical to bonding a block of
Rohacell foam to a composite surface/detail
procedure (paragraph 5-5.5).
5-5.5 Bonding a Block of Rohacell
Foam to a Composite Surface/
Detail
WARNING
Epoxy adhesive is flammable and
toxic. Use in well-ventilated area
only. Avoid eye and skin contact or
breathing of vapors. Protective
equipment consisting of goggles,
gloves and respiratory protection is
required. Failure to comply may
result in injury or health problems
to personnel.
NOTE
· Composite surface/detail is
referred to as spar, web, ribs.
mountain clip, etc.
· This procedure shall be used when
one side of polymethacrylimide
foam is to be bonded to a solid
surface.
5-6
1. Prepare a two part epoxy adhesive, per MS
05.0007. Continue mixing until homogenous
mass of uniform viscosity is obtained, free
of lumps. Add chopped glass fibers, as
necessary to obtain a non-sagging mixture.
2. Apply a thin coat of epoxy adhesive and
short glass fibers mix to faring surfaces of
the details to be joined.
3. Bond details together, ensuring good contact
exists between surfaces. Hold surfaces under
pressure using clamps or weights for eight
hours minimum at room temperature.
4. Using 180 grit abrasive paper, sand off
excess and smooth out surfaces until a
uniformly smooth surface is obtained.
5-5.6 Bonding Metal Details to
Rohacell Foam
NOTE
· Ethanol may be used sparingly for
cleaning fairing surfaces
· If solvent cleaning is essential,
foam shall be thoroughly dried
prior to bonding.
1. Thoroughly clean surfaces to be bonded
using ethanol.
2. Rout groove in the foam to the dimension
required, allowing a clearance of 1 to 1.6
mm all around detail periphery.
3. Clean groove thoroughly with compressed
air.
4. Prior to bonding, clean and prepare
aluminium alloy parts per PS 21.3100 and
prime per PS 37.40.03.

WARNING
MEK is flammable. Avoid eye and
skin contact or breathing of vapors.
Protective equipment consisting of
goggles and gloves is required.
Failure to observe this warning may
result in injury to personnel and/or
damage to UAV or equipment.
CAUTION
Primed surfaces must not be
abraded. Failure to comply may
result in damage to structure.
NOTE
Aluminium parts locked by adhesive
can be prepared for bonding by
applying chromate conversion
coating per PS 23.3200.
5. Wipe primed surface of aluminium detail
with MEK and dry thoroughly.
WARNING
Epoxy adhesive is harmful and toxic.
Use in well-ventilated area only. Avoid
eye and skin contact or breathing of
vapors. Protective equipment
consisting of goggles, gloves and
respiratory protection is required.
Failure to comply may result in injury
or health problems to personnel.
U900/000/TM/E/323
6. Mix a two part epoxy adhesive, per MS
05.0007 ad up to 20% by weight of short
glass fibers. Continue mixing until a
homogenous mass of uniform viscosity is
obtained, free of lumps.
7. Fill groove with adhesive/short fiber mix.
8. Using spatula, fill holes and cut-outs on
bonding area of metal part with adhesive/
fibers mix.
NOTE
Agitating of part is necessary to
allow trapped air to escape and
prevent poor bonding quality.
9. Insert part into prepared groove while
agitating part until all trapped air escapes.
10. Position part and detail on assembly fixture/
tool.
11. Add adhesive as required, while agitating
parts or details.
12. Clean surrounding area of excess adhesive
as required.
13. Prior to removing part from fixture, allow
to cure for a minimum of eight hours at room
temperature.
14. Using 180 grit sandpaper, sand off excess
adhesive. Leave adhesive fillets at the hinge/
skin corners.
5-7/(5-8 Blank)
5-7

CHAPTER 6
TYPICAL STRUCTURAL REPAIRS
6-1 GENERAL INFORMATION
The instructions in this chapter are applicable
to general repair. This chapter contains
authorised repairs for damage to Unmanned Air
Vehicle (UAV) fuselage, wings and tail assembly.
Damage beyond the limits specified in this
chapter shall require specific instructions from
a structural repair engineer.
Repairs illustrated in this section are normally
circular. However, they may be of any shape
provided they do not exceed dimensions
specified and corners are rounded to a workable
radius. Several damage areas apart less than 30
mm shall be considered as one damage.
U900/000/TM/E/323
6-2 DETERMINING APPLICABLE
REPAIR
When damage occurs to UAV fuselage, wings
or tail assembly, the following steps must be
complied with to determine and accomplish the
applicable repair.
1. Note area in which damage is located (Figure
6-1).
2. Determine damage limitation, skin thickness
and core used in damage area (Tables 6-4 to
6-6).
3. Select proper repair procedure (Table 6-2).
4. Read and comply with safety precautions.
5. Read instructions in repair procedure to
ensure a complete understanding of repair.
6. Repair damage in accordance with
appropriate repair procedure.
6-1
U900/000/TM/E/323

6-3 NON-REPAIRABLE AREAS 6-4 SAFETY PRECAUTIONS

The following areas and parts are non Some materials used in repairs of UAV
repairable (Figure 6-1): fuselage, wing and tail assemblies are toxic and
flammable. The following general and personal
1. Upper and lower fuselage spars precautions shall be observed.

2. Wing and tail spars NOTE

All warnings, cautions and limitations
3. Fuel tank area provided on labels and containers by
manufacturers of the material should
4. Antenna post and radome be read and observed.

5. Actuator boxes 6-4.1 General Precautions

Observe the following general precautions when
6. Latches and hinges areas repairing UAV fuselage, wings or tail assembly:

7. Fitting areas in: 1. Have fire fighting equipment available

a. Nose and main landing gear
b. Engine mountings
c. Booster launch
d. Parachute connections
e. Hoisting and jacking points
f. Wing-to-fuselage attaching points.
(carbon dioxide extinguisher is preferred)
2. Keep solvents and cleaners in safety
containers
3. Discard soiled rags in safety cans
4. Keep oil and grease away from work area
5. Use only pneumatic tools and explosion
proof elements. Usage of internal
combustion motor operated equipment is
prohibited in the repair area
6. Room temperature of working area shall be
kept at 20 to 28 °C. Do not heat room by
open fire or electric heating elements
7. Do not produce carbon dust in the vicinity
of electrical equipment, electrical motor-
operated equipment and electrical sockets
8. Vacuum clean dust during sanding
operations.

6-4.2 Personal Precautions

Observe the following personal precautions

when repairing UAV structure:

1. Wear a respirator and goggles when using

adhesives paints and cleaning fluids or sanding.

2. Wear rubber gloves when handling cleaning

materials, resins and adhesives.

6-2

6-5 EVALUATION OF DAMAGE
Severity of damage for all types of damage is
determined by the size of the damage, the
distance between damaged areas and amount of
damage within the assembly. The permissible
accumulation of repairable damage within a
structural member described in this Chapter is
shown in Figure 6-2.
If the minimum distance between two
adjacent damages is less than 10% of L damage
dimension or less than 30 mm, both damages
shall be considered as a single damage. If the
minimum distance between two damages is
greater than 10% of L and at least 30 mm, the
damages shall be treated as separate damages.
6-5.1 Evaluation of Repair
Any structural assembly repaired shall be
inspected to insure proper performance of the
repaired part as follows:
Figure 6-1. Structural Damage in Fuselage, Wings or Tail Assembly (Sheet 1)
U900/000/TM/E/323
1. Visually inspect the repaired part for the
following:
a. Smooth and faired into contour of panel
surface(s).
b. All fibers of the repair patches are
uniformly coated with resin.
c. Uniform in appearance.
2. Visual inspect repair for internal defects to
ensure repair is free of voids and
delamination.
6-5.2 Repair in Areas of Metal Brackets
When a repair is performed in an area in which
a metal bracket has to be assembled, an additional
external repair glass ply , style 1581 shall be
applied to ensure the metal bracket is fully
separated away from graphite plies, thus
preventing galvanic corrosion.
6-3
U900/000/TM/E/323

Figure 6-1. Structural Damage in Fuselage, Wings or Tail Assembly (Sheet 2)

6-4
 U900/000/TM/E/323

Figure 6-1. Structural Damage in Fuselage, Wings or Tail Assembly (Sheet 3)

6-5
U900/000/TM/E/323

Table 6-1. Evaluation of Damage

REPAIR TYPE OF REPAIRABLE DAMAGE REPAIR REPAIR MATERIALS

AREA DAMAGE PARA

Fuselage Laminate a. Maximum damage length 6-6 Carbon fiber fabric ±45°
damage 15 mm (D MAX = 15) (Style 3K-70P)
dents and
cavities b. Distance of damage from assy Milled glass fiber
(Note 1) support greater then 1/32" to 1/8"
30 mm (d MIN = 30)

Fuselage Laminate a. Maximum damage length 6-7 Carbon fiber fabric (Style 3K-
damage a 200 mm (D MAX = 200) 70P)
through hole
(Note 2) b. Distance of damage from assy Fiber laminate made of glass
support fiber fabric ±45° (Style 3K-
(Figure 6-3, sheet 1 to 3) 70P)

Fuselage Damage in a. Maximum damage length 6-8 Carbon fiber fabric (Style 3K-
laminate and 200 mm (D MAX = 200) 70P)
stiffener
b. Distance of damage from assy Fiber laminate made of glass
support greater then fiber fabric ±45° (Style 3K-
30 mm (d MIN = 30) 70P)

Fuselage Damage to a. Maximum damage length 6-9 Carbon fiber fabric (Style 3K-
stiffener, no 200 mm (D MAX = 200) 70P)
damage to
laminate b. Distance of damage from assy Rohacell 71A
outer skin support greater then
30 mm (d MIN = 30)

Fuselage Sandwich a. Maximum damage length 6-10 Carbon fiber fabric (Style 3K-
structure no 15 mm (D MAX = 15) 70P)
broken skin
(dents and b. Distance of damage from assy Rohacell 71A
cavities) support greater then
30 mm (d MIN = 30)

c. Maximum depth of damage

3 mm (H MAX = 3)

6-6
 U900/000/TM/E/323

Table 6-1. Evaluation of Damage (Contd)

REPAIR TYPE OF REPAIRABLE DAMAGE REPAIR REPAIR

AREA DAMAGE PARA MATERIALS

Fuselage Laminate skin a. Maximum damage length 6-11 Carbon fiber

damage to doors, 15 mm (D MAX = 15) fabric (Style 3K-
fairing covers, etc. 70P)
b. Distance of damage from assy
support greater then
30 mm (d MIN = 30)

Fuselage Laminate skin a a. Maximum damage length 6-12 Carbon fiber

through hole in 100 mm (D MAX = 100) fabric (Style 3K-
doors, fairing 70P)
covers, etc. b. Distance of damage from assy
support greater then
30 mm (d MIN = 30)

Fuselage Laminate skin a. Maximum damage length 6-13 Carbon fiber

damage to curved 15 mm (D MAX = 15) fabric (Style 3K-
fairing, covers, 70P)
doors etc. (dents b. Distance of damage from assy
and cavities) support greater then
15 mm (d MIN = 15)

Fuselage Laminate skin a. Maximum damage length 6-12 Carbon fiber

damage to curved 80 mm (D MAX = 80) fabric ±45°
fairing, covers (Style 3K-70P)
doors, etc. (a b. Distance of damage from assy
through hole) support greater then Aluminium tape
30 mm (d MIN = 30)

Fuselage Laminate See Table 6-6. 6-13 Carbon fiber

structure skin fabric (Style 3K-
damage to plane 70P)
landing area of
fairing covers,
doors, etc.

6-7
U900/000/TM/E/323

Table 6-1. Evaluation of Damage (Contd)

REPAIR TYPE OF REPAIRABLE DAMAGE REPAIR REPAIR MATERIALS

AREA DAMAGE PARA

Fuselage Damage to plane a. Maximum damage length 6-14 Carbon Fiber Fabric
laminate surfaces 100 mm (D MAX = 100) (Style 3K-70P)
of covers doors
including damage b. Distance of damage from Rohacell Block
to core assy support greater then 71 kg/m3
30 mm (d MIN = 30)

Wings or Damage to contour a. Length of damage 30 mm 6-15 See Table 4-3.

Tail of surface with no or less (L)
Assembly broken skin
b. Width of damage 30 mm
or less (W)

c. Height of damage 6 mm
or less (h).

Wings or Debonding a. Length of damage 30 mm 6-16 Carbon fiber fabric (Style

Tail between skin and or less (L) 3K-70P) or glass fiber
Assembly core fabric,
b. Width of damage 30 mm style 1581
or less (W)

Wings or Damage to skin a. Length of damage 600 mm 6-17 Carbon glass fiber fabric
Tail and core without or less, spanwise (L) (Style 3K-70P) or glass
Assembly damage to fiber fabric, style 1581
opposite skin b. Ratio of width of damage to
length of wing or stabiliser Polystyrene foam,
chord-less then 0.25 (W/C) Polyvid F-15

Polyurethane foam,
IN2340F A/B

Wings or Repair of damage a. Length of damage 600 mm 6-18 Carbon glass fiber fabric
Tail to both skins and or less, spanwise (L) (Style 3K-70P) or glass
Assembly Core fiber fabric, style 1581
b. Ratio of width of damage to
length of wing or stabilizer Polystyrene foam,
chord-less then 0.25 (W/C) Polyvid F-15

Polyurethane foam,
IN2340F A/B

6-8
 U900/000/TM/E/323

Table 6-1. Evaluation of Damage (Contd)

REPAIR TYPE OF REPAIRABLE DAMAGE REPAIR REPAIR MATERIALS

AREA DAMAGE PARA

Wings Damage to trailing a. Length of damage 600 mm 6-19 Carbon fiber fabric (Style
edge of outer or less, spanwise (L) 3K-70P)
wings
b. Ratio of width of damage to Polystyrene foam,
length of wing less then 0.25 Polyvid F-15
(W/C)
Polyurethane foam,
IN2340F A/B

Wings Damage to trailing Length of damage 600 mm 6-20 Carbon fiber fabric (Style
edge of flap and or less, spanwise (L) 3K-70P)
central wing
Polystyrene foam,
Polyvid F-15

Polyurethane foam,
IN2340F A/B

Wings Damage not 6-21

including
aluminium mesh

Wings Damage to leading a. Length of damage 600 mm or 6-22 Glass fiber fabric
edge including less, spanwise (L) style 1581.
damage to
aluminium mesh b. Width of damage 250 mm Polystyrene foam,
or less (W) Polyvid F-15

Polyurethane foam,
IN2340F A/B

Aluminium mesh
Astrostrike 16AL

Wings Damage in a. Length of damage 80 mm 6-23 Carbon fiber fabric

actuator panel or less, spanwise (D=80) (Style 3K-70P)

b. Distance from edge of

damage no less than 20 mm
(d min =20)

6-9
U900/000/TM/E/323

Table 6-1. Evaluation of Damage (Contd)

REPAIR TYPE OF DAMAGE REPAIRABLE DAMAGE REPAIR REPAIR MATERIALS

AREA PARA

Wings Repair of damage in a. Length of damage 60 mm 6-24 Carbon fiber fabric

actuator fairing or less, spanwise (D=60) (Style 3K-70P)

b. Width of damage 20 mm Polystyrene foam,

or less (W=20) Polyvid F-15

Wing Repair of minor See Figure 6-21. 6-25 Carbon fiber fabric
damage Rohacell (Style 3K-70P)
block hinge\ lever
Rohacell Block
71 kg/m3

Wing Repair of major See Figure 6-22. 6-26 Carbon fiber fabric
damage Rohacell (Style 3K-70P)
block hinge\ lever
Rohacell block
71 kg/m3

NOTES:

1. Any dent damage causing delamination, breaking, and/or creasing skin must be considered as a
fracture and repaired accordingly.

2. A peel ply has to be laid and fully impregnated on outer repair plies in all types of repair.

6-6 FUSELAGE LAMINATE STRUC- 6-6.2 Equipment

TURE (OUT OF FUEL TANK
AREA) 1. High speed (15,000 to 20,000 rpm) router
with diamond coated or solid carbide bit
6-6.1 General 2. Face shield
This paragraphs provide information 3. Industrial Goggles
regarding the Fuselage Laminate structure -
Repair of dents and cavities, repair of damage to 4. Respirator
cowlings, fairing, covers, doors and access panels 5. Rubber gloves
(Damage to plane areas - no broken skin), repair
of damage to curved laminate structure with no 6. Spatula (or thin piece of metal sheet)
broken skin (dents and cavities) (Figure 6-2)
7. Vacuum cleaner.

6-10

6-6.3 Part Materials
1. Carbon fiber fabric Style 3K-70P
2. Epoxy adhesive, Hysol EA 9309.1NA
3. Hardener, HY560
4. Milled glass fibers 1/32" - 1/8"
5. Epoxy resin, LY564-1.
6-6.4 Auxiliary Materials and Dispos-
able Items
1. Lint-free cloth or lint free paper towels
2. Contacts spray
3. Ethyl alcohol
4. Masking tape
5. 80 to 100 grit abrasive paper/cloth
6. 220 to 280 grit abrasive paper/cloth
7. Plastic sheet: nylon, polyvinyl chloride
(PVC), polyethylene or polyvinyl alcohol
(PVA)
8. Wrapping paper (FED Spec. OU-P-
268E, No. 2)
9. Nylon fiber peel ply.
6-6.5 Safety Conditions:
WARNING
· Ethyl alcohol is flammable.
Avoid eye and skin contact or
breathing of vapors. Protective
equipment consisting of goggles
and gloves is required.
· Epoxy resin and adhesive EA
9309.1NA are toxic and
flammable. Use in well-ventilated
area only. Avoid eye and skin
contact or breathing of vapors.
Protective equipment consisting
of goggles, gloves and respiratory
protection is required. Failure to
comply may result in injury or
health problems to personnel.
U900/000/TM/E/323
6-6.5 Repair Procedure
A. Evaluate damage and determine applicable
repair (paragraph 6-6) (If damage exceeds
allowable limits, repair per paragraph 6-8).
B. Repair as follows:
1. Remove assemblies required to allow
access to repair area.
2. Vacuum clean all loose resin particles from
between plies located in damaged area.
CAUTION
This procedure requires sanding of
carbon fiber components. Resultant
dust is an electrical conducting
material which may cause electrical
short circuits. Protect all electrical
equipment and components against
dust. Failure to comply may result
in damage to equipment.
3. Using wrapping paper, wrap electrical
boxes in area of damage. Protect all open
lines and electrical connectors.
4. Using 220 to 280 grit abrasive paper,
remove paint from undamaged area to a
distance of 30 mm around damage.
NOTE
After area has been thoroughly cleaned
with ethyl alcohol, the skin shall be
checked for cracks and damage.
5. Vacuum clean all dust particles and wipe
damaged and surrounding area using Lint-
free cloth impregnated with ethyl alcohol.
6. Check cleaned area for cracks and
damage.
7. Dry milled glass fibers in an oven at 110°
for 1 to 2 hours prior to mixture with
adhesive.
6-11
U900/000/TM/E/323

DIMENSION MAXIMUM REPAIRABLE DAMAGE SIZE

D MAX (mm) ........................................................ 15
d MIN (mm) .......................................................... 30

REPAIRABLE DAMAGE SIZE

Figure 6-2. Fuselage Laminate structure (Out of Fuel Tank Area) - Repair of Dents and Cavities

