Custom Kit oo Creedmoor, NG 27522-8294 Tels (918) 886-4900 Fax: (919)-582-3786 } CUSTOM KIT No. 163, August 4, 1998 PPG WINDSHIELD MOISTURE SEAL INSTALLATION AND REPAIR PROCEDURE FOR INSTALLED TWIN COMMANDER WINDSHIELDS MODELS AFFECTED: 6S0A/BICID, 695/15 REASON FOR PUBLICATION: This procedure is applicable to installed windshields for the addition or repair of hump seals as the primary weather seal between the glass and fiberglass strap. It is necessary to perform the glass surface preparationicleaning procedure detailed below for al repairs that require replacement of a portion of the seal that contacts the glass surface or fberalass surface(s) ‘COMPLIANCE: At owner's discretion. BY WHOM WORK WILL BE ACCOMPLISHED: A & P mechanics or equivalent APPROVAL: Engineering design aspects are FAA approved ESTIMATED MANHOURS: 12 Hours PLANNING INFORMATION: It is recommended that all subject windshields be inspected for outboard moisture seal erosion or delamination every four months. Particular attention should be taken at the areas eroded by the wiper blades. The entire hump seal area should be inspected to determine if it is well bonded to the glass and fiberglass strap surfaces. If there is evidence that portions of the seal can be lifted with finger or plastic spatula pressure, those portions should be removed and repaired per the following instructions, NOTE IT IS ESSENTIAL THAT REPAIRS BE MADE AS NEEDED TO INSURE MAXIMIZATION OF WINDSHIELD SERVICE LIFE. PARTS DATA: The kit is available from authorized Twin Commander Service Centers. Order kit no. CK163, MATERIALS SUPPLIED WITH KIT: 1 Products Research Primer PR142 (16 02.) 6 Courteudis PR 1425 8-1/2 Black with PR 142 Primer (Model 654 SEMKIT) 5Pr Rubber Gloves (Powder Free) PAGE 1 0F @(CUSTOM KIT NO. 163 1 Plastic Spatula 4 Roll Maskirg Tape (3m Scotch #232 Or Equiv. Crepe Paper Tape) Box Gauze Pads 5 Cotton Cloths 1 Gellulcse Sponge 2Sht