6-12
 U900/000/TM/E/323

NOTE 6-7 FUSELAGE LAMINATE STRUC-

TURE - REPAIR OF A THROUGH
Only small quantities up to 100 g HOLE DAMAGE (Figure 6-3)
shall be mixed at one time.
8. Prepare a mixture of EA 9309.1NA 6-7.1 Equipment
adhesive and milled glass fibers. Use long
and small strokes and mix thoroughly 1. Face shield
until homogeneous mass of uniform
viscosity is obtained, free of lumps. 2. Industrial goggles
9. Using spatula (or thin piece of metal sheet) 3. Respirator
fill cavity or dent with mixture of EA
9309.1NA adhesive and milled glass fibers. 4. Rubber gloves
10. Cure at least six hours at room temperature. 5. Spatula (or thin piece of metal sheet)
11. Using 80 to 100 grit abrasive paper, sand
area smoothly to prepare for bonding. 6. Vacuum cleaner.
12. Prepare a mixture of 100 g of epoxy resin 6-7.2 Part Materials
and 27 g of hardener.
13. Impregnate carbon fiber fabric, on a plastic 1. Carbon fiber fabric, style 3K-70P
sheet, with epoxy resin/hardener mixture.
2. Micro balloons. glass eccospheres-
14. Lay another plastic sheet on top of the
1G101
fabric. Squeeze out excess resin with a
spatula or a squeegee. 3. Hardener, HY560
15. Cut one ply of impregnated fabric 50±5
4. Epoxy resin, LY564-1.
mm larger than diameter of damage (fiber
direction ±45°). 6-7.3 Auxiliary Materials and Dispos-
16. Brush a thin layer of epoxy resin/ able Items
hardener on the repair area.
17. Peel off one plastic sheet ply and lay it 1. Lint-free cloth or lint free paper towels
on centre of the damage, so it uniformly
2. Contacts spray
overlaps the damage circumference. Peel
off the remaining plastic sheet. Lay and 3. Ethyl alcohol
impregnate peel ply 20±5 mm larger than
the diameter of the carbon fabric. 4. Masking tape
18. Cure for at least six hours at room 5. 80 to 100 grit abrasive paper/cloth
temperature and remove peel ply.
6. 220 to 280 grit abrasive paper/cloth
19. Prime and finish repair area as specified
in Chapter 3. 7. Plastic sheet: nylon, PVC, polyethylene
20. Clean work area and remove remaining or PVA
unused repair material. 8. Wrapping paper (FED Spec. OU-P-
21. Remove wrapping paper from work area 268E, No. 2)
and protective devices from all lines and
electrical connectors. 9. Nylon fiber peel ply.
22. Check electrical connectors for epoxy
and carbon dust and clean with vacuum
cleaner and contacts spray.
6-13
U900/000/TM/E/323
6-7.4 Safety Conditions
WARNING
· Ethyl alcohol is flammable. Avoid eye
and skin contact or breathing of vapors.
Protective equipment consisting of
goggles and gloves is required.
· Epoxy resin is toxic and
flammable. Use in well-ventilated
area only. Avoid eye and skin
contact or breathing of vapors.
Protective equipment consisting
of goggles, gloves and respiratory
protection is required. Failure to
comply may result in injury or
health problems to personnel.
· Micro balloons may be harmful to the
respiratory system. Avoid breathing of
particles. Respiratory protection
against fine dust is required. Failure
to comply may result in injury or health
problems to personnel.
6-7.5 Repair Procedure
A. Evaluate damage and determine applicable
repair (paragraph 6-6).
B. Repair as follows:
1. Remove assemblies to allow access to
repair area.
2. Vacuum clean all loose resin particles in
damaged area.
CAUTION
This procedure requires sanding of
carbon fiber components. Resultant
dust is an electrical conducting
material which may cause electrical
short circuits. Protect all electrical
equipment and components against
dust. Failure to comply may result
in damage to equipment.
6-14
3. Using wrapping paper, wrap electrical
boxes in area of damage. Protect all open
lines and electrical connectors.
4. Rout with diamond coated or solid
carbide bit all damaged skin and around
damage to a distance up to 5 mm. Check
for minimum radius of 5 mm at corners
of damage.
5. Using 220 to 280 grit abrasive paper,
remove paint from undamaged inner area
to a distance of 35±5 mm for filler
thickness of four plies, 50±5 mm for
filler thickness of nine plies (Table 6-3)
and 50±5 mm for outer side of fuselage
skin.
6. Vacuum clean all dust particles and wipe
damaged area and surrounding area with
clean Lint-free cloth impregnated with
ethyl alcohol.
7. Prepare a laminate patch per PS
32.17.03, Class III, Type 1, Grade 1
(directions ±45°) from carbon fiber fabric
to match hole in laminate (for number
of plies, see Table 6-3).
8. Cut prepared laminate patch to match
cutout thickness and size, leaving a
maximum gap of 2 mm between filler
laminate and undamaged structure.
9. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
10. Add 15 to 25 g of micro balloons-glass
to the mixed epoxy resin. Continue
mixing until a homogeneous mass of
uniform viscosity is obtained, free of
lumps.
11. Apply mixture to laminate filler edges
and reworked damaged area edges and
bond laminate filler in place.
12. Cure for at least six hours at room
temperature.

13. Using 220 to 280 grit abrasive paper,
shape upper and lower surface until
laminate filler is flush with undamaged
structure.
14. Vacuum clean all dust particles from sand
and wipe damaged area and surrounding
area with clean Lint-free cloth
impregnated with ethyl alcohol.
15. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
16. Impregnate a large carbon fiber fabric,
on a plastic sheet, with epoxy resin/
hardener mixture.
17. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.
NOTE
Steps 18 to 26 for repair of zones I
and II (Table 6-2). For repair of zones
III, IV and V, see steps 27 to 39 and
steps 40 to 52 respectively.
18. Cut five plies of impregnated fabric
(three for outer side and two for inner
side) as follows:
1) One ply 50±5 mm larger than
diameter of damage for outer skin side
(fiber direction ±45°).
2) One ply 100±5 mm larger than
diameter of damage for outer skin side
(fiber direction 0/90°).
3) One ply 150±5 mm larger than
diameter of damage for outer skin side
(fiber direction ±45°).
4) One ply 40±5 mm larger than
diameter of damage for inner skin side
(fiber direction 0/90°).
5) One ply 40±5 mm larger than
diameter of damage for inner skin side
(fiber direction ±45°).
U900/000/TM/E/323
19. Brush a thin layer of epoxy resin/
hardener on the repair area.
NOTE
Fiber direction of 0/90° ply shall
conform to structure longitudinal
axis.
20. Peel off one plastic sheet from smaller
ply and lay it on centre of the damage
from outer side, so it uniformly overlaps
the damage circumference. Peel off the
remaining plastic.
21. Repeat step 20 with the two larger plies
(outer side).
22. Lay peel ply on the repair plies, smoothen
and impregnate.
23. Peel off one plastic sheet from 0/90° ply
and lay it on centre of the damage from
inner side, so it uniformly overlaps the
damage circumference. Peel off the
remaining plastic
24 Repeat step 22 with the ±45° ply (inner
side).
25. Lay peel ply on the repair plies, smooth
and impregnate.
26. Cure for at least six hours at room
temperature and remove peel ply.
NOTE
· To finish repair of damage in
zones I and II, go to step 49.
· Steps 27 to 39 apply to repair of
zones IV and V (Table 6-2). For
repair of zone III, see steps 40 to
52.
6-15
U900/000/TM/E/323
27. Cut eight plies of impregnated fabric
(four for forward side and four for aft
side) as follows:
1) Two plies 40±5 mm larger than
diameter of damage for forward frame
side (fiber direction ±45° and 0/90°).
2) Two plies 80±5 mm larger than
diameter of damage for forward frame
side (fiber direction ±45° and 0/90°).
3) Two plies 40±5 mm larger than
diameter of damage for aft frame side
(fiber direction ±45° and 0/90°).
4) Two plies 80±5 mm larger than
diameter of damage for aft frame side
(fiber direction ±45° and 0/90°).
28. Brush a thin layer of epoxy resin/
hardener on the repair area.
NOTE
Fiber direction of 0/90° ply shall
conform to structure longitudinal axis.
29. Peel off one plastic sheet from 0/90°
smaller ply and lay it on centre of the
damage from forward side, so it uniformly
overlaps the damage circumference. Peel
off the remaining plastic.
30. Peel off one plastic sheet from ±45°
smaller ply and lay it on centre of the
damage from forward side, so it uniformly
overlaps the damage circumference. Peel
off the remaining plastic.
31. Peel off one plastic sheet from 0/90° larger
ply and lay it on centre of the damage from
forward side, so it uniformly overlaps the
damage circumference. Peel off the
remaining plastic.
32. Peel off one plastic sheet from ±45° larger
ply and lay it on centre of the damage from
forward side, so it uniformly overlaps the
damage circumference. Peel off the
remaining plastic.
6-16
33. Lay peel ply on the repair plies, smooth
and impregnate.
34. Peel off one plastic sheet from 0/90°
smaller ply and lay it on centre of the
damage from aft side, so it uniformly
overlaps the damage circumference. Peel
off the remaining plastic.
35. Peel off one plastic sheet from ±45°
smaller ply and lay it on centre of the
damage from aft side, so it uniformly
overlaps the damage circumference. Peel
off the remaining plastic.
36. Peel off one plastic sheet from 0/90°
larger ply and lay it on centre of the
damage from aft side, so it uniformly
overlaps the damage circumference. Peel
off the remaining plastic.
37. Peel off one plastic sheet from ±45°
larger ply and lay it on centre of the
damage from aft side, so it uniformly
overlaps the damage circumference. Peel
off the remaining plastic.
38. Lay peel ply on the repair plies, smooth
and impregnate.
39. Cure for at least six hours at room
temperature and remove peel ply.
NOTE
· To finish repair of damage in
zones IV and V, go to step 49.
· Steps 40 to 52 for repair of zones
III (Table 6-3).
40. Cut four plies of impregnated fabric
(two for forward side and two for aft
side) as follows:
1) One ply 40±5 mm larger than
diameter of damage for forward frame
side (fiber direction ±45°).
 U900/000/TM/E/323

2) One ply 40±5 mm larger than
diameter of damage for forward frame
side (fiber direction 0/90°).
3) One ply 40±5 mm larger than
diameter of damage for aft frame side
(fiber direction ±45°).
4) One ply 40±5 mm larger than
diameter of damage for aft frame side
(fiber direction 0/90°).
41. Brush a thin layer of epoxy resin/
hardener on the repair area.
NOTE
Fiber direction of 0/90° ply shall
conform to structure longitudinal axis.
42. Peel off one plastic sheet from 0/90° ply
and lay it on centre of the damage from
forward side, so it uniformly overlaps the
damage circumference. Peel off the
remaining plastic.
43. Peel off one plastic sheet from ±45° ply
and lay it on centre of the damage from
forward side, so it uniformly overlaps the
damage circumference. Peel off the
remaining plastic.
44. Lay peel ply on the repair plies, smooth
and impregnate.
45. Peel off one plastic sheet from 0/90° ply
and lay it on centre of the damage from
aft side, so it uniformly overlaps the
damage circumference. Peel off the
remaining plastic.
46. Peel off one plastic sheet from ±45° ply
and lay it on centre of the damage from
aft side, so it uniformly overlaps the
damage circumference. Peel off the
remaining plastic.
47. Lay peel ply on the repair plies, smooth
and impregnate.
48. Cure for at least six hours at room
temperature and remove peel ply.
49. Prime and finish repair area as specified
in Chapter 3.
50. Clean work area and remove remaining
unused repair material.
51. Remove wrapping paper from work area
and protective devices from all lines and
electrical connectors.
52. Check electrical connectors for epoxy
and carbon dust and clean with vacuum
cleaner and contact spray.

Table 6-2. Filler Laminate Number of Plies

ZONE PART ZONE / REGION FILLER REQUIRED

INDEX DESCRIPTION PLIES AND DIRECTION

I Bottom Skin Stations -662 to 232 4 and ±45°

II Side Skin Stations 232 to 652 4 and ±45°
III Region A 4 and ±45°
(Figure 6-3, sheet 7)
ST. -662 Frame
IV Region B, 9 and ±45°
(Figure 6-3, sheet 6)
V ST. 2178 Frame (Figure 6-3, sheet 7) 9 and ±45°

6-17
U900/000/TM/E/323

DIMENSION MAXIMUM REPAIRABLE DAMAGE SIZE

D MAX (mm) ....................................................... 200
d MIN (mm) .......................................................... 30

REPAIRABLE DAMAGE SIZE FOR SKIN

DIMENSION MAXIMUM REPAIRABLE DAMAGE SIZE

D MAX (mm) ....................................................... 200
d MIN (mm) ................................................. 50 (Region A)
..................................................................... 25 (Region B)

REPAIRABLE DAMAGE SIZE FOR FRAME -662

Figure 6-3. Fuselage Laminate Structure - Repair of Damage a Through Hole (Sheet 1)

6-18
 U900/000/TM/E/323

DIMENSION MAXIMUM REPAIRABLE DAMAGE SIZE

D MAX (mm) ....................................................... 200
d MIN (mm) .......................................................... 50

REPAIRABLE DAMAGE SIZE FOR SKIN

Figure 6-3. Fuselage Laminate Structure - Repair of Damage a Through Hole (Sheet 2)

6-19
U900/000/TM/E/323

FILLER LAMINATE BONDING

Figure 6-3. Fuselage Laminate Structure - Repair of Damage a Through Hole (Sheet 3)

6-20
 U900/000/TM/E/323

NOTE

Fiber direction of 0/90° ply shall follow fuselage longitudinal direction.

PLIES REPAIR FOR ZONES INDEX I AND II

NOTE

Fiber direction of 0/90° ply shall follow fuselage longitudinal direction.

PLIES REPAIR FOR ZONES INDEX IV AND V

Figure 6-3. Fuselage Laminate Structure - Repair of Damage a Through Hole (Sheet 4)

6-21
U900/000/TM/E/323

NOTE

Fiber direction of 0/90° ply shall follow fuselage longitudinal direction.

PLIES REPAIR FOR ZONES INDEX III

Figure 6-3. Fuselage Laminate Structure - Repair of Damage a Through Hole (Sheet 5)

6-22
 U900/000/TM/E/323

6-8 FUSELAGE LAMINATE STRUC- 6-8.4 Safety Conditions

TURE - REPAIR OF DAMAGE IN
LAMINATE AND STIFFENER
WARNING
(Figure 6-4)

6-8.1 Equipment
· Ethyl alcohol is flammable.
Avoid eye and skin contact or
breathing of vapors. Protective
1. High speed (15,000 to 20,000 rpm) router equipment consisting of goggles
with diamond coated or solid carbide bit and gloves is required.
2. Face shield
3. Industrial goggles · Epoxy resin is toxic and
flammable. Use in well-ventilated
4. Respirator area only. Avoid eye and skin
5. Rubber gloves contact or breathing of vapors.
Protective equipment consisting
6. Spatula (or thin piece of metal sheet)
of goggles, gloves and respiratory
7. Vacuum cleaner. protection is required. Failure to
comply may result in injury or
6-8.2 Part Materials health problems to personnel.
1. Carbon fiber fabric, style 3K-70P
6-8.5 Repair Procedure
2. Micro balloons, glass eccospheres-
1G101 1. Evaluate damage and determine applicable
3. Rohacell 71A kg/m3 repair (paragraph 6-6).

4. Hardener, HY560 2. Repair as follows:

5. Epoxy resin, LY564-1.
1. Remove assemblies to allow access to
6-8.3 Auxiliary Materials and Dispos- repair area.
able Items
2. Vacuum clean all loose resin particles in
1. Lint-free cloth or lint free paper towels damaged area.
2. Contact spray
CAUTION
3. Ethyl alcohol
This procedure requires sanding of
4. Masking tape
carbon fiber components. Resultant
5. 80 to 100 grit abrasive paper/cloth dust is an electrical conducting
6. 220 to 280 grit abrasive paper/cloth material which may cause electrical
short circuits. Protect all electrical
7. Plastic sheet: nylon, PVC, polyethylene equipment and components against
or PVA dust. Failure to comply may result
8. Wrapping paper (FED Spec. OU-P- in damage to equipment.
268E, No. 2)
3. Using wrapping paper wrap, electrical
9. Nylon fiber peel ply. boxes in area of damage. Protect all open
lines and electrical connectors.

6-23
U900/000/TM/E/323
CAUTION
Exercise care during routing to
prevent damage from adjacent
structure.
4. Rout with diamond coated or solid
carbide bit all damaged skin and core
around damage to a distance up to 5 mm.
Check for minimum radius of 5 mm at
corners of damage.
CAUTION
Take care not to further damage the
intact portion of stiffener and skin.
Failure to comply may result in
damage to equipment.
5. Remove stiffener to a distance of 30±3
mm from the cutout edge (Figure 6-4,
sheet 3).
6. Using 220 to 280 grit abrasive paper,
remove paint from stiffener cut edges and
skin around cutout to a distance of 35±5
mm.
7. Vacuum clean all dust particles and wipe
damaged area and surrounding area with
clean Lint-free cloth impregnated with
ethyl alcohol.
8. Prepare a laminate patch per PS
32.17.03, Class III, Type 1, Grade 1
(directions ±45°) from carbon fiber fabric
to match hole in laminate (four plies
thick).
9. Cut prepared laminate patch to match
cutout thickness and size, leaving a
maximum gap of 2 mm between filler
laminate and undamaged structure.
10. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
6-24
11. Add 15 to 25 g of micro balloons-glass
to the mixed epoxy resin. Continue
mixing until a homogeneous mass of
uniform viscosity is obtained, free of
lumps.
12. Apply mixture to laminate filler edges
and reworked damaged area edges and
bond laminate filler in place.
13. Cure for at least six hours at room
temperature.
14. Using 220 to 280 grit abrasive paper,
sand upper and lower surface until
laminate filler is flush with undamaged
structure.
15. Vacuum clean all dust particles from sand
and wipe damaged area and surrounding
area with clean Lint-free cloth
impregnated with ethyl alcohol.
16. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
17. Impregnate a large carbon fiber fabric,
on a plastic sheet, with epoxy resin/
hardener mixture.
18. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.
NOTE
A typical overlap of 25±5 mm shall
be maintained per each ply.
19. Cut five plies of impregnated fabric
(three for outer side and two for inner
side) as follows:
1) One ply 50±5 mm larger than
diameter of damage for outer skin side
(fiber direction ±45°)
2) One ply 100±5 mm larger than
diameter of damage for outer skin side
(fiber direction 0/90°)

3) One ply 150±5 mm larger than
diameter of damage for outer skin side
(fiber direction ±45°)
4) One ply 50±5 mm larger than
diameter of damage for inner skin side
(fiber direction 0/90°)
5) One ply 50±5 mm larger than
diameter of damage for inner skin side
(fiber direction ±45°).
20. Brush a thin layer of epoxy resin/
hardener on the repair area.
NOTE
Fiber direction of 0/90° ply shall
conform to structure longitudinal axis.
21. Peel off one plastic sheet from the ±45°
smallest ply and lay it on centre of the
damage from outer side, so it uniformly
overlaps the damage circumference. Peel
off the remaining plastic.
22. Peel off one plastic sheet from the 0/90°
medium ply and lay it on centre of the
damage from outer side, so it uniformly
overlaps the damage circumference. Peel
off the remaining plastic.
23. Peel off one plastic sheet from ±45°
largest ply and lay it on centre of the
damage from outer side, so it uniformly
overlaps the damage circumference. Peel
off the remaining plastic.
24. Lay peel ply on the repair plies, smooth
and impregnate.
25. Peel off one plastic sheet from the 0/90°
ply and lay it on centre of the damage
from inner side, so it uniformly overlaps
the damage circumference. Peel off the
remaining plastic.
26. Peel off one plastic sheet from ±45° ply
and lay it on centre of the damage from
inner side, so it uniformly overlaps the
damage circumference. Peel off the
remaining plastic.
U900/000/TM/E/323
27. Lay peel ply on the repair plies, smooth
and impregnate.
28. Cure for at least six hours at room
temperature and remove peel ply.
29. Prepare a Rohacell block 71 kg/m3 with
damaged stiffener shape to match
removed stiffener area.
30. Trim Rohacell block to damaged area
with maximum gap of 2 mm between
existing stiffener and Rohacell block.
31. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
32. Add 15 to 25 g of glass micro balloons
to the mixed epoxy resin. Continue
mixing until a homogenous mass of
uniform viscosity is obtained, free of
lumps.
33. Using a piece of thin sheet metal or a
spatula, apply resin mixture to Rohacell
block and structure.
34. Attach Rohacell block in place and cure
resin mixture at least six hours at room
temperature.
35. Using 80 to 100 grit abrasive paper
smooth, Rohacell block flush with
undamaged area.
36. Vacuum clean all dust particles and wipe
damaged area and surrounding area with
clean Lint-free cloth impregnated with
ethyl alcohol.
37. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
38. Impregnate carbon fiber fabric, on a
plastic sheet, with epoxy resin/hardener
mixture.
39. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.
6-25
U900/000/TM/E/323

40. Cut three plies of impregnated fabric at 43. Repeat step 20 with the two larger plies.
0/90° as follows:
44. Lay peel ply on the repair plies, smooth
1) One ply 50±5 mm larger than contour and impregnate.
of shaped stiffener.
45. Cure for at least six hours at room
2) One ply 100±5 mm larger than temperature and remove peel ply.
contour of shaped stiffener.
46. Prime and finish repair area as specified
3) One ply 150±5 mm larger than in Chapter 3.
contour of shaped stiffener.
47. Clean work area and remove remaining
41. Brush a thin layer of epoxy resin/ unused repair material.
hardener on the repair area.
48. Remove wrapping paper from work area
42. Peel off one plastic sheet from smaller and protective devices from all lines and
ply and lay it on centre of shaped electrical connectors.
stiffener, so it equally overlaps stiffener.
Peel off the remaining plastic sheet. 49. Check electrical connectors for epoxy
and carbon dust and clean with vacuum
cleaner and contact spray.

DIMENSION MAXIMUM REPAIRABLE DAMAGE SIZE

D MAX (mm) ....................................................... 200
d MIN (mm) .......................................................... 30

REPAIRABLE DAMAGE SIZE

Figure 6-4. Fuselage Laminate Structure - Repair of Damage in Laminate and Stiffener (Sheet 1)

6-26
 U900/000/TM/E/323

SECTION A-A

DAMAGED STRUCTURE REMOVAL

Figure 6-4. Fuselage Laminate Structure - Repair of Damage in Laminate and Stiffener (Sheet 2)

6-27
U900/000/TM/E/323

SECTION B-B

STIFFENER REMOVAL

Figure 6-4. Fuselage Laminate Structure - Repair of Damage in Laminate and Stiffener (Sheet 3)

6-28
 U900/000/TM/E/323

SECTION B-B (Sheet 3)

LAMINATE PLIES REPAIR

NOTE
Fiber direction of 0/90° ply shall
follow fuselage longitudinal direction.

SECTION C-C (Sheet 3)

SECTION B-B (Sheet 3)

ROHACELL BONDING

Figure 6-4. Fuselage Laminate Structure - Repair of Damage in Laminate and Stiffener (Sheet 4)

6-29
U900/000/TM/E/323

SECTION C-C (Sheet 3)

NOTE

Fiber direction of 0/90° ply shall follow fuselage longitudinal direction.

SECTION B-B (Sheet 3)

REPAIR PLIES

Figure 6-4. Fuselage Laminate Structure - Repair of Damage in Laminate and Stiffener (Sheet 5)

6-30
 U900/000/TM/E/323

6-9 FUSELAGE LAMINATE STRUC- 6-9.4 Safety Conditions

TURE - REPAIR OF DAMAGE TO
STIFFENER SKIN WITH NO DAM-
WARNING
AGE TO LAMINATE OUTER SKIN
(Figure 6-5)
· Ethyl alcohol is flammable.
Avoid eye and skin contact or
6-9.1 Equipment breathing of vapors. Protective
equipment consisting of goggles
1. High speed (15,000 to 20,000 rpm) router and gloves is required.
with diamond coated or solid carbide bit
2. Industrial goggles · Epoxy resin is toxic and
flammable. Use in well-ventilated
3. Respirator area only. Avoid eye and skin
4. Rubber gloves contact or breathing of vapors.
Protective equipment consisting
5. Spatula (or thin piece of metal sheet)
of goggles, gloves and respiratory
6. Vacuum cleaner. protection is required. Failure to
comply may result in injury or
6-9.2 Part Materials health problems to personnel.
1. Carbon fiber fabric, style 3K-70P
6-9.5 Repair Procedure
2. Micro balloons. glass eccospheres-
1G101 A. Evaluate damage and determine applicable
3. Rohacell WF 71 kg/m3 repair (paragraph 6-6).

4. Hardener, HY560 B. Prepare damaged area for repair as follows:

5. Epoxy resin, LY564-1.
1. Remove assemblies to allow access to
6-9.3 Auxiliary Materials and Dispos- repair area.
able Items
2. Vacuum clean all loose resin particles in
1. Lint-free cloth or lint free paper towels damaged area.
2. Contacts spray
CAUTION
3. Ethyl alcohol
This procedure requires sanding of
4. Masking tape
carbon fiber components. Resultant
5. 80 to 100 grit abrasive paper/cloth dust is an electrical conducting
6. 220 to 280 grit abrasive paper/cloth material which may cause electrical
short circuits. Protect all electrical
7. Plastic sheet: nylon, PVC, polyethylene equipment and components against
or PVA dust. Failure to comply may result
8. Wrapping paper (FED Spec. OU-P- in damage to equipment.
268E, No. 2)
3. Using wrapping paper wrap, electrical
9. Nylon fabric peel ply. boxes in area of damage. Protect all open
lines and electrical connectors.

6-31
U900/000/TM/E/323
CAUTION
Exercise care during routing to
prevent damage from adjacent
structure.
4. Rout with diamond coated or solid
carbide bit all damaged skin and core
around damage to a distance up to 10
mm. Check for minimum radius of 5 mm
at corners of damage.
5. Using 220 to 280 grit abrasive paper,
remove paint from undamaged area
around cutout to a maximum distance of
75 mm.
6. Vacuum clean all dust particles and wipe
damaged area and surrounding area with
clean Lint-free cloth impregnated with
ethyl alcohol.
7. Prepare a Rohacell block 71 kg/m3 with
damaged stiffener shape to match
removed stiffener area.
8. Trim Rohacell block to damaged area
with maximum gap of 3 mm between
existing stiffener and Rohacell block.
9. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
10. Add 15 to 25 g of glass micro balloons
to the mixed epoxy resin. Continue
mixing until a homogenous mass of
uniform viscosity is obtained, free of
lumps.
11. Using a piece of thin sheet metal or a
spatula, apply resin mixture both to
Rohacell block and structure.
12. Attach Rohacell block in place and cure
resin mixture at least six hours at room
temperature.
13. Using 80 to 100 grit abrasive paper,
smooth Rohacell block flush with
undamaged area.
6-32
14. Vacuum clean all dust particles and wipe
damaged area and surrounding area with
clean Lint-free cloth impregnated with
ethyl alcohol.
15. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
16. Impregnate carbon fiber fabric, on a
plastic sheet, with epoxy resin/hardener
mixture.
17. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.
18. Cut three plies of impregnated fabric as
follows:
1) One ply 50±5 mm larger than
diameter of damage (fiber direction
0/90°).
2) One ply 100±5 mm larger than
diameter of damage (fiber direction
±45°).
3) One ply 150±5 mm larger than
diameter of damage (fiber direction
0/90°).
19. Brush a thin layer of epoxy resin/
hardener on the repair area.
20. Peel off one plastic sheet from first 0/
90° smaller ply and lay it on centre of
damage, so it equally overlaps the
damage. Peel off the remaining plastic
sheet.
21. Peel off one plastic sheet from the ±45°
ply and lay it on centre of damage, so it
equally overlaps the damage. Peel off the
remaining plastic sheet.
22. Peel off one plastic sheet from 0/90°
larger ply and lay it on centre of damage,
so it equally overlaps the damage. Peel
off the remaining plastic sheet.
 U900/000/TM/E/323

23. Lay peel ply on the repair plies, smooth
and impregnate.
24. Cure for at least six hours at room
temperature and remove peel ply.
25. Prime and finish repair area as specified
in Chapter 3.
26. Clean work area and remove remaining
unused repair material.
27. Remove wrapping paper from work area
and protective devices from all lines and
electrical connectors.
28. Check electrical connectors for epoxy
and carbon dust and clean with vacuum
cleaner and contact spray.

DIMENSION MAXIMUM REPAIRABLE DAMAGE SIZE

D MAX (mm) ....................................................... 200
d MIN (mm) .......................................................... 30

Figure 6-5. Fuselage Laminate Structure - Repair of Damage to Stiffener Skin with no Damage
to Laminate Outer Skin (Sheet 1)

6-33
U900/000/TM/E/323

Figure 6-5. Fuselage Laminate Structure - Repair of Damage to Stiffener Skin with no Damage
to Laminate Outer Skin (Sheet 2)

6-34
 U900/000/TM/E/323

6-10 FUSELAGE SANDWICH STRUC- 6-10.4 Safety Conditions

TURE - REPAIR OF DENTS AND
CAVITIES (Figure 6-6) WARNING
6-10.1 Equipment · Ethyl alcohol is flammable.
Avoid eye and skin contact or
1. High speed (15,000 to 20,000 rpm) router breathing of vapors. Protective
with diamond coated or solid carbide bit equipment consisting of goggles
and gloves is required.
2. Face shield
3. Industrial goggles · Epoxy resin and adhesive EA
9309.1NA are toxic and flammable.
4. Respirator
Use in well-ventilated area only. Avoid
5. Rubber gloves eye and skin contact or breathing of
6. Spatula (or thin piece of metal sheet) vapors. Protective equipment
consisting of goggles, gloves and
7. Vacuum cleaner respiratory protection is required.
Failure to comply may result in injury
6-10.2 Part Materials
or health problems to personnel.
1. Carbon fiber fabric Style 3K-70P
6-10.5 Repair Procedure
2. Epoxy adhesive, Hysol EA 9309.1NA
A. Evaluate damage and determine applicable
3. Hardener, HY560
repair (paragraphs 6-6). (If damage exceeds
4. Milled glass fibers, 1/32 to 1/8" allowable limits, repair per paragraph 6-12)
5. Epoxy resin, LY564-1. B. Repair as follows:
6-10.3 Auxiliary Materials and Dispos- 1. Remove assemblies to allow access to
able Items repair area.
2. Vacuum clean all loose resin particles from
1. Lint-free cloth or lint free paper towels
between plies located in damaged area.
2. Contacts spray
3. Ethyl alcohol CAUTION
4. Masking tape This procedure requires sanding of carbon
fiber components. Resultant dust is an
5. 80 to100 grit abrasive paper/cloth electrical conducting material which may
6. 220 to280 grit abrasive paper/cloth cause electrical short circuits. Protect all
electrical equipment and components
7. Plastic sheet: nylon, PVC, polyethylene
against dust. Failure to comply may result
or PVA
in damage to equipment.
8. Wrapping paper (FED Spec. OU-P-
268E, No. 2) 3. Using wrapping paper, wrap electrical
boxes in area of damage. Protect all open
9. Nylon fabric peel ply. lines and electrical connectors.
4. Using 220 to 280 grit abrasive paper,
remove paint from undamaged area to a
distance of 30 mm around damage.

6-35
U900/000/TM/E/323

NOTE 9. Using spatula (or thin piece of metal sheet)

After area has been thoroughly cleaned
with ethyl alcohol, the skin shall be
checked for cracks and damage.
5. Vacuum all dust particles and wipe
damaged and surrounding area with Lint-
free cloth impregnated with ethyl alcohol.
6. Check cleaned area for cracks and damage.
7. Dry milled glass fibers in an oven at 110° for
1 to 2 hours prior to mixture with adhesive.
NOTE
Only small quantities up to 100 g
shall be mixed at one time.
8. Prepare a mixture of EA 9309.1NA
adhesive and milled glass fibers. Use long
and small strokes and mix thoroughly
until homogeneous mass of uniform
viscosity is obtained, free of lumps.
fill cavity or dent with mixture of EA
9309.1NA adhesive and milled glass fibers.
10. Cure at least six hours at room temperature.
11. Using Lint-free cloth impregnated with
ethyl alcohol thoroughly wipe area.
12. Prime and finish repair area as specified
in Chapter 3.
13. Clean work area and remove remaining
unused repair material.
14. Remove wrapping paper from work area
and protective devices from all lines and
electrical connectors.
15. Check electrical connectors for epoxy
and carbon dust and clean with vacuum
cleaner and contact spray.

REPAIRABLE DAMAGE SIZE

DAMAGE REPAIR
Figure 6-6. Fuselage Sandwich Structure - Repair of Dents and Cavities
6-36
 U900/000/TM/E/323

6-11 DAMAGE TO PLANE SURFACE 6-11.4 Safety Conditions

AREAS OF COWLINGS, FAIRING,
COVERS, DOORS AND ACCESS WARNING
PANELS (DAMAGE TO LAMI-
NATE STRUCTURE - A
THROUGH HOLE) (Figure 6-7) · Ethyl alcohol is flammable.
Avoid eye and skin contact or
breathing of vapors. Protective
6-11.1 Equipment equipment consisting of goggles
and gloves is required.
1. Face shield
2. Industrial goggles · Epoxy resin is toxic and
flammable. Use in well-ventilated
3. Respirator area only. Avoid eye and skin
4. Rubber gloves contact or breathing of vapors.
Protective equipment consisting
5. Spatula (or thin piece of metal sheet)
of goggles, gloves and respiratory
6. Steel ruler protection is required. Failure to
7. Vacuum cleaner. comply may result in injury or
health problems to personnel.
6-11.2 Part Materials

1. Carbon fiber fabric Style 3K-70P

· Micro balloons may be harmful to the
respiratory system. Avoid breathing of
particles. Respiratory protection
2. Micro balloons glass Eccospheres-
against fine dust is required. Failure
1G101
to comply may result in injury or health
3. Hardener, HY560 problems to personnel.
4. Milled glass fibers 1/32 to 1/8 in
6-11.5 Repair Procedure
5. Epoxy resin, LY564-1.
A. Evaluate damage and determine applicable
6-11.3 Auxiliary Materials and Dispos-
repair (paragraph 6-6).
able Items
B. Repair as follows:
1. Lint-free cloth or lint free paper towels
1. Remove assemblies to allow access to
2. Contacts spray
repair area.
3. Ethyl alcohol
2. Vacuum clean all loose resin particles in
4. Masking tape damaged area.
5. 80 to 100 grit abrasive paper/cloth
6. 220 to 280 grit abrasive paper/cloth CAUTION
7. Plastic sheet: nylon, PVC, polyethylene This procedure requires sanding of carbon
or PVA fiber components. Resultant dust is an
electrical conducting material which may
8. Wrapping paper (FED Spec. OU-P-
cause electrical short circuits. Protect all
268E, No. 2).
electrical equipment and components
against dust. Failure to comply may result
in damage to equipment.

6-37
U900/000/TM/E/323
3. Using wrapping paper wrap, electrical
boxes in area of damage. Protect all open
lines and electrical connectors.
4. Rout with diamond coated or solid bit carbide
all damaged skin and core around damage to
a distance up to 5 mm. Check for minimum
radius of 5 mm at corners of damage.
5. Using 220 to 280 grit abrasive paper,
remove paint from undamaged area to a
maximum distance of 25 mm for filler
thickness of four plies and 50 mm for
filler thickness of six plies (Table 6-4).
6. Vacuum clean all dust particles and wipe
damaged area and surrounding area with
clean Lint-free cloth impregnated with
ethyl alcohol.
7. Prepare a ply laminate patch per PS
32.17.03, Class III, Type 1, Grade 1
(directions ±45°) from carbon fiber fabric
to match hole in laminate (for number
of plies and direction, see Table 6-4).
8. Cut prepared laminate patch to match
cutout thickness and size, leaving a
maximum gap of 2 mm between filler
laminate and undamaged structure.
9. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
10. Add 15 to 25 g of micro balloons-glass to
the mixed epoxy resin. Continue mixing
until a homogeneous mass of uniform
viscosity is obtained, free of lumps.
11. Apply mixture to laminate filler edges
and reworked damaged area edges and
bond laminate filler in place.
12. Cure for at least six hours at room
temperature.
13. Using 220 to 280 grit abrasive paper, shape
upper and lower surface until laminate filler
is flush with undamaged structure.
14. Vacuum clean all dust particles from sand
and wipe damaged area and surrounding
area with clean Lint-free cloth
impregnated with ethyl alcohol.
6-38
15. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
16. Impregnate a large carbon fiber fabric,
on a plastic sheet, with epoxy resin/
hardener mixture.
17. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.
18. Cut five plies of impregnated fabric
(three for outer side and two for inner
side) as follows:
1) One ply 50±5 mm larger than
diameter of damage for outer skin side
(fiber direction ±45°).
2) One ply 100±5 mm larger than
diameter of damage for outer skin side
(fiber direction 0/90°).
3) One ply 150±5 mm larger than
diameter of damage for outer skin side
(fiber direction ±45°).
4) One ply 50±5 mm larger than
diameter of damage for inner skin side
(fiber direction 0/90°).
5) One ply 50±5 mm larger than
diameter of damage for inner skin side
(fiber direction ±45°).
19. Brush a thin layer of epoxy resin/hardener
on the repair area (on both sides).
NOTE
Fiber direction of 0/90° ply shall
conform to structure longitudinal axis.
20. Peel off one plastic sheet from ±45°
smaller ply and lay it on centre of the
damage from outer side, so it uniformly
overlaps the damage circumference. Peel
off the remaining plastic.
21. Peel off one plastic sheet from 0/90°
larger ply and lay it on centre of the
damage from outer side, so it uniformly
overlaps the damage circumference. Peel
off the remaining plastic.
 U900/000/TM/E/323

22. Peel off one plastic sheet from ±45°
larger ply and lay it on centre of the
damage from outer side, so it uniformly
overlaps the damage circumference. Peel
off the remaining plastic.
23. Lay peel ply on the repair plies, smooth
and impregnate.
24. Peel off one plastic sheet from 0/90°
smaller ply and lay it on centre of the
damage from inner side, so it uniformly
overlaps the damage circumference. Peel
off the remaining plastic.
25. Peel off one plastic sheet from ±45°
smaller ply and lay it on centre of the
damage from inner side, so it uniformly
overlaps the damage circumference. Peel
off the remaining plastic.
26. Lay peel ply on the repair plies, smooth
and impregnate.
27. Cure for at least six hours at room
temperature and remove peel ply.
28. Prime and finish repair area as specified
in Chapter 3.
29. Clean work area and remove remaining
unused repair material.
30. Remove wrapping paper from work area
and protective devices from all lines and
electrical connectors.
31. Check electrical connectors for epoxy
and carbon dust and clean with vacuum
cleaner and contact spray.

Table 6-3. Filler Laminate Number of Plies

P/N DESCRIPTION FILLER PLIES

AND DIRECTION

JIM1110450-501 ............ FORWARD UPPER ENGINE COVER .................... 4±45°

JIM1110451-501 ............ FORWARD LOWER ENGINE COVER .................. 4±45°
JIM1110452-501 ............ LEFT FWD ENGINE ACCESS PANEL .................. 4±45°
JIM1110452-502 ............ RIGHT FWD ENGINE ACCESS PANEL ................ 4±45°
JIM1110320-501 ............ FWD SCOOP ........................................................... 6±45°
JIM1110300-519 ............ FWD COVER .......................................................... 6±45°
JIM1110200-505 ............ FWD DOOR ............................................................ 6±45°
JIM1110301-509 ............ PAYLOAD COVER ................................................. 6±45°
JIM1110303-501 ............ PARACHUTE COVER ............................................ 6±45°
JIM1110304-507 ............ AFT COVER ........................................................... 6±45°
JIM1110201-509 ............ LEFT AFT DOOR ................................................... 6±45°
JIM1110201-506 ............ RIGHT AFT DOOR ................................................. 6±45°
JIM1110450-503 ............ AFT UPPER ENGINE COVER ............................... 4±45°
JIM1110451-503 ............ AFT LOWER ENGINE COVER.............................. 4±45°
JIM1110452-503 ............ AFT LOWER ACCESS PANEL, LEFT ................... 4±45°
JIM1110452-504 ............ AFT LOWER ACCESS PANEL, RIGHT ................. 4±45°

6-39
U900/000/TM/E/323

DIMENSION MAXIMUM REPAIRABLE DAMAGE SIZE

D MAX (mm) ....................................................... 100
d MIN (mm) .......................................................... 30

REPAIRABLE DAMAGE SIZE

NOTE

Fiber direction of 0/90° ply shall follow fuselage longitudinal direction.

Figure 6-7. Damage to Plane Surface Areas of Cowlings, Fairing, Covers, Doors and Access
Panels (Damage to Laminate Structure - a Through Hole) (Sheet 1)

6-40
 U900/000/TM/E/323

SECTION A-A
REMOVAL OF DAMAGED STRUCTURE

FILLER LAMINATE BONDING

Figure 6-7. Damage to Plane Surface Areas of Cowlings, Fairing, Covers, Doors and Access
Panels (Damage to Laminate Structure - a Through Hole) (Sheet 2)

6-41
U900/000/TM/E/323

6-12 REPAIR OF DAMAGE TO CURVED 6-12.4 Safety Conditions

LAMINATE STRUCTURE -
A THROUGH HOLE (Figure 6-8)
WARNING
6-12.1 Equipment
· Ethyl alcohol is flammable.
Avoid eye and skin contact or
1. High speed (15,000 to 20,000 rpm) router breathing of vapors. Protective
with diamond coated or solid carbide bit equipment consisting of goggles
2. Face shield and gloves is required.
3. Industrial goggles
4. Respirator · Epoxy resin and adhesive EA
9309.1NA are toxic and
5. Rubber gloves flammable. Use in well-ventilated
area only. Avoid eye and skin
6. Spatula (or thin piece of metal sheet)
contact or breathing of vapors.
7. Vacuum cleaner. Protective equipment consisting
of goggles, gloves and respiratory
6-12.2 Part Materials protection is required. Failure to
comply may result in injury or
1. Carbon fiber fabric Style 3K-70P
health problems to personnel.
2. Epoxy adhesive, Hysol EA 9309.1NA
3. Hardener, HY560 6-12.5 Repair Procedure

4. Milled glass fibers. 1/32 to 1/8 in A. Evaluate damage and determine applicable
5. Epoxy resin, LY564-1. repair (paragraph 6-6).

6-12.3 Auxiliary Materials and Dispos- B. Repair as follows:

able Items
1. Remove assemblies to allow access to
1. Lint-free cloth or lint free paper towels repair area.
2. Contacts spray
2. Vacuum clean all loose resin particles
3. Ethyl alcohol from between plies in damaged area.
4. Masking tape
CAUTION
5. Tape, Aluminium
6. 80 to 100 grit abrasive paper/cloth This procedure requires sanding of
carbon fiber components. Resultant
7. 220 to 280 grit abrasive paper/cloth dust is an electrical conducting
8. Plastic sheet: nylon, PVC, polyethylene material which may cause electrical
or PVA short circuits. Protect all electrical
equipment and components against
9. Wrapping paper (FED Spec. OU-P-
dust. Failure to comply may result
268E, No. 2)
in damage to equipment.
10. Nylon fiber peel ply.
3. Using wrapping paper, wrap electrical
boxes in area of damage. Protect all open
lines and electrical connectors.
6-42

CAUTION
Exercise care during routing to
prevent damage from adjacent
structure.
4. Rout with diamond coated or solid
carbide bit all damaged skin around
damage to a distance up to 5 mm. Check
for minimum radius of 5 mm at corners
of damage.
5. Using 220 to 280 grit abrasive paper,
remove paint from undamaged area to a
distance of 60±5 mm for repair of inner
surface and 35±5 mm for repair of outer
surface.
6. Vacuum all dust particles and wipe
damaged and surrounding area with a
rag/towel impregnated with ethyl
alcohol.
7. Apply an aluminium tape to inner surface
around damaged area.
8. Dry milled glass fibers in an oven at 110°
for 1 to 2 hours prior to mixture with
adhesive.
NOTE
Only small quantities up to 250 g
shall be mixed at one time.
9. Prepare a mixture of EA 9309.1NA
adhesive and milled glass fibers. Use
long and small strokes and mix
thoroughly until homogeneous mass of
uniform viscosity is obtained, free of
lumps.
10. Using spatula (or thin piece of metal
sheet) fill cavity with mixture of EA
9309.1NA adhesive and milled glass
fibers.
11. Cure at least six hours at room
temperature.
U900/000/TM/E/323
12. Using 80 to 100 grit abrasive paper, sand
smooth area to prepare for bonding
ensuring filling material is flush with
remaining undamaged area. Ensure
external contour of the repair is smooth
and streamline with the undamaged
structure.
13. Vacuum clean all dust particles from
sanded area.
14. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
15. Impregnate carbon fiber fabric, on a
plastic sheet, with epoxy resin/hardener
mixture.
16. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.
17. Cut three plies of impregnated fabric
(one for outer side and two for inner side)
as follows:
1) One ply 50±5 mm larger than
diameter of damage for outer skin side
(fiber direction ±45°).
2) One ply 50±5 mm larger than
diameter of damage for inner skin side
(fiber direction ±45°).
3) One ply 100±5 mm larger than
diameter of damage for inner skin side
(fiber direction ±45°).
18. Brush a thin layer of epoxy resin/
hardener on external side of the repair
area.
19. Peel off one plastic sheet from outer ply
and lay it on centre of the damage, so it
uniformly overlaps the damage
circumference. Peel off the remaining
plastic sheet. Lay and impregnate peel
ply.
20. Cure for at least six hours at room
temperature and remove peel ply.
6-43
U900/000/TM/E/323

21. Remove aluminium tape from inner
surface. Clean the leftover masking tape
adhesive and brush a thin layer of epoxy
resin/hardener on internal side of the
repair area.
22. Peel off one plastic sheet from smaller
inner ply and lay it on centre of the
damage, so it uniformly overlaps the
damage circumference. Peel off the
remaining plastic sheet.
23. Peel off one plastic sheet from larger
inner ply and lay it on centre of the
damage, so it uniformly overlaps the
damage circumference. Peel off the
remaining plastic sheet. Lay and
impregnate peel ply.
24. Cure for at least six hours at room
temperature and remove peel ply.
25. Prime and finish repair area as specified
in Chapter 3.
26. Clean work area and remove remaining
unused repair material.
27. Remove wrapping paper from work area
and protective devices from all lines and
electrical connectors.
28. Check electrical connectors for epoxy
and carbon dust and clean with vacuum
cleaner and contact spray.

DIMENSION MAXIMUM REPAIRABLE DAMAGE SIZE

D MAX (mm) .......................................................... 80*
d MIN (mm) ............................................................ 30

REPAIRABLE DAMAGE SIZE

NOTE

* Maximum repairable damage size depends, also, on complexity of part geometry.

The capability to restore the original aerodynamic contour of the part is mandatory,
performing the repair as defined on this chapter, without using production tools.

Figure 6-8. Repair of Damage to Curved Laminate Structure - a Through Hole (Sheet 1)

6-44
 U900/000/TM/E/323

DAMAGE REMOVAL

DAMAGE FILLING

Figure 6-8. Repair of Damage to Curved Laminate Structure - a Through Hole (Sheet 2)

6-45
U900/000/TM/E/323

6-13 FUSELAGE LAMINATE STRUC- 6-13.4 Safety Conditions

TURE - REPAIR OF DAMAGE TO
EDGE ZONES OF SKIN, COVERS WARNING
AND DOORS (Figure 6-9)
· Ethyl alcohol is flammable.
Avoid eye and skin contact or
6-13.1 Equipment
breathing of vapors. Protective
1. High speed (15,000 to 20,000 rpm) router equipment consisting of goggles
with diamond coated or solid carbide bit and gloves is required.

2. Face shield
3. Industrial goggles
· Epoxy resin is toxic and
flammable. Use in well-ventilated
area only. Avoid eye and skin
4. Respirator contact or breathing of vapors.
5. Rubber gloves Protective equipment consisting
of goggles, gloves and respiratory
6. Spatula (or thin piece of metal sheet)
protection is required. Failure to
7. Vacuum cleaner. comply may result in injury or
health problems to personnel.
6-13.2 Part Materials

1. Carbon fiber fabric Style 3K-70P · Micro balloons may be harmful

to the respiratory system. Avoid
2. Micro balloons. glass, Eccospheres- breathing of particles. Respiratory
1G101 protection against fine dust is
required. Failure to comply may
3. Hardener, HY560
result in injury or health problems
4. Epoxy resin, LY564-1. to personnel.

6-13.3 Auxiliary Materials and Dispos- 6-13.5 Repair Procedure

able Items
A. Evaluate damage and determine applicable
1. Rag/towel or lint free paper towels repair (paragraph 6-5).
2. Contacts spray
B. Repair as follows:
3. Ethyl alcohol
1. Remove assemblies to allow access to
4. Masking tape repair area.
5. 80 to 100 grit abrasive paper/cloth 2. Vacuum clean all loose resin particles in
6. 220 to 280 grit abrasive paper/cloth damaged area.

7. Plastic sheet: nylon, PVC, polyethylene CAUTION

or PVA
This procedure requires sanding of carbon
8. Wrapping paper (FED Spec. OU-P- fiber components. Resultant dust is an
268E, No. 2) electrical conducting material which may
9. Nylon fiber peel ply. cause electrical short circuits. Protect all
electrical equipment and components
against dust. Failure to comply may result
in damage to equipment.

6-46

3. Using wrapping paper, wrap electrical
boxes in area of damage. Protect all open
lines and electrical connectors.
4. Rout with diamond coated or solid
carbide bit all damaged skin and core
around damage to a distance up to 3 mm.
Check for minimum radius of 5 mm at
corners of damage.
5. Using 220 to 280 grit abrasive paper,
remove paint from undamaged area to a
maximum distance of 30 mm.
6. Vacuum clean all dust particles and wipe
damaged area and surrounding area using
clean rag/cloth impregnated with ethyl
alcohol.
7. Prepare a ply laminate patch per PS
32.17.03, Class III, Type 1, Grade 1
(directions ±45°) from carbon fiber fabric
to match hole in laminate (for number
of plies and direction, see Table 6-6).
8. Cut prepared laminate patch to match
cutout thickness and size, leaving a
maximum gap of 2 mm between filler
laminate and undamaged structure.
9. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
10. Add 15 to 25 g of micro balloons-glass
to the mixed epoxy resin. Continue
mixing until a homogeneous mass of
uniform viscosity is obtained, free of
lumps.
11. Apply mixture to laminate filler edge and
reworked damaged area edge and bond
laminate filler in place.
12. Cure for at least six hours at room
temperature.
13. Using 220 to 280 grit abrasive paper,
shape upper and lower surface until
laminate filler is flush with undamaged
structure.
U900/000/TM/E/323
14. Vacuum clean all dust particles from sand
and wipe damaged area and surrounding
area with clean rag/cloth impregnated
with ethyl alcohol.
15. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
16. Impregnate a large carbon fiber fabric,
on a plastic sheet, with epoxy resin/
hardener mixture.
17. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.
18. Cut two plies of impregnated fabric as
follows:
1) One ply 50±5 mm larger than length
of damage and 5 to 10 mm larger than
width of damage for outer skin side
(fiber direction 0/90°).
2) One ply 50±5 mm larger than length
of damage and 5 to 10 mm larger than
width of damage for inner skin side
(fiber direction 0/90°).
19. Brush a thin layer of epoxy resin/
hardener on both sides of the repair area.
NOTE
Fiber direction of 0/90° ply shall
conform to structure longitudinal
axis.
20. Peel off one plastic sheet from outer ply
and lay it on centre of the damage from
outer side, so it uniformly overlaps the
damage circumference. Peel off the
remaining plastic.
21. Lay peel ply on the repair ply, smooth
and impregnate.
22. Peel off one plastic sheet from inner ply
and lay it on centre of the damage from
inner side, so it uniformly overlaps the
damage circumference. Peel off the
remaining plastic.
6-47
U900/000/TM/E/323

23. Lay peel ply on the repair ply, smooth
and impregnate.
24. Cure for at least six hours at room
temperature and remove peel ply.
25. Prime and finish repair area as specified
in Chapter 3.
26. Clean work area and remove remaining
unused repair material.
27. Remove wrapping paper from work area
and protective devices from all lines and
electrical connectors.
28. Check electrical connectors for epoxy
and carbon dust and clean with vacuum
cleaner and contact spray.

Table 6-4. Repairable Damage Size

PANEL P/N DESCRIPTION LMAX* WMAX* dMAX*

BHT1110450-501...... FORWARD UPPER ENGINE COVER ...... 100 ........ 20.......... 30

JIM1110451-501 ....... FORWARD LOWER ENGINE COVER..... 100 ........ 20.......... 30
JIM1110450-503 ....... AFT UPPER ENGINE COVER .................. 100 ........ 20.......... 30
13490111-501 ........... AFT LOWER ENGINE COVER ................ 100 ........ 20.......... 30
JIM1110452-501 ....... FWD LOWER ACCESS PANEL, LEFT .... 100 ........ 20.......... 30
JIM1110452-502 ....... FWD LOWER ACCESS PANEL, RIGHT .. 100 ........ 20.......... 30
JIM1110452-503 ....... AFT LOWER ACCESS PANEL, LEFT ...... 100 ........ 20.......... 30
JIM1110452-504 ....... AFT LOWER ACCESS PANEL, RIGHT ... 100 ........ 20.......... 30
13490110-501 ........... SCOOP, FWD ............................................ 100 ........ 10.......... 30
13490106-501 ........... FWD COVER ............................................ 100 ........ 10.......... 30
JIM1110200-505 ....... FWD DOOR............................................... 100 ........ 10.......... 30
JIM1110301-509 ....... PAYLOAD COVER ................................... 100 ........ 10.......... 30
JIM1110303-501 ....... PARACHUTE COVER .............................. 100 ........ 10.......... 30
JIM1110304-507 ....... AFT COVER .............................................. 100 ........ 10.......... 30
JIM1110201-505 ....... LEFT AFT DOOR ...................................... 100 ........ 10.......... 30
JIM1110201-506 ....... RIGHT AFT DOOR ................................... 100 ........ 10.......... 30

* Refer to Figure 6-9, sheet 1.

6-48
 U900/000/TM/E/323

Table 6-5. Filler Laminate Number of Plies and Orientation

P/N DESCRIPTION FILLER PLIES

AND DIRECTION

BHT1110450-501 ........... FORWARD UPPER ENGINE COVER .................... 10±45°

JIM1110451-501 ............ FORWARD LOWER ENGINE COVER .................. 10±45°
13490111-501 ................ AFT UPPER ENGINE COVER ............................... 10±45°
JIM1110451-503 ............ AFT LOWER ENGINE COVER.............................. 10±45°
JIM1110452-501 ............ FWD LOWER ACCESS PANEL, LEFT .................. 12±45°
JIM1110452-502 ............ FWD LOWER ACCESS PANEL, RIGHT ............... 12±45°
JIM1110452-503 ............ AFT LOWER ACCESS PANEL, LEFT ................... 12±45°
JIM1110452-504 ............ AFT LOWER ACCESS PANEL, RIGHT ................. 12±45°
BHT1110450-501 ........... SCOOP, FWD .......................................................... 6±45°
13490111-501 ................ FWD COVER .......................................................... 6±45°
JIM1110200-505 ............ FWD DOOR ............................................................ 6±45°
JIM1110301-509 ............ PAYLOAD COVER ................................................. 6±45°
JIM1110303-501 ............ PARACHUTE COVER ............................................ 6±45°
JIM1110304-507 ............ AFT COVER ........................................................... 6±45°
JIM1110201-505 ............ LEFT AFT DOOR ................................................... 6±45°
JIM1110201-506 ............ RIGHT AFT DOOR ................................................. 6±45°

NOTE

· For repairable damage size, see

Table 6-5.

· In case of edge chipped or

delaminated, damage is
negligible if L<30 mm, W<10
mm and d<20 mm.

Figure 6-9. Fuselage Laminate Structure - Repair of Damage to Edge Zones of Skin, Covers and
Doors (Sheet 1)
6-49
U900/000/TM/E/323

Figure 6-9. Fuselage Laminate Structure - Repair of Damage to Edge Zones of Skin, Covers and
Doors (Sheet 2)

6-50
 U900/000/TM/E/323

6-14 REPAIR OF DAMAGE TO DOORS 6-14.4 Safety Conditions

AND ACCESS PANELS INCLUD-
ING DAMAGE TO CORE AREA WARNING
(Figure 6-10)

6-14.1 Equipment
· Ethyl alcohol is flammable.
Avoid eye and skin contact or
breathing of vapors. Protective
1. High speed (15,000 to 20,000 rpm) router equipment consisting of goggles
with diamond coated or solid carbide bit and gloves is required.
2. Face shield · Epoxy resin is toxic and
flammable. Use in well-ventilated
3. Industrial goggles
area only. Avoid eye and skin
4. Respirator contact or breathing of vapors.
5. Rubber gloves Protective equipment consisting
of goggles, gloves and respiratory
6. Spatula (or thin piece of metal sheet) protection is required. Failure to
7. Vacuum cleaner. comply may result in injury or
health problems to personnel.
6-14.2 Part Materials

1. Carbon fiber fabric Style 3K-70P

· Micro balloons may be harmful
to the respiratory system. Avoid
breathing of particles. Respiratory
2. Micro balloons glass, Eccospheres- protection against fine dust is
1G101 required. Failure to comply may
3. Rohacell WF 71 kg/m3 result in injury or health problems
to personnel.
4. Hardener, HY560
5. Epoxy resin, LY564-1. 6-14.5 Repair Procedure

6-14.3 Auxiliary Materials and Dispos- A. Evaluate damage and determine applicable
able Items repair (paragraph 6-6).
1. Lint-free cloth or lint free paper towels B. Repair as follows:
2. Contacts spray 1. Remove assemblies to allow access to
3. Ethyl alcohol repair area.

4. Masking tape 2. Vacuum clean all loose resin particles in

5. 80 to 100 grit abrasive paper/cloth
6. 220 to 280 grit abrasive paper/cloth
7. Plastic sheet: nylon, PVC, polyethylene
or PVA
8. Wrapping paper (FED, Spec. OU-P-
268E, No. 2)
9. Nylon fabric peel ply.
damaged area.
CAUTION
This procedure requires sanding of carbon
fiber components. Resultant dust is an
electrical conducting material which may
cause electrical short circuits. Protect all
electrical equipment and components
against dust. Failure to comply may result
in damage to equipment.

6-51
U900/000/TM/E/323
3. Using wrapping paper, wrap electrical
boxes in area of damage. Protect all open
lines and electrical connectors.
CAUTION
Exercise care during routing to
prevent damage from adjacent
structure.
4. Rout with diamond coated or solid
carbide bit all damaged skin and core
around damage to a distance up to 10
mm. Check for minimum radius of 5 mm
at corners of damage.
5. Rout with diamond coated or solid
carbide bit inner skin and core another
30 mm around previous cutout. Check
for minimum radius of 5 mm at corners
of damage.
6. Using 220 to 280 grit abrasive paper,
remove paint around damage edges to a
maximum distance of 30 mm.
7. Vacuum clean all dust particles and wipe
damaged area and surrounding area with
clean rag/towel impregnated with ethyl
alcohol.
8. Prepare a ply laminate patch per PS
32.17.03, Class III, Type 1, Grade 1
(directions ±45°) from carbon fiber fabric
to match hole in laminate.
9. Cut prepared laminate patch to match
cutout thickness and size, leaving a
maximum gap of 2 mm between filler
laminate and undamaged structure.
10. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
11. Add 15 to 25 g of micro balloons-glass
to the mixed epoxy resin. Continue
mixing until a homogeneous mass of
uniform viscosity is obtained, free of
lumps.
6-52
12. Apply mixture to laminate filler edges
and reworked damaged area edges and
bond laminate filler in place.
13. Cure for at least six hours at room
temperature.
14. Using 220 to 280 grit abrasive paper,
shape upper and lower surface until
laminate filler is flush with undamaged
structure.
15. Vacuum clean all dust particles from sand
and wipe damaged area and surrounding
area with clean Lint-free cloth
impregnated with ethyl alcohol.
16. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
17. Impregnate a large carbon fiber fabric,
on a plastic sheet, with epoxy resin/
hardener mixture.
18. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.
19. Cut four plies of impregnated fabric (two
for outer side and two for inner side) as
follows:
1) Two plies 50±5 mm larger than
diameter of damage for outer skin side
(fiber direction ±45°).
2) Two plies 50±5 mm larger than
diameter of damage for inner skin side
(fiber direction ±45°).
20. Brush a thin layer of epoxy resin/
hardener on both sides of the repair area.
NOTE
Fiber direction of 0/90° ply shall
conform to structure longitudinal
axis.

21. Peel off one plastic sheet from first inner
ply and lay it on centre of the damage
from inner side, so it uniformly overlaps
the damage circumference. Peel off the
remaining plastic.
22. Peel off one plastic sheet from second
inner ply and lay it on centre of the
damage from inner side, so it uniformly
overlaps the damage circumference. Peel
off the remaining plastic.
23. Lay peel ply on the repair plies, smooth
and impregnate.
24. Peel off one plastic sheet from first outer
ply and lay it on centre of the damage
from outer side, so it uniformly overlaps
the damage circumference. Peel off the
remaining plastic.
25. Peel off one plastic sheet from second
outer ply and lay it on centre of the
damage from outer side, so it uniformly
overlaps the damage circumference. Peel
off the remaining plastic.
26. Lay peel ply on the repair plies, smooth
and impregnate.
27. Cure for at least six hours at room
temperature and remove peel ply.
28. Prepare a Rohacell block 71 kg/m3 , 10
mm thick.
29. Trim Rohacell block to damaged area
with maximum gap of 2 mm between
routed structure and Rohacell block.
30. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
31. Add 15 to 25 g of glass micro balloons
to the mixed epoxy resin. Continue
mixing until a homogenous mass of
uniform viscosity is obtained, free of
lumps.
32. Using a piece of thin sheet metal or a
spatula, apply resin mixture both to
Rohacell block and structure.
U900/000/TM/E/323
33. Attach Rohacell block in place and cure
resin mixture at least six hours at room
temperature.
34. Using 220 to 280 grit abrasive paper,
smooth Rohacell block flush with
undamaged area.
35. Vacuum clean all dust particles and wipe
damaged area and surrounding area using
clean Lint-free cloth impregnated with
ethyl alcohol.
36. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
37. Impregnate carbon fiber fabric, on a
plastic sheet, with epoxy resin/hardener
mixture.
38. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.
39. Cut two plies of impregnated fabric as
follows:
1) One ply 50±5 mm larger than contour
of Rohacell (fiber direction 0°/90°).
2) One ply 50±5 mm larger than contour
of Rohacell (fiber direction 0°/90°).
40. Brush a thin layer of epoxy resin/
hardener on the repair area.
41. Peel off one plastic sheet from first ply
and lay it on centre of the damage, so it
uniformly overlaps the damage
circumference. Peel off the remaining
plastic sheet.
42. Peel off one plastic sheet from second
ply and lay it on centre of the damage,
so it uniformly overlaps the damage
circumference. Peel off the remaining
plastic sheet.
43. Lay peel ply on the repair plies, smooth
and impregnate.
6-53
U900/000/TM/E/323

44. Cure for at least six hours at room
temperature and remove peel ply.
45. Prime and finish repair area as specified
in Chapter 3.
46. Clean work area and remove remaining
unused repair material.
47. Remove wrapping paper from work area
and protective devices from all lines and
electrical connectors.
48. Check electrical connectors for epoxy
and carbon dust and clean with vacuum
cleaner and contact spray.

DIMENSION MAXIMUM REPAIRABLE DAMAGE SIZE

D MAX (mm) .......................................................... 100
d MIN (mm) ............................................................ 30

REPAIRABLE DAMAGE SIZE

STIFFENER REPAIR
Figure 6-10. Repair of Damage to Doors and Access Panels Including Damage to Core Area (Sheet 1)

6-54
 U900/000/TM/E/323

Figure 6-10. Repair of Damage to Doors and Access Panels Including Damage to Core Area (Sheet 2)

6-55
U900/000/TM/E/323

6-15 WING AND TAIL ASSEMBLIES -

REPAIR OF DAMAGE TO SUR- WARNING
FACE CONTOUR WITH NO BRO-
KEN SKIN (Figure 6-11) · Epoxy resin is toxic and
flammable. Use in well-ventilated
6-15.1 Equipment area only. Avoid eye and skin
contact or breathing of vapors.
1. Face shield Protective equipment consisting
of goggles, gloves and respiratory
2. Industrial goggles protection is required. Failure to
3. Respirator comply may result in injury or
health problems to personnel.
4. Rubber gloves
5. Spatula (or thin piece of metal sheet) · Micro balloons may be harmful
to the respiratory system. Avoid
6. Vacuum cleaner. breathing of particles. Respiratory
protection against fine dust is
6-15.2 Part Materials required. Failure to comply may
result in injury or health problems
1. Hardener, HY560 to personnel.
2. Micro balloons glass, Eccospheres-
1G101 6-15.5 Repair Procedure

3. Epoxy resin, LY564-1. A. Evaluate damage and determine applicable

repair (paragraph 6-5).
6-15.3 Auxiliary Materials and Dispos-
able Items B. Repair as follows:

1. Rag/towel or lint free paper towels 1. Vacuum clean all loose particles in
2. Ethyl alcohol damaged area.

3. 80 to 100 grit abrasive paper/cloth
4. 220 to 280 grit abrasive paper/cloth.
6-15.4 Safety Conditions
WARNING
Ethyl alcohol is flammable. Avoid
eye and skin contact or breathing of
vapors. Protective equipment
consisting of goggles and gloves is
required.
2. Using 220 to 280 grit abrasive paper sand
damage area to remove paint
3. Vacuum clean all dust particles and wipe
damaged and surrounding area with rag/
towel impregnated with ethyl alcohol.
4. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
5. Add 15 to 25 g of glass micro balloons
to the mixed epoxy resin. Continue
mixing until a homogenous mass of
uniform viscosity is obtained, free of
lumps.

6-56
 U900/000/TM/E/323

6. Using a piece of thin sheet metal or a 8. Using 80 to 100 grit abrasive paper,
spatula, apply resin mixture and work smooth resin mixture to contour and
into damage until uniform smooth clean old paint.
surface is obtained.
9. Vacuum clean all dust particles and wipe
7. Cure resin mixture as required. damaged and surrounding area using
Lint-free cloth impregnated with ethyl
NOTE alcohol.
Old paint spots can remain on 10. Prime and finish repair area as specified
surface if sanding may cause damage in Chapter 3.
to fabric.
11. Clean work area and remove remaining
unused repair material.

DIMENSION MAXIMUM REPAIRABLE DAMAGE SIZE

L (mm) .................................................................... 30
W ............................................................................ 30
h .............................................................................. 6

Figure 6-11. Wing and Tail Assembly - Repair of Damage to Surface Contour with no Broken Skin

6-57
U900/000/TM/E/323

6-16 WING AND TAIL ASSEMBLIES - 6-16.4 Safety Conditions

DEBONDING BETWEEN SKIN
AND CORE (Figure 6-12) WARNING
6-16.1 Equipment
· Ethyl alcohol is flammable.
Avoid eye and skin contact or
1. High speed (15,000 to 20,000 rpm) router breathing of vapors. Protective
bit, diamond coated or solid carbide bit equipment consisting of goggles
and gloves is required.
2. Spatula (or thin piece of metal sheet)
3. Vacuum cleaner · Epoxy resin is toxic and
flammable. Use in well-ventilated
4. Face shield area only. Avoid eye and skin
contact or breathing of vapors.
5. Industrial goggles
Protective equipment consisting
6. Respirator of goggles, gloves and respiratory
protection is required. Failure to
7. Rubber gloves. comply may result in injury or
health problems to personnel.
6-16.2 Part Materials

1. Carbon fiber fabric, Style 3K-70P · Micro balloons may be harmful

to the respiratory system. Avoid
2. Glass fiber fabric, Style 1581 breathing of particles. Respiratory
protection against fine dust is
3. Hardener, HY560 required. Failure to comply may
result in injury or health problems
4. Micro balloons, glass, Eccospheres-
to personnel.
1G101
5. Epoxy resin, LY564-1. NOTE

6-16.3 Auxiliary Materials and Dispos-
able Items
1. Lint-free cloth or lint free paper towels
2. Ethyl alcohol
3. 80 to 100 grit abrasive paper/cloth
4. 220 to 280 grit abrasive paper/cloth
5. Wrapping paper (FED Spec. OU-P-
268E, No. 2)
6. Plastic sheet: nylon, PVC, polyethylene
or PVA
The repair method for damage in
wings or tail assembly is identical;
therefore only a typical repair to
wings is described.
6-16.5 Repair Procedure
A. Evaluate damage and determine applicable
repair (paragraph 6-6).
B. Repair as follows:
1. Remove assemblies to allow access to
repair area.

7. Nylon fabric peel ply 2. Vacuum clean all loose particles in

damaged area.
8. Paint brushes.

6-58

CAUTION
This procedure requires sanding of
carbon fiber components. Resultant
dust is an electrical conducting
material which may cause electrical
short circuits. Protect all electrical
equipment and components against
dust. Failure to comply may result
in damage to equipment.
3. Using wrapping paper, wrap electrical
boxes in area of damaged. Protect all
open lines and electrical connectors.
WARNING
Routing operations create chips
which may cause serious eye injury.
Protective equipment consisting of
goggles is required
CAUTION
· Exercise care during routing to
prevent damage to adjacent
structure or opposite skin.
· Only fabric layers shall be cut.
Exercise extreme care to prevent
damage to existing core. If core is
damaged, refer to paragraph 6-21.
4. Rout with diamond coated or solid
carbide bit all damaged skin around
damage, to a distance of up to 10 mm
Check for minimum radius of 5 mm at
corners of damage.
5. Vacuum clean all dust particles from
sanded area.
6. Using 220 to 280 grit abrasive paper,
sand outer damaged skin area to remove
paint to a distance of 40±5 mm from
cutout.
U900/000/TM/E/323
7. Vacuum clean all dust particles and wipe
damaged area and surrounding area with
a clean rag/towel impregnated with ethyl
alcohol. Do not wipe polystyrene foam.
8. Prepare slurry as follows:
1) Prepare a mixture of 100 g of epoxy
resin and 27 g of hardener.
2) Add 15 to 25 g of micro balloons-
glass to the mixed epoxy resin.
Continue mixing until a homogeneous
mass of uniform viscosity is obtained,
free of lumps.
9. Fill damage with slurry and smooth to
flush with undamaged structure.
NOTE
Steps 10 to 17 for damage in wing
area of one fabric ply.
10. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
11. Impregnate carbon fiber fabric, on a
plastic sheet, with epoxy resin/hardener
mixture.
12. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.
13. Cut one ply of impregnated fabric to a
size of 50±5 mm larger in diameter then
damage size (fiber direction ±45°).
14. Brush a thin layer of epoxy resin/
hardener on the repair area.
15. Peel off one plastic sheet from ply and
lay it on centre of the damage, so it
uniformly overlaps the damage
circumference. Peel off the remaining
plastic sheet.
16. Lay peel ply on the repair plies, smooth
and impregnate.
17. Cure for at least six hours at room
temperature and remove peel ply.
6-59
U900/000/TM/E/323

NOTE
Steps 19 to 27 for damage in wing
area of two carbon fabric plies.
18. Remove paint to a distance of 65±5 mm.
19. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
20. Impregnate carbon fiber fabric, on a plastic
sheet, with epoxy resin/hardener mixture.
21. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.
22. Cut two plies of impregnated fabric as follows:
1) One ply 50±5 mm larger than diameter
of damage (fiber direction ±45°).
2) One ply 100±5 mm larger than diameter
of damage (fiber direction ±45°).
23. Brush a thin layer of epoxy resin/
hardener on the repair area.
24. Peel off one plastic sheet from smaller ply and
lay it on centre of the damage, so it uniformly
overlaps the damage circumference. Peel off
the remaining plastic sheet.
25. Repeat step 24 with the larger ply.
26. Lay peel ply on the repair plies, smooth
and impregnate.
27. Cure for at least six hours at room
temperature and remove peel ply.
28. Prime and finish repair area as specified
in Chapter 3.
29. Clean work area and remove remaining
unused repair material.
30. Remove wrapping paper from work area
and protective devices from all lines and
electrical connectors.
31. Check electrical connectors for epoxy
and carbon dust and clean with vacuum
cleaner and contact spray.

DIMENSION MAXIMUM REPAIRABLE DAMAGE SIZE

L (mm) .................................................................... 30
W ............................................................................ 30
h .............................................................................. 6

Figure 6-12. Wing and Tail Assembly - Debonding between Skin and Core (Sheet 1)
6-60
 U900/000/TM/E/323

Figure 6-12. Wing and Tail Assemblies - Debonding between Skin and Core (Sheet 2)

6-61
U900/000/TM/E/323

6-17 WING AND TAIL ASSEMBLIES - 6-17.4 Safety Conditions

REPAIR OF DAMAGE TO ONE
SKIN AND CORE WITHOUT DAM-
AGE TO OPPOSITE SKIN (Figure
6-13)
6-17.1 Equipment
1. High speed (15,000 to 20,000 rpm) router
bit, with solid carbide bit
2. Spatula (or thin piece of metal sheet)
3. Vacuum cleaner
4. Face shield
5. Industrial goggles
6. Respirator
7. Rubber gloves.
6-17.2 Part Materials
1. Carbon fiber fabric, Style 3K-70P
2. Glass fiber fabric, Style 1581
3. Hardener, HY560
4. Epoxy resin, LY564-1
5. Polystyrene foam 15 to 16 kg/m3
6. Polyurethane foaming compound, IN
2340, A/B.
6-17.3 Auxiliary Materials and Dispos-
able Items
1. Rag/towel or lint free paper towels
2. Ethyl alcohol
3. Masking tape
4. 80 to 100 grit abrasive paper/cloth
5. 220 to 280 grit abrasive paper/cloth
6. Plastic sheet: nylon, PVC, polyethylene
or PVA
7. Wrapping paper (FED Spec. OU-P-
268E, No. 2)
8. Nylon fabric peel ply
9. Paint brushes.
WARNING
· Ethyl alcohol is flammable.
Avoid eye and skin contact or
breathing of vapors. Protective
equipment consisting of goggles
and gloves is required.
· Epoxy resin and polyurethane are
toxic and flammable. Use in well-
ventilated area only. Avoid eye
and skin contact or breathing of
vapors. Protective equipment
consisting of goggles, gloves and
respiratory protection is required.
Failure to comply may result in
injury or health problems to
personnel.
6-17.5 Repair Procedure
A. Evaluate damage and determine applicable
repair (paragraph 6-6).
B. Repair as follows:
1. Remove assemblies to allow access to
repair area.
2. Vacuum clean all loose resin particles
from between plies in damaged area.
CAUTION
This procedure requires sanding of
carbon fiber components. Resultant
dust is an electrical conducting
material which may cause electrical
short circuits. Protect all electrical
equipment and components against
dust. Failure to comply may result
in damage to equipment.
3. Using wrapping paper, wrap electrical
boxes in area of damage. Protect all open
lines and electrical connectors.

6-62

WARNING
Routing operations create chips
which may cause serious eye injury.
Protective equipment consisting of
goggles is required.
CAUTION
Exercise care during routing to
prevent damage to adjacent structure
or opposite skin.
4. Rout with solid carbide bit, remove
structure 10 mm surrounding damage
area. Check for minimum radius of 5 mm
at corners of damage.
5. Using 220 to 280 grit abrasive paper,
remove paint from undamaged area
around cutout to a distance of 40±5 mm
(for one repair ply), 65±5 mm (for two
repair plies) and 90 mm (for three or
more repair plies) from edge of cutout.
6. Using a clean Lint-free cloth
impregnated with ethanol thoroughly
wipe reworked area. Do not wet foam
core.
7. Prepare a 15 to 16 kg/m3 polystyrene
foam block (Chapter 5).
8. Trim the block to damaged area with
maximum gap of 3 mm between routed
structure and polystyrene block.
9. Prepare a mixture of equal amounts of
polyurethane components A and B by
thoroughly mixing for 20 to 30 seconds.
Apply the mixture with a brush or spatula
on the mating surface of the block and
the undamaged foam.
10. Locate polystyrene block in place and
bond with foamed polyurethane within
30 seconds after completing mixing
(Chapter 5).
U900/000/TM/E/323
NOTE
Light pressure shall be applied on top
of polystyrene block during curing
process.
11. Cure bonding while applying light
pressure on top of block for at least 1/2
hour.
12. Using 80 to 100 grit abrasive paper,
smooth polystyrene block flush with
undamaged area.
13. Vacuum clean all dust particles from sand
area and wipe damaged area and
surrounding area with a clean Lint-free
cloth impregnated with ethyl alcohol. Do
not wet foam core.
14. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
NOTE
Required number of repair plies shall
be identical in number and material
to the original plies in damaged
structure. The following steps refer
to a typical repair of two carbon fabric
plies only. For areas of three or four
plies, see Figure 6-13, sheet 3.
15. Impregnate carbon fiber fabric, on a
plastic sheet, with epoxy resin/hardener
mixture.
16. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.
17. Cut two plies of impregnated fabric as
follows:
1) One ply 50±5 mm larger than
diameter of damage (fiber direction
±45°).
2) One ply 100±5 mm larger than
diameter of damage (fiber direction
±45°).
6-63
U900/000/TM/E/323

18. Brush a thin layer of epoxy resin/
hardener on the repair area.
19. Peel off one plastic sheet from smaller
ply and lay it on centre of the damage,
so it uniformly overlaps the damage
circumference . Peel off the remaining
plastic sheet.
20. Peel off one plastic sheet from larger ply
and lay it on centre of the damage, so it
uniformly overlaps the damage
circumference . Peel off the remaining
plastic sheet.
21. Lay peel ply on the repair plies, smooth
and impregnate.
22. Cure for at least six hours at room
temperature and remove peel ply.
23. Prime and finish repair area as specified
in Chapter 3.
24. Clean work area and remove remaining
unused repair material.
25. Remove wrapping paper from work area
and protective devices from all lines and
electrical connectors.
26. Check electrical connectors for epoxy
and carbon dust and clean with vacuum
cleaner and contact spray.

SECTION A-A

Figure 6-13. Wing and Tail Assembly - Repair of Damage to One Skin and Core without Damage
to Opposite Skin (Sheet 1)
6-64
 U900/000/TM/E/323

Figure 6-13. Wing and Tail Assembly - Repair of Damage to One Skin and Core without Damage
to Opposite Skin (Sheet 2)
6-65
U900/000/TM/E/323

REPAIR OF DAMAGE IN SKIN AND CORE FOR FOUR PLIES AREA LAMINATE

Figure 6-13. Wing and Tail Assembly - Repair of Damage to One Skin and Core without Damage
to Opposite Skin (Sheet 3)
6-66
 U900/000/TM/E/323

6-18 WING AND TAIL ASSEMBLY - 6-18.4 Safety Conditions

REPAIR OF DAMAGE TO BOTH
SKINS AND CORE (A THROUGH WARNING
HOLE) (Figure 6-14)

6-18.1 Equipment
· Ethyl alcohol is flammable.
Avoid eye and skin contact or
breathing of vapors. Protective
1. High speed (15,000 to 20,000 rpm) router equipment consisting of goggles
bit, with solid carbide bit and gloves is required.
2. Spatula (or thin piece of metal sheet)
3. Vacuum cleaner · Epoxy resin and polyurethane are
toxic and flammable. Use in well-
4. Face shield ventilated area only. Avoid eye
5. Industrial goggles and skin contact or breathing of
vapors. Protective equipment
6. Respirator
consisting of goggles, gloves and
7. Rubber gloves respiratory protection is required.
Failure to comply may result in
6-18.2 Part Materials injury or health problems to
personnel.
1. Carbon fiber fabric, Style 3K-70P
2. Glass fiber fabric, Style 1581 6-18.5 Repair Procedure
3. Hardener, HY560
A. Evaluate damage and determine applicable
4. Epoxy resin, LY564-1 repair (paragraph 6-6).
5. Polystyrene foam 15 to 16 kg/m3
B. Repair as follows:
6. Polyurethane foaming compound, Parts
A and B.
1. Remove assemblies to allow access to
6-18.3 Auxiliary Materials and Dispos- repair area.
able Items 2. Vacuum clean all loose resin particles
from between plies in damaged area.
1. Rag/towel or lint free paper towels
2. Ethyl alcohol CAUTION
3. Masking tape
This procedure requires sanding of
4. 80 to 100 grit abrasive paper/cloth carbon fiber components. Resultant
5. 220 to 280 grit abrasive paper/cloth dust is an electrical conducting
material which may cause electrical
6. Plastic sheet: nylon, PVC, polyethylene short circuits. Protect all electrical
or PVA equipment and components against
7. Wrapping paper (FED Spec. OU-P- dust. Failure to comply may result
268E, No. 2) in damage to equipment.
8. Nylon fabric peel ply 3. Using wrapping paper, wrap electrical
9. Paint brushes. boxes in area of damage. Protect all open
lines and electrical connectors.
6-67
U900/000/TM/E/323
WARNING
Routing operations create chips
which may cause serious eye injury.
Protective equipment consisting of
goggles is required
CAUTION
Exercise care during routing to
prevent damage to adjacent structure
or opposite skin.
4. Rout with solid carbide bit, remove
structure 10 mm surrounding damage
area. Check for minimum radius of 5 mm
at corners of damage.
5. Using 220 to 280 grit abrasive paper,
remove paint from undamaged area
around cutout to a distance of 40±5 mm
(for one repair ply), 65±5 mm (for two
repair plies) and 90 mm (for three or
more repair plies), from edge of cutout.
6. Using a clean Lint-free cloth
impregnated with ethanol thoroughly
wipe reworked area. Do not wet foam
core.
7. Prepare a 15 to 16 kg/m3 polystyrene
foam block (Chapter 5).
8. Trim the block to damaged area with
maximum gap of 3 mm between routed
structure and polystyrene block.
9. Prepare a mixture of equal amounts of
polyurethane components A and B by
thoroughly mixing for 20 to 30 seconds.
Apply the mixture with a brush or spatula
on the mating surface of the block and
the undamaged foam.
6-68
10. Locate polystyrene block in place and
bond with foamed polyurethane within
30 seconds after completing mixing
(Chapter 5).
NOTE
Light pressure shall be applied on top
of polystyrene block during curing
process.
11. Cure bonding while applying light
pressure on top of block for at least 1/2
hour.
12. Using 80 to 100 grit abrasive paper,
smooth polystyrene block flush with
undamaged area.
13. Vacuum clean all dust particles from sand
area and wipe damaged area and
surrounding area with a clean Lint-free
cloth impregnated with ethyl alcohol. Do
not wet foam core.
14. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
NOTE
Required number of repair plies shall
be identical in number and material
to the original plies in damaged
structure. The following steps refer
to a typical repair of two carbon
fabric plies only.
15. Impregnate carbon fiber fabric, on a
plastic sheet, with epoxy resin/hardener
mixture.
16. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.

17. Cut four plies of impregnated fabric (two
for upper skin and two for lower skin) as
follows:
1) One ply 50±5 mm larger than
diameter of damage for upper skin
side.
2) One ply 100±5 mm larger than
diameter of damage for upper skin
side.
3) One ply 50±5 mm larger than
diameter of damage for lower skin
side.
4) One ply 100±5 mm larger than
diameter of damage for lower skin
side.
18. Brush a thin layer of epoxy resin/
hardener on the repair area.
19. Peel off one plastic sheet from smaller
ply and lay it on centre of the damage,
so it uniformly overlaps the damage
circumference . Peel off the remaining
plastic sheet.
20. Peel off one plastic sheet from larger ply
and lay it on centre of the damage, so it
uniformly overlaps the damage
circumference . Peel off the remaining
plastic sheet.
U900/000/TM/E/323
21. Lay peel ply on the repair plies, smooth
and impregnate.
22. Peel off one plastic sheet from smaller
ply and lay it on centre of the damage
from lower side, so it uniformly overlaps
the damage circumference. Peel off the
remaining plastic sheet.
23. Peel off one plastic sheet from larger ply
and lay it on centre of the damage from
lower side, so it uniformly overlaps the
damage circumference. Peel off the
remaining plastic sheet.
24. Lay peel ply on the repair plies, smooth
and impregnate.
25. Cure for at least six hours at room
temperature and remove peel ply.
26. Prime and finish repair area as specified
in Chapter 3.
27. Clean work area and remove remaining
unused repair material.
28. Remove wrapping paper from work area
and protective devices from all lines and
electrical connectors.
29. Check electrical connectors for epoxy
and carbon dust and clean with vacuum
cleaner and contact spray.
6-69
U900/000/TM/E/323

DIMENSION MAXIMUM REPAIRABLE DAMAGE SIZE

L (mm) .................................................................... 600
W / C ....................................................................... 0.25

Figure 6-14. Wing and Tail Assembly - Repair of Damage to Both Skins and Core
(a Through Hole) (Sheet 1)
6-70
 U900/000/TM/E/323

Figure 6-14. Wing and Tail Assembly - Repair of Damage to Both Skins and Core
(a Through Hole) (Sheet 2)
6-71
U900/000/TM/E/323

6-19 OUTBOARD WING - REPAIR OF 6-19.4 Safety Conditions

DAMAGE IN TRAILING EDGE
(Figure 6-15) WARNING
6-19.1 Equipment
· Ethyl alcohol is flammable.
Avoid eye and skin contact or
1. High speed (15,000 to 20,000 rpm) router breathing of vapors. Protective
bit, diamond coated or solid carbide equipment consisting of goggles
2. Spatula (or thin piece of metal sheet) and gloves is required.
3. Vacuum cleaner
4. Face shield · Epoxy resin and polyurethane are
toxic and flammable. Use in well-
5. Industrial goggles ventilated area only. Avoid eye
and skin contact or breathing of
6. Respirator
vapors. Protective equipment
7. Rubber gloves. consisting of goggles, gloves and
respiratory protection is required.
6-19.2 Part Materials Failure to comply may result in
injury or health problems to
1. Carbon fiber fabric, Style 3K-70P
personnel.
2. Hardener, HY560
3. Epoxy resin, LY564-1 6-19.5 Repair Procedure

4. Polystyrene foam 15 to 16 kg/m3 A. Evaluate damage and determine applicable

5. Polyurethane foaming compound, Parts repair (paragraph 6-6).
A and B.
B. Repair as follows:
6-19.3 Auxiliary Materials and Dispos-
able Items 1. Remove assemblies to allow access to
repair area.
1. Lint-free cloth or lint free paper towels
2. Vacuum clean all loose particles from
2. Ethyl alcohol
damaged area.
3. Masking tape
4. 80 to 100 grit abrasive paper/cloth CAUTION
5. 220 to 280 grit abrasive paper/cloth This procedure requires sanding of
6. Plastic sheet: nylon, PVC, polyethylene carbon fiber components. Resultant
or PVA dust is an electrical conducting
material which may cause electrical
7. Wrapping paper (FED Spec. OU-P- short circuits. Protect all electrical
268E, No. 2) equipment and components against
8. Nylon fabric peel ply dust. Failure to comply may result
in damage to equipment.
9. Paint brushes.
3. Using wrapping paper, wrap electrical
boxes in area of damage. Protect all open
lines and electrical connectors.
6-72

WARNING
Routing operations create chips
which may cause serious eye injury.
Protective equipment consisting of
goggles is required
CAUTION
Exercise care during routing to
prevent damage to adjacent structure
or opposite skin.
4. Rout with solid carbide bit , remove all
damaged structure up to 10 mm
surrounding damage area. Check for
minimum radius of 5 mm at corners of
damage.
5. Using 220 to 280 grit abrasive paper,
remove paint from undamaged area
around cutout to a distance of 25 mm
from edge of cutout.
6. Using a clean rag/towel impregnated
with ethanol thoroughly wipe reworked
area. Do not wet foam core.
7. Prepare a 15 to 16 kg/m3 polystyrene
foam block (Chapter 5).
8. Trim the block to damaged area with
maximum gap of 3 mm between routed
structure and polystyrene block and
exceeding 30±5 mm in trailing edge side.
CAUTION
Polyurethane mixture shall be used
within one minute after mixing material
components. Failure to comply may
degrade quality of bonding.
9. Prepare a mixture of equal amounts of
polyurethane components A and B by
thoroughly mixing for 20 to 30 seconds.
Apply the mixture with a brush or spatula
on the mating surface of the block and
the undamaged foam.
U900/000/TM/E/323
10. Locate polystyrene block in place and
bond with foamed polyurethane within
30 seconds after completing mixing
(Chapter 5).
11. Cure bonding while block is tightly hold
against damaged area.
12. Using 80 to 100 grit abrasive paper, send
upper surface of polystyrene block flush
with upper wing surface structure.
13. Vacuum clean all dust particles from sand
area and wipe damaged area and
surrounding area with a clean Lint-free
cloth impregnated with ethyl alcohol. Do
not wet foam core.
14. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
15. Impregnate carbon fiber fabric, on a
plastic sheet, with epoxy resin/hardener
mixture.
16. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.
17. Cut one ply of impregnated fabric to a
size of 50±5 mm larger in diameter then
damage size on upper wing surface and
exceeding 15±5 mm in trailing edge side
(fiber direction ±45°).
18. Brush a thin layer of epoxy resin/
hardener on the upper surface of the
repair area.
19. Peel off one plastic sheet from ply and
lay it on centre of the damage, on upper
trailing edge surface, so it uniformly
overlaps 25±5 mm the undamaged
circumference structure. (remaining
width of repair ply is out of trailing edge
contour). Peel off the remaining plastic
sheet.
20. Lay peel ply on the repair ply, smooth
and impregnate.
6-73
U900/000/TM/E/323

21. Cure for at least six hours at room 30. Lay peel ply on the repair ply, smooth
temperature and remove peel ply. and impregnate.
22. Using 80 to 100 grit abrasive paper, send 31. Cure for at least six hours at room
lower surface of polystyrene block flush temperature and remove peel ply.
with lower wing surface structure.
32. Trim trailing edge of repair plies to match
23. Vacuum clean all dust particles from sand with trailing edge contour of wing.
area and wipe damaged area and
surrounding area with a clean Lint-free 33. Prime and finish repair area as specified
cloth impregnated with ethyl alcohol. Do in Chapter 3.
not wet foam core. 34. Clean work area and remove remaining
unused repair material.
24. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener. 35. Remove wrapping paper from work area
and protective devices from all lines and
25. Impregnate carbon fiber fabric, on a
electrical connectors.
plastic sheet, with epoxy resin/hardener
mixture. 36. Check electrical connectors for epoxy
26. Lay another plastic sheet on top of the and carbon dust and clean with vacuum
fabric. Squeeze out excess resin with a cleaner and contact spray.
spatula or a squeegee.
27. Cut one ply of impregnated fabric to a
size of 50±5 mm larger in diameter then
damage size on lower wing surface and
exceeding 15±5 mm in trailing edge side
(fiber direction ±45°).
28. Brush a thin layer of epoxy resin/
hardener on the lower surface of the
repair area.
29. Peel off one plastic sheet from ply and
lay it on centre of the damage, on lower
trailing edge surface, so it uniformly
overlaps 25±5 mm the undamaged
circumference structure. (remaining
width of repair ply is out of trailing edge
contour). Peel off the remaining plastic
sheet.

6-74
 U900/000/TM/E/323

DIMENSION MAXIMUM REPAIRABLE DAMAGE SIZE

L (mm) .................................................................... 600
W / C ....................................................................... 0.25

Figure 6-15. External Wing - Repair of Damage in Trailing Edge (Sheet 1)

6-75
U900/000/TM/E/323

Figure 6-15. External Wing - Repair of Damage in Trailing Edge (Sheet 2)

6-76
 U900/000/TM/E/323

6-20 CENTER WING - REPAIR OF 6-20.4 Safety Conditions

DAMAGE IN TRAILING EDGE
(Figure 6-16) WARNING
6-20.1 Equipment
· Ethyl alcohol is flammable.
Avoid eye and skin contact or
1. High speed (15,000 to 20,000 rpm) router breathing of vapors. Protective
bit, diamond coated or solid carbide equipment consisting of goggles
2. Spatula (or thin piece of metal sheet) and gloves is required.
3. Vacuum cleaner
4. Face shield · Epoxy resin and polyurethane are
toxic and flammable. Use in well-
5. Industrial goggles ventilated area only. Avoid eye
and skin contact or breathing of
6. Respirator
vapors. Protective equipment
7. Rubber gloves. consisting of goggles, gloves and
respiratory protection is required.
6-20.2 Part Materials Failure to comply may result in
injury or health problems to
1. Carbon fiber fabric, Style 3K-70P
personnel.
2. Hardener, HY560
3. Epoxy resin, LY564-1 6-20.5 Repair Procedure

4. Polystyrene foam 15 to 16 kg/m3 A. Evaluate damage and determine if repair is

5. Polyurethane foaming compound, Parts applicable (paragraph 6-6).
A and B.
B. Repair as follows:
6-20.3 Auxiliary Materials and Dispos-
able Items 1. Remove assemblies to allow access to
repair area.
1. Rag/towel or lint free paper towels
2. Vacuum clean all loose particles from
2. Ethyl alcohol
damaged area.
3. Masking tape
4. 80 to 100 grit abrasive paper/cloth CAUTION
5. 220 to 280 grit abrasive paper/cloth This procedure requires sanding of
6. Plastic sheet: nylon, PVC, polyethylene carbon fiber components. Resultant
or PVA dust is an electrical conducting
material which may cause electrical
7. Wrapping paper (FED Spec. OU-P- short circuits. Protect all electrical
268E, No. 2) equipment and components against
8. Peel ply, nylon fine dust. Failure to comply may result
in damage to equipment.
9. Paint brushes.
3. Using wrapping paper, wrap electrical
boxes in area of damage. Protect all open
lines and electrical connectors.
6-77
U900/000/TM/E/323
WARNING
Routing operations create chips
which may cause serious eye injury.
Protective equipment consisting of
goggles is required
CAUTION
Exercise care during routing to
prevent damage to adjacent structure
or opposite skin.
4. Rout with solid carbide bit, remove all
damaged structure up to 10 mm
surrounding damage area. Check for
minimum radius of 5 mm at corners of
damage.
5. Vacuum clean all dust particles from
reworked area.
6. Using 220 to 280 grit abrasive paper,
sand damaged area up to 40±5 mm
beyond damage circumference to remove
paint.
7. Using a clean Lint free cloth impregnated
with ethanol thoroughly wipe reworked
area. Do not wet foam core.
8. Prepare a 15 to 16 kg/m3 polystyrene
foam block (Chapter 5).
9. Trim the block to damaged area with
maximum gap of 3 mm between routed
structure and polystyrene block and
exceeding 30±5 mm on trailing edge
side.
CAUTION
Polyurethane mixture shall be used
within one minute after mixing
material components. Failure to
comply may degrade quality of
bonding.
6-78
10. Prepare a mixture of equal amounts of
polyurethane components A and B by
thoroughly mixing for 20 to 30 seconds.
Apply the mixture with a brush or spatula
on the mating surface of the block and
the undamaged foam.
11. Locate polystyrene block in place and
bond with foamed polyurethane within
30 seconds after completing mixing
(Chapter 5).
12. Cure bonding while block is tightly hold
against damaged area.
13. Using 80 to 100 grit abrasive paper, send
upper surface of polystyrene block flush
with upper trailing edge surface structure.
14. Vacuum clean all dust particles from sand
area and wipe damaged area and
surrounding area with a clean Lint-free
cloth impregnated with ethyl alcohol. Do
not wet foam core.
15. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
16. Impregnate carbon fiber fabric, on a
plastic sheet, with epoxy resin/hardener
mixture.
17. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.
18. Cut one ply of impregnated fabric 50±5
mm larger than size of damage on upper
wing surface and exceeding 15±5 mm
in trailing edge side (fiber direction
±45°).
19. Brush a thin layer of epoxy resin/
hardener on the upper surface of the
repair area.

20. Peel off one plastic sheet from ply and
lay it on centre of the damage, on upper
trailing edge surface, so it uniformly
overlaps 25±5 mm the undamaged
circumference structure. (remaining
width of repair ply is out of trailing edge
contour). Peel off the remaining plastic
sheet.
21. Lay peel ply on the repair ply, smooth
and impregnate.
22. Cure for at least six hours at room
temperature and remove peel ply.
23. Using 80 to 100 grit abrasive paper, send
lower surface of polystyrene block flush
with lower trailing edge surface structure.
24. Vacuum clean all dust particles from sand
area and wipe damaged area and
surrounding area with a clean Lint-free
cloth impregnated with ethyl alcohol. Do
not wet foam core.
25. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
26. Impregnate carbon fiber fabric, on a
plastic sheet, with epoxy resin/hardener
mixture.
27. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.
28. Cut one ply of impregnated fabric 50±5
mm larger than size of damage on lower
wing surface and exceeding 15±5 mm
in trailing edge side (fiber direction
±45°).
29. Brush a thin layer of epoxy resin/
hardener on the lower surface of the
repair area.
U900/000/TM/E/323
30. Peel off one plastic sheet from ply and
lay it on centre of the damage, on lower
trailing edge surface, so it uniformly
overlaps 25±5 mm the undamaged
circumference structure. (remaining
width of repair ply is out of trailing edge
contour). Peel off the remaining plastic
sheet.
31. Lay peel ply in the repair ply, smoothen
and impregnate.
32. Cure for at least six hours at room
temperature and remove peel ply.
33. Trim trailing edge of repair plies to match
with trailing edge contour of control
surface.
34. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
35. Impregnate carbon fiber fabric, on a
plastic sheet, with epoxy resin/hardener
mixture.
36. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.
37. Cut one ply of impregnated fabric to
wrap surface trailing edge with excess
of 25±5 mm on upper lower and span-
wise sides (fiber direction ±45°).
38. Brush a thin layer of epoxy resin/
hardener on the repair area.
39. Peel off one plastic sheet from ply and
lay it on centre of the damage, on upper
and lower trailing edge surface, so it
uniformly overlaps the damage
circumference. Peel off the remaining
plastic sheet.
40. Lay peel ply on the repair ply, smooth
and impregnate.
41. Cure for at least six hours at room
temperature and remove peel ply.
6-79
U900/000/TM/E/323

42. Prime and finish repair area as specified
in Chapter 3.
NOTE
If repair of damage in central wing
trailing edge is performed, omit step 43.
43. Perform weigh and static balance check.
44. Clean work area and remove remaining
unused repair material.
45. Remove wrapping paper from work area
and protective devices from all lines and
electrical connectors.
46. Check electrical connectors for epoxy
and carbon dust and clean with vacuum
cleaner and contact spray.

DIMENSION MAXIMUM REPAIRABLE DAMAGE SIZE

L (mm) .................................................................... 600
W / C ....................................................................... 0.25

NOTE
Crack damage up to L<30 mm and W<10 mm is negligible. Repair is not required.

Figure 6-16. Central Wing - Repair of Damage in Trailing Edge (Sheet 1)

6-80
 U900/000/TM/E/323

Figure 6-16. Central Wing - Repair of Damage in Trailing Edge (Sheet 2)

6-81
U900/000/TM/E/323

Figure 6-16. Central Wing - Repair of Damage in Trailing Edge (Sheet 3)

6-82

6-21 WING - REPAIR OF DAMAGE TO
LEADING EDGE, NOT INCLUDING
ALUMINUM MESH (Figure 6-17)
6-21.1 Equipment
1. High speed (15,000 to 20,000 rpm) router
with solid carbide bit
2. Vacuum cleaner
3. Face shield
4. Industrial goggles
5. Respirator
6. Rubber gloves.
6-21.2 Part Materials
1. Glass fiber fabric, Style 1581 or 7781
2. Hardener, HY560
3. Epoxy resin, LY564-1
4. Polystyrene foam 15 to 16 kg/m3
5. Polyurethane foaming compound, Parts
A and B
6. Micro balloons glass, Eccospheres-
1G101.
6-21.3 Auxiliary Materials and Dispos-
able Items
1. Rag/towel or lint free paper towels
2. Ethyl alcohol
3. 80 to 100 grit abrasive paper/cloth
4. 220 to 280 grit abrasive paper/cloth
5. Plastic sheet: nylon, PVC, polyethylene
or PVA
6. Nylon fabric peel ply
7. Paint brushes
8. Melamine board (formica) 1 to 1.5 mm
thick or aluminum sheet 1 to 1.5 mm.
U900/000/TM/E/323
6-21.4 Safety Conditions
WARNING
· Ethyl alcohol is flammable.
Avoid eye and skin contact or
breathing of vapors. Protective
equipment consisting of goggles
and gloves is required.
· Epoxy resin is toxic and
flammable. Use in well-ventilated
area only. Avoid eye and skin
contact or breathing of vapors.
Protective equipment consisting
of goggles, gloves and respiratory
protection is required. Failure to
comply may result in injury or
health problems to personnel.
· Micro balloons may be harmful
to the respiratory system. Avoid
breathing of particles. Respiratory
protection against fine dust is
required. Failure to comply may
result in injury or health problems
to personnel.
6-21.5 Repair Procedure
A. Evaluate damage and determine applicable
repair (paragraph 6-6).
B. Repair as follows:
1. Remove assemblies to allow access to
repair area.
2. Vacuum clean all loose particles from
damaged area.
WARNING
Routing operations create chips
which may cause serious eye injury.
Protective equipment consisting of
goggles is required
6-83
U900/000/TM/E/323
CAUTION
Exercise care during routing to prevent
damage to adjacent structure or
opposite skin or to the aluminum mesh.
3. Rout with solid carbide bit, remove all
damaged structure up to 10 mm
surrounding damage area. Check for a 5
mm minimum in radius at corners of
damage.
4. Vacuum clean all dust particles from
reworked area.
5. Using a clean Lint-free cloth impregnated
with ethanol thoroughly wipe reworked
area. Do not wet foam core.
6. Using 220 to 280 grit abrasive paper,
sand damaged area up to 30 mm beyond
damage circumference to remove paint.
CAUTION
Do not sand the torsion box carbon
ply. Failure to comply may damage
the material.
NOTE
If paint is removed on top of main
spar flange it is required to remove
the filling material up to the torsion
box carbon ply.
7. Vacuum clean all dust particles and wipe
damaged area and surrounding area with
a clean rag/towel impregnated with ethyl
alcohol. Do not wet foam core.
8. Prepare a 15 to 16 kg/m3 polystyrene
foam block (Chapter 5).
9. Trim the block to damaged area with
maximum gap of 3 mm between routed
structure and polystyrene block.
6-84
CAUTION
Polyurethane mixture shall be used
within one minute after mixing
material components. Failure to
comply may degrade quality of
bonding.
10. Prepare a mixture of equal amounts of
polyurethane components A and B by
thoroughly mixing for 20 to 30 seconds.
11. Apply the mixture with a brush or
spatula, on the mating surfaces of the
block and the undamaged leading edge
foam.
12. Locate block in place and bond with
foamed polyurethane within 30 seconds
after completing mixing (Chapter 5).
13. Hold block in place for at least 1/2 hour.
14. Using 80 to 100 grit abrasive paper, sand
the block to flush with wing contour.
15. Prepare a mixture of 100 g of epoxy
resin, 27 g of hardener and 20 to 25 g
glass micro balloons. Mix until a
uniform, lump-free slurry is obtained.
16. Apply a thin layer of slurry on the
polystyrene foam sanded surface.
17. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
18. Impregnate glass fiber fabric, on a
plastic sheet with epoxy resin/hardener
mixture.
19. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.
20. Cut one ply of impregnated fabric to a
size of 50±5 mm larger in diameter then
damage size (fiber direction ±45°).
21. Brush a thin layer of epoxy resin/
hardener on the repair area.
 U900/000/TM/E/323

22. Peel off one plastic sheet from ply and 26. Clean work area and remove remaining
lay it on centre of the damage, so it unused repair material.
uniformly overlaps the damage
27. Remove wrapping paper from work area
circumference. Peel off the remaining
and protective devices from all lines and
plastic sheet.
electrical connectors.
23. Lay peel ply in the repair ply, smoothen
and impregnate. 28. Check electrical connectors for epoxy
and carbon dust and clean with vacuum
24. Cure for at least six hours at room cleaner and contact spray.
temperature and remove peel ply.
25. Prime and finish repair area as specified
in Chapter 3.

DIMENSION MAXIMUM REPAIRABLE DAMAGE SIZE

L (mm) .................................................................... 600
W (mm) ................................................................... 250

Figure 6-17. Wing - Repair of Damage to Leading Edge, not including Aluminum Mesh (Sheet 1)

6-85
U900/000/TM/E/323

Figure 6-17. Wing - Repair of Damage to Leading Edge, not including Aluminum Mesh (Sheet 2)

6-86
 U900/000/TM/E/323

6-22 WING - REPAIR OF DAMAGE TO 6-22.4 Safety Conditions

LEADING EDGE INCLUDING
ALUMINUM MESH (Figure 6-18)
WARNING
6-22.1 Equipment
· Ethyl alcohol is flammable.
Avoid eye and skin contact or
1. High speed (15,000 to 20,000 rpm) router breathing of vapors. Protective
with solid carbide bit equipment consisting of goggles
2. Vacuum cleaner and gloves is required.
3. Face shield
4. Industrial goggles
· Epoxy resin is toxic and
flammable. Use in well-ventilated
area only. Avoid eye and skin
5. Respirator
contact or breathing of vapors.
6. Rubber gloves. Protective equipment consisting
of goggles, gloves and respiratory
6-22.2 Part Materials protection is required. Failure to
comply may result in injury or
1. Glass fiber fabric, Style 1581 or 7781
health problems to personnel.
2. Aluminum mesh, Astrostrike AL 0.16
PSF · Micro balloons may be harmful
to the respiratory system. Avoid
3. Hardener, HY560
breathing of particles. Respiratory
4. Epoxy resin, LY564-1 protection against fine dust is
5. Polystyrene foam 15 to 16 kg/m3 required. Failure to comply may
result in injury or health problems
6. Polyurethane foaming compound, Parts to personnel.
A and B.
6-22.5 Repair Procedure
6-22.3 Auxiliary Materials and Dispos-
able items
A. Evaluate damage and determine applicable
1. Rag/towel or lint free paper towels repair (paragraph 6-6).

2. Ethyl alcohol B. Repair as follows:

3. 80 to 100 grit abrasive paper/cloth
4. 220 to 280 grit abrasive paper/cloth
5. Plastic sheet: nylon, PVC, polyethylene
or PVA
6. Nylon fabric peel ply
7. Paint brushes
8. Melamine board (formica) 1 to 1.5 mm
thick or aluminum sheet 1 to 1.5 mm
9. Micro balloons glass, eccospheres-
1G101.
1. Remove assemblies to allow access to
repair area.
2. Vacuum clean all loose particles from
damaged area.
WARNING
Routing operations create chips
which may cause serious eye injury.
Protective equipment consisting of
goggles is required

6-87
U900/000/TM/E/323
CAUTION
Exercise care during routing to
prevent damage to adjacent structure
or opposite skin.
3. Rout with solid carbide bit, remove all
damaged skin mesh and core up to 10
mm surrounding damage area. Check for
a minimum of 5 mm in radius at the
corners of damage.
4. Vacuum clean all dust particles from
reworked area.
5. Using a clean Lint-free cloth
impregnated with ethanol thoroughly
wipe reworked area. Do not wet foam
core.
6. Using 220 to 280 grit abrasive paper,
sand damaged area up to 40±5 mm
beyond damage circumference to remove
paint.
7. Vacuum clean all dust particles and wipe
damaged area and surrounding area using
a clean Lint-free cloth impregnated with
ethyl alcohol. Do not wet foam core.
8. Remove Polystyrene foam from
damaged area until a plan parallel to the
spar web is obtained.
9. Prepare two triangular templates from
melamine board/aluminum sheet. The
sizes of the templates should be that of
the aluminum mesh triangles at the edges
of the repair zone.
10. Prepare a 15 to 16 kg/m3 block that
matches the shape of the removed core.
A maximum of 3 mm gap is allowed.
11. Nail the templates to the opposite edges
of a polystyrene block.
12. Cut with a hot wire the polystyrene foam
into two blocks: block I and block II. Cut
the two blocks to the required length.
13. Using 220 to 280 grit abrasive paper,
smooth the cut surfaces.
6-88
14. Prepare a piece of aluminum mesh.
CAUTION
Polyurethane mixture shall be used
within one minute after mixing material
components. Failure to comply may
degrade quality of bonding.
15. Prepare a mixture of equal amounts of
polyurethane components A and B by
thoroughly mixing for 20 to 30 seconds.
16. Apply the mixture with a brush or
spatula, on the mating surfaces of block
I and the undamaged leading edge foam.
17. Locate block in place and bond with
foamed polyurethane within 30 seconds
after completing mixing (Chapter 5).
18. Hold block I in place for at least 1/2 hour.
NOTE
Ensure maximum gap between block
II and undamaged core and block I
is up to 2 mm.
19. Prepare a mixture of 100 g of epoxy
resin, 27 g of hardener and 20 to 25 g
glass micro balloons. Mix until a
uniform, lump-free slurry is obtained.
20. Apply a thin layer of slurry on block I.
Lay the aluminum mesh and press with
a brush into the slurry.
21. Apply a thin layer of slurry on the mating
surfaces of block II with block I and the
undamaged leading edge foam.
22. Press gently block II onto block I. Hold
in place and cure for at least 6 hour.
23. Trim block II flush with the undamaged
leading edge by mechanical cutting,
sanding or hot wire cutting,
24. Vacuum clean all dust particles from
reworked area.
25. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
 U900/000/TM/E/323

26. Impregnate glass fiber fabric, on a plastic
sheet, with epoxy resin/hardener mixture.
27. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.
28. Cut one ply of impregnated fabric to a
size of 50±5 mm larger in diameter then
damage size (fiber direction ±45°).
29. Brush a thin layer of epoxy resin/
hardener on the repair area.
30. Peel off one plastic sheet from ply and lay
it on centre of the damage, so it uniformly
overlaps the damage circumference. Peel
off the remaining plastic sheet.
31. Lay peel ply on the repair ply, smooth
and impregnate.
32. Cure for at least six hours at room
temperature and remove peel ply.
33. Prime and finish repair area as specified
in Chapter 3.
34. Clean work area and remove remaining
unused repair material.
35. Remove wrapping paper from work area
and protective devices from all lines and
electrical connectors.
36. Check electrical connectors for epoxy
and carbon dust and clean with vacuum
cleaner and contact spray.

DIMENSION MAXIMUM REPAIRABLE DAMAGE SIZE

L (mm) .................................................................... 600
W (mm) ................................................................... 250

Figure 6-18. Wing - Repair of Damage to Leading Edge including Aluminum Mesh (Sheet 1)
6-89
U900/000/TM/E/323

Figure 6-18. Wing - Repair of Damage to Leading Edge including Aluminum Mesh (Sheet 2)

6-90
 U900/000/TM/E/323

6-23 REPAIR IN SERVO-ACTUATOR 6-23.4 Safety Conditions

PANEL (Figure 6-19)
WARNING
6-23.1 Equipment

1. High speed (15,000 to 20,000 rpm) router

· Ethyl alcohol is flammable.
Avoid eye and skin contact or
with solid carbide bit breathing of vapors. Protective
equipment consisting of goggles
2. Industrial goggles
and gloves is required.
3. Respirator
4. Rubber gloves · Epoxy resin is toxic and
flammable. Use in well-ventilated
5. Spatula (or thin piece of metal sheet) area only. Avoid eye and skin
contact or breathing of vapors.
6. Vacuum cleaner. Protective equipment consisting
of goggles, gloves and respiratory
6-23.2 Part Materials
protection is required. Failure to
comply may result in injury or
1. Carbon fiber fabric Style 3K-70P
health problems to personnel.
2. Micro balloons glass Eccospheres-
1G101
· Micro balloons may be harmful
to the respiratory system. Avoid
3. Hardener, HY560
breathing of particles. Respiratory
4. Epoxy resin, LY564-1. protection against fine dust is
required. Failure to comply may
6-23.3 Auxiliary Materials and Dispos- result in injury or health problems
able Items to personnel.

1. Rag/towel or lint free paper towels NOTE

2. Contacts spray Repair Procedures for outer wing,

3. Ethyl alcohol
4. Masking tape
5. 80 to 100 grit abrasive paper/cloth
6. 220 to 280 grit abrasive paper/cloth
7. Plastic sheet: nylon, PVC, Polyethylene
or PVA
8. Wrapping paper (FED Spec. OU-P-
268E, No. 2)
9. Nylon fabric peel ply.
vertical stabiliser and horizontal
stabiliser are identical, therefore only
a typical repair of horizontal
stabiliser is described.
6-23.5 Repair Procedure
A. Evaluate damage and determine applicable
repair (paragraph 6-6).
B. Repair as follows:
1. Remove assemblies to allow access to
repair area.
2. Vacuum clean all loose resin particles in
damaged area.

6-91
U900/000/TM/E/323
CAUTION
This procedure requires sanding of
carbon fiber components. Resultant
dust is an electrical conducting
material which may cause electrical
short circuits. Protect all electrical
equipment and components against
dust. Failure to comply may result
in damage to equipment.
3. Using wrapping paper, wrap electrical
boxes in area of damage. Protect all open
lines and electrical connectors.
WARNING
Routing operations create chips
which may cause serious eye injury.
Protective equipment consisting of
goggles is required
CAUTION
Exercise care during routing to
prevent damage to adjacent
structure.
4. Rout with diamond coated or solid
carbide bit, remove all damage skin and
up to 5 mm surrounding damage area.
Check for minimum radius of 5 mm at
corners of damage.
5. Vacuum clean all dust particles and wipe
damaged area and surrounding area with
clean Lint-free cloth impregnated with
ethyl alcohol.
6. Using 220 to 280 grit abrasive paper,
remove paint from undamaged area to a
maximum distance of 40±5 mm from
edge of cutout.
7. Prepare a laminate patch per PS
32.17.03, Class III, Type 1, Grade 1
(directions ±45°) from carbon fiber fabric
to match hole in laminate, (for number
of plies, see Table 6-7).
6-92
8. Cut prepared laminate patch to match
cutout thickness and size, leaving a
maximum gap of 2 mm between patch
and undamaged structure.
9. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
10. Add 15 to 25 g of micro balloons-glass
to the mixed epoxy resin. Continue
mixing until a homogeneous mass of
uniform viscosity is obtained, free of
lumps.
11. Apply mixture to laminate patch edges
to edges of damaged area and bond
laminate patch in place.
12. Cure for at least six hours at room
temperature.
13. Using 220 to 280 grit abrasive paper,
shape upper and lower surface until
laminate patch is flush with undamaged
structure.
14. Vacuum clean all dust particles from sand
and wipe damaged area and surrounding
area with clean Lint-free cloth
impregnated with ethyl alcohol.
15. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
16. Impregnate carbon fiber fabric, on a
plastic sheet, with epoxy resin/hardener
mixture.
17. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.
18. Cut four plies of impregnated fabric (two
for outer side and two for inner side) as
follows (all plies ±45°):
1) Two plies 50±5 mm larger than
diameter of damage for outer skin side
2) Two plies 50±5 mm larger than
diameter of damage for inner skin
side.
 U900/000/TM/E/323

19. Brush a thin layer of epoxy resin/
hardener on both sides of the repair area.
20. Peel off one plastic sheet from first outer
ply and lay it on centre of the damage
from outer side, so it uniformly overlaps
the damage circumference. Peel off the
remaining plastic.
21. Peel off one plastic sheet from second
outer ply and lay it on centre of the
damage from outer side, so it uniformly
overlaps the damage circumference. Peel
off the remaining plastic.
22. Lay peel ply on the repair plies, smooth
and impregnate.
23. Peel off one plastic sheet from first inner
ply and lay it on centre of the damage
from inner side, so it uniformly overlaps
the damage circumference. Peel off the
remaining plastic.
24. Peel off one plastic sheet from second
inner ply and lay it on centre of the
damage from inner side, so it uniformly
overlaps the damage circumference. Peel
off the remaining plastic
25. Lay peel ply on the repair plies, smooth
and impregnate.
26. Cure for at least six hours at room
temperature and remove peel ply.
27. Prime and finish repair area as specified
in Chapter 3.
28. Clean work area and remove remaining
unused repair material.
29. Remove wrapping paper from work area
and protective devices from all lines and
electrical connectors.
30. Check electrical connectors for epoxy
and carbon dust and clean with vacuum
cleaner and contact spray.

Table 6-6. Definition of Repair Patch Laminates

PANEL P\N LOCATION NUMBER OF PLIES
JIM1130089-501 ............. Horiz. Stab. (left)........................................ 8
JIM1130089-502 ............. Horiz. Stab. (right) ..................................... 8
JIM1130090-501 ............. Vert. Stab. (left) .......................................... 8
JIM1130090-502 ............. Vert. Stab. (right) ........................................ 8
JIM1120010-501 ............. Wing Flap (left) .......................................... 12
JIM1120010-502 ............. Wing Flap (right) ........................................ 12
JIM1120021-501 ............. Wing Aileron (left) ..................................... 12
JIM1120021-502 ............. Wing Aileron (right) ................................... 12

6-93
U900/000/TM/E/323

DIMENSION MAXIMUM REPAIRABLE DAMAGE SIZE

D (mm) .................................................................... 80
d (mm) ..................................................................... 20

REMOVAL OF DAMAGED STRUCTURE

Figure 6-19. Repair of Damage in Actuator Panel (Sheet 1)

6-94
 U900/000/TM/E/323

Figure 6-19. Repair of Damage in Actuator Panel (Sheet 2)

6-95
U900/000/TM/E/323

6-24 REPAIR OF DAMAGE IN ACTUA- 6-24.4 Safety Conditions

TOR FAIRING (Figure 6-20)
WARNING
6-24.1 Equipment

1. Face shield
· Ethyl alcohol is flammable.
Avoid eye and skin contact or
breathing of vapors. Protective
2. Industrial goggles
equipment consisting of goggles
3. Respirator and gloves is required.

4. Rubber gloves
5. Spatula (or thin piece of metal sheet)
6. Vacuum cleaner.
6-24.2 Part Materials
1. Carbon fiber fabric Style 3K-70P
2. Epoxy adhesive, Hysol EA 9309.1NA
3. Hardener, HY560
4. Milled glass fibers 1/32" to 1/8"
· Epoxy resin and adhesive EA
9309.1NA are toxic and
flammable. Use in well-ventilated
area only. Avoid eye and skin
contact or breathing of vapors.
Protective equipment consisting
of goggles, gloves and respiratory
protection is required. Failure to
comply may result in injury or
health problems to personnel.
6-24.5 Repair Procedure

5. Epoxy resin, LY564-1. A. Evaluate damage and determine applicable

repair (paragraph 6-6).
6-24.3 Auxiliary Materials and Dispos-
able Items B. Repair as follows:

1. Rag/towel or lint free paper towels 1. Remove assemblies to allow access to

2. Contacts spray repair area.

3. Ethyl alcohol 2. Vacuum clean all loose resin particles

4. Masking tape
5. Tape, Aluminum
6. 80 to 100 grit abrasive paper/cloth
7. 220 to 280 grit abrasive paper/cloth
8. Plastic sheet: nylon, PVC, polyethylene
or PVA
9. Wrapping paper (FED Spec. OU-P-
268E, No. 2).
from between plies in damaged area.
CAUTION
This procedure requires sanding of
carbon fiber components. Resultant
dust is an electrical conducting
material which may cause electrical
short circuits. Protect all electrical
equipment and components against
dust. Failure to comply may result
in damage to equipment.

3. Using wrapping paper, wrap electrical

boxes in area of damage. Protect all open
lines and electrical connectors.
6-96

CAUTION
Exercise care during routing to
prevent damage from adjacent
structure.
4. Rout with diamond coated or solid
carbide bit all damaged skin and around
damage to a distance up to 5 mm. Check
for minimum radius of 5 mm at corners
of damage.
5. Vacuum all dust particles and wipe
damaged and surrounding area with Lint-
free cloth impregnated with ethyl
alcohol.
6. Using 220 to 280 grit abrasive paper,
remove paint from undamaged area on
outer side of damaged fairing to a
maximum distance of 25±5 mm
7. Vacuum all dust particles and wipe
damaged and surrounding area with Lint-
free cloth impregnated with ethyl
alcohol.
8. Cut aluminum tape 20 mm larger than
damage while keeping the original
fairing contour, and lay aluminum tape
over center of inner surface of damage
to allow filling of damaged cutout.
9. Dry milled glass fibers in an oven at
110 °C for 1 to 2 hours prior to mixture
with adhesive.
NOTE
Only small quantities up to 250 g
shall be mixed at one time.
10. Prepare a mixture of EA 9309.1NA
adhesive and milled glass fibers. Use
long and small strokes and mix
thoroughly until homogeneous mass of
uniform viscosity is obtained, free of
lumps.
U900/000/TM/E/323
11. Using spatula (or thin piece of metal
sheet) fill cavity or dent with mixture of
EA 9309.1NA adhesive and milled glass
fibers.
12. Cure at least six hours at room
temperature.
13. Using 80 to 100 grit abrasive paper, sand
smooth area to prepare for bonding,
ensuring filling material is flush with
remaining undamaged area, keeping the
original fairing contour.
14. Vacuum clean all dust particles from
sanded area.
15. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
16. Impregnate carbon fiber fabric, on a
plastic sheet, with epoxy resin/hardener
mixture.
17. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.
18. Cut one ply of impregnated fabric to a
size of 20 to 30 mm larger in diameter
then damage size (fiber direction ±45°).
19. Brush a thin layer of epoxy resin/
hardener on repair area of the outer
surface of fairing..
20. Peel off one plastic sheet from ply and
lay it on centre of the damage, on outer
surface, so it uniformly overlaps the
damage circumference. Peel off the
remaining plastic sheet.
21. Cure for at least six hours at room
temperature and remove peel ply.
22. Remove aluminum tape from inner
surface.
23. Prime and finish repair area as specified
in Chapter 3.
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U900/000/TM/E/323

24. Clean work area and remove remaining

unused repair material.
25. Remove wrapping paper from work area
and protective devices from all lines and
electrical connectors.
26. Check electrical connectors for epoxy
and carbon dust and clean with vacuum
cleaner and contact spray.

DIMENSION MAXIMUM REPAIRABLE DAMAGE SIZE

L (mm) .................................................................... 60
W (mm) ................................................................... 20

Figure 6-20. Repair of Damage in Actuator Fairing (Sheet 1)

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 U900/000/TM/E/323

Figure 6-20. Repair of Damage in Actuator Fairing (Sheet 2)

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U900/000/TM/E/323

6-25 HINGE/LEVER ASSEMBLY - 6-25.4 Safety Conditions

REPAIR OF MINOR DAMAGE TO
ROHACELL BLOCK (Figure 6-21) WARNING
6-25.1 Equipment
· Ethyl alcohol is flammable.
Avoid eye and skin contact or
1. High speed (15,000 to 20,000 rpm) router breathing of vapors. Protective
with solid carbide bit equipment consisting of goggles
2. Face shield and gloves is required.
3. Industrial goggles
4. Respirator · Epoxy resin is toxic and
flammable. Use in well-ventilated
5. Rubber gloves area only. Avoid eye and skin
contact or breathing of vapors.
6. Spatula (or thin piece of metal sheet)
Protective equipment consisting
7. Vacuum cleaner. of goggles, gloves and respiratory
protection is required. Failure to
6-25.2 Part Materials comply may result in injury or
health problems to personnel.
1. Carbon fiber fabric Style 3K-70P
2. Micro balloons glass, Eccospheres-
1G101 · Micro balloons may be harmful
to the respiratory system. Avoid
3. Hardener, HY560 breathing of particles. Respiratory
protection against fine dust is
4. Epoxy resin, LY564-1
required. Failure to comply may
5. Rohacell 71A kg/m3 result in injury or health problems
6. Milled glass fibers 1/32" to 1/8". to personnel.

6-25.3 Auxiliary materials and Dispos- 6-25.5 Repair Procedure

able Items
A. Evaluate damage and determine applicable
1. Rag/towel or lint free paper towels repair (Table 6-7).
2. Contacts spray
NOTE
3. Ethyl alcohol
The inspections performed in the
4. Masking tape
following steps b through d will
5. 80 to 100 grit abrasive paper/cloth determine if the repair can be
6. 220 to 280 grit abrasive paper/cloth accomplished by using the following
minor damage procedures. If results
7. Plastic sheet: nylon, PVC, polyethylene of these inspections are not
or PVA satisfactory, repair shall be
8. Wrapping paper (FED Spec. OU-P- accomplished according to
268E, No. 2) procedures specified for major
damage procedures (paragraph 6-26).
9. Nylon fabric peel ply.

6-100

B. Apply moderate hand pressure to check
hinge/lever for looseness.
C. Check metallic hinge/lever for damage.
D. Ensure no more than 20% of the bonding
interface between the metallic hinge/lever
and the foam is damaged.
E. Repair as follows:
1. Remove assemblies to allow access to
repair area.
2. Vacuum clean all loose resin particles in
damaged area.
CAUTION
This procedure requires sanding of
carbon fiber components. Resultant
dust is an electrical conducting
material which may cause electrical
short circuits. Protect all electrical
equipment and components against
dust. Failure to comply may result
in damage to equipment.
3. Using wrapping paper, wrap electrical
boxes in area of damage. Protect all open
lines and electrical connectors.
CAUTION
· Exercise care during routing to
prevent damage to adjacent
structure.
· During routing operations,
bonded foam adjacent to hinge
should remain intact. Exercise
care not to remove bonded foam
adjacent to the metallic hinge.
Failure to comply may result in
damage to equipment.
U900/000/TM/E/323
4. Rout with diamond coated or solid
carbide bit all damaged skin and core
around damage to a distance up to 5 mm.
Check for minimum radius of 5 mm at
corners of damage.
5. Using 220 to 280 grit abrasive paper,
sand damaged area to remove paint up
to 30 mm around edge of cutout.
6. Vacuum clean all dust particles and wipe
damaged area and surrounding area with
clean Lint-free cloth impregnated with
ethyl alcohol.
7. Prepare a Rohacell block 71 kg/m3 to
match hole of removed Rohacell
8. Trim Rohacell block to damaged area
with maximum tolerance of 2 mm
between routed foam and Rohacell
block, and 0.4 to 1 mm between metal
part and repair block.
9. Prepare a mixture of adhesive EA
9309.1NA resin and milled glass fibers.
10. Using a piece of thin sheet metal or
spatula, apply adhesive mixture to both
Rohacell block and structure.
11. Attach Rohacell block in place, ensuring
gap between Rohacell block and
hinge\lever is 0.4 to 1 mm and maximum
2 mm between Rohacell block and
undamaged Rohacell.
12. Using 80 to 100 grit abrasive paper,
smooth Rohacell block flush with
undamaged area.
13. Vacuum clean all dust particles and wipe
damaged area and surrounding area using
clean Lint-free cloth impregnated with
ethyl alcohol.
14. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
6-101
U900/000/TM/E/323

NOTE
The following repair procedures are
typical for one ply only.
15. Impregnate carbon fiber fabric, on a
plastic sheet, with epoxy resin/hardener
mixture.
19. Peel off one plastic sheet from ply and
lay it on centre of the damage, so it
uniformly overlaps the damage
circumference. Peel off the remaining
plastic sheet.
20. Cure for at least six hours at room
temperature and remove peel ply.

16. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.
17. Cut one ply of impregnated fabric to a
size of 50±5 mm larger in diameter then
damage size (fiber direction ±45°).
18. Brush a thin layer of epoxy resin/
hardener on smoothened Rohacell and
sanded area.
21. Prime and finish repair area as specified
in Chapter 3.
22. Clean work area and remove remaining
unused repair material.
23. Remove wrapping paper from work area
and protective devices from all lines and
electrical connectors.
24. Check electrical connectors for epoxy
and carbon dust and clean with vacuum
cleaner and contact spray.

Table 6-7. Hinges and Levers Repair Limitations

AILERON PART NO. LMAX HMAX DOUBLE/SINGLE NO. OF PLIES

HINGE 1120055-001 15 11 * 2x GR\EP
LEVER 1120073-001 16 13 * 2x GR\EP
WING-HINGE 1120070-501 18 15 * 1x GR\EP

FLAP PART NO. LMAX HMAX DOUBLE/SINGLE NO. OF PLIES

HINGE (INBD) 1120056-501 22 13 * 2x GR\EP
HINGE (MIDDLE) 1120081-501 9 13 * 2x GR\EP
HINGE (OUTBD) 1120080-501 22 13 * 2x GR\EP
LEVER 1120083-001 16 13 * 2x GR\EP
WING -HINGE

(INBD)
(MIDDLE) 1120015-001 25 23 * 1x GR\EP
(OUTBD)

DESCRIPTION PART NO. LMAX HMAX DOUBLE/SINGLE NO. OF PLIES

ELEVATOR 1130058-001 16 18 * 2x GR\EP
RUDDER 1130061-001 16 18 * 1x GR\EP

6-102
 U900/000/TM/E/323

Figure 6-21. Hinge/Lever Assembly - Repair of Minor Damage to Rohacell Block (Sheet 1)

6-103
U900/000/TM/E/323

Figure 6-21. Hinge/Lever Assembly - Repair of Minor Damage to Rohacell Block (Sheet 2)

6-104
 U900/000/TM/E/323

6-26 HINGE/LEVER ASSEMBLY - 6-26.4 Safety Conditions

REPAIR OF MAJOR DAMAGE TO
ROHACELL BLOCK (Figure 6-22) WARNING
6-26.1 Equipment · Ethyl alcohol is flammable.
Avoid eye and skin contact or
1. High speed (15,000 to 20,000 rpm) router breathing of vapors. Protective
with solid carbide bit (1/8 or 3 mm bit) equipment consisting of goggles
2. Face shield and gloves is required.
3. Industrial goggles
4. Respirator
· Epoxy resin is toxic and
flammable. Use in well-ventilated
area only. Avoid eye and skin
5. Rubber gloves contact or breathing of vapors.
6. Spatula (or thin piece of metal sheet) Protective equipment consisting
7. Vacuum cleaner. of goggles, gloves and respiratory
protection is required. Failure to
6-26.2 Part Materials comply may result in injury or
health problems to personnel.
1. Carbon fiber fabric Style 3K-70P
2. Micro balloons glass, Eccospheres- · Micro balloons may be harmful to the
respiratory system. Avoid breathing of
1G101 particles. Respiratory protection
3. Hardener, HY560 against fine dust is required. Failure
4. Epoxy resin, LY564-1 to comply may result in injury or health
problems to personnel.
5. Rohacell 71A kg/m3
6. Milled glass fibers 1/32" to 1/8". 6-26.5 Repair Procedure

6-26.3 Auxiliary Materials and Dispos- A. Evaluate damage and determine applicable
able Items repair (Table 6-8).

1. Rag/towel or lint free paper towels B. Repair as follows:

2. Contacts spray 1. Remove assemblies to allow access to
repair area.
3. Ethyl alcohol
2. Vacuum clean all loose resin particles in
4. Masking tape damaged area.
5. 80 to 100 grit abrasive paper/cloth
6. 220 to 280 grit abrasive paper/cloth
CAUTION
7. Plastic sheet: nylon, PVC, polyethylene This procedure requires sanding of
or PVA carbon fiber components. Resultant
dust is an electrical conducting
8. Wrapping paper (FED Spec. OU-P- material which may cause electrical
268E, No. 2). short circuits. Protect all electrical
equipment and components against
dust. Failure to comply may result
in damage to equipment.
6-105
U900/000/TM/E/323
3. Using wrapping paper, wrap electrical
boxes in area of damage. Protect all open
lines and electrical connectors.
WARNING
Routing operations create chips
which may cause serious eye injury.
Protective equipment consisting of
goggles is required.
CAUTION
Exercise care during routing to
prevent damage to adjacent
structure.
4. Rout with diamond coated or solid
carbide bit all damaged skin and up to 5
mm surrounding damage area together
with attached hinge/lever. Check for
minimum radius of 5 mm at corners of
damage.
5. Vacuum clean all dust particles and wipe
damaged area and surrounding area with
clean Lint-free cloth impregnated with
ethyl alcohol.
CAUTION
During sanding operations a thin
layer of foam bonded to hinge should
remain. Ensure at least 80% of
bonding interface between the
metallic part and foam should be
intact. If it is not intact use a new
metallic part. The new metallic part
should be prepared for bonding,
etched and primed with BR127
bonding primer. Failure to comply
may result in damage to hinge.
NOTE
If the repair procedure is performed
with a new hinge omit step 6.
6-106
6. Using 80 to 100 grit abrasive paper,
carefully sand foam bonded to hinge. Do
not reach the metal surface of the hinge.
7. Using 220 to 280 grit abrasive paper,
sand damaged area to remove paint from
undamaged area around cutout to
distance of 40±5 mm (for one repair ply)
or 60±5 mm (for two repair plies).
8. Vacuum clean all dust particles and wipe
damaged area and surrounding area with
clean Lint-free cloth impregnated with
ethyl alcohol.
9. Prepare a Rohacell block 71A kg/m3 to
match hole of removed Rohacell.
10. Trim Rohacell block to damaged area
with maximum gap of 2 mm between
routed foam and Rohacell block.
11. Prepare a mixture of epoxy resin and
micro balloons.
12. Using a piece of thin sheet metal or a
spatula, apply adhesive mixture to both
Rohacell block and structure.
13. Attach Rohacell block in place, ensuring
maximum 2 mm bond line thickness
between Rohacell block and undamaged
Rohacell.
NOTE
Light pressure shall be applied on top
of Rohacell block during curing
process.
14. Cure bonding while applying pressure on
top of block.
15. Using 220 to 280 grit abrasive paper,
smooth Rohacell block flush with
undamaged area.
16. Vacuum clean all dust particles and wipe
damaged area and surrounding area using
clean Lint-free cloth impregnated with
ethyl alcohol.

17. Prepare a mixture of 100 g of epoxy resin
and 27 g of hardener.
NOTE
The following repair procedures are
typical for two plies. For a correct
number of plies, refer to Table 6-7.
18. Impregnate carbon fiber fabric, on a
plastic sheet with epoxy resin/hardener
mixture.
19. Lay another plastic sheet on top of the
fabric. Squeeze out excess resin with a
spatula or a squeegee.
20. Cut two plies of impregnated fabric as
follows:
1) One ply 50±5 mm larger then
diameter of damage (fiber direction
±45°).
2) One ply 100±5 mm larger then
diameter of damage (fiber direction
±45°).
21. Brush a thin layer of epoxy resin/
hardener on smoothened Rohacell and
sanded area.
22. Peel off one plastic sheet from smaller
ply and lay it on centre of the damage,
so it uniformly overlaps the damage
circumference. Peel off the remaining
plastic sheet.
23. Peel off one plastic sheet from larger ply
and lay it on centre of the damage, so it
uniformly overlaps the damage
circumference. Peel off the remaining
plastic sheet. Lay and impregnate peel
ply.
24. Cure for at least six hours at room
temperature and remove peel ply.
U900/000/TM/E/323
NOTE
Groove should be jig and located at
the exact location, and proper
dimensions shall be determined
using a tool kit.
25. Using 1/8" or 3 mm router bit, cut one or
two grooves as applicable (refer to Table
6-8 for installation of a single or double
hinge/lever).
26. Prepare a mixture of EA 9309.1 NA
adhesive and chopped glass fiber s.
27. Using a piece of thin sheet metal or
spatula, apply adhesive mixture to both
grooves of Rohacell block and hinge/
lever.
28. Attach hinge/lever in place, ensuring gap
between Rohacell slots and hinge/lever
is 0.4 to 1 mm.
29. Ensure installed hinge\lever meets
correct location and positioning prior to
proceeding with the curing process.
30. Cure for at least eight hours at room
temperature.
31. Prime and finish repair area as specified
in Chapter 3.
32. Clean work area and remove remaining
unused repair material.
33. Remove wrapping paper from work area
and protective devices from all lines and
electrical connectors.
34. Check electrical connectors for epoxy
and carbon dust and clean with vacuum
cleaner and contact spray.
6-107
U900/000/TM/E/323

Figure 6-22. Hinge/Lever Assembly - Repair of Major Damage to Rohacell Block (Sheet 1)

6-108
 U900/000/TM/E/323

Figure 6-22. Hinge/Lever Assembly - Repair of Major Damage to Rohacell Block (Sheet 2)

6-109
U900/000/TM/E/323

Figure 6-22. Hinge/Lever Assembly - Repair of Major Damage to Rohacell Block (Sheet 3)

6-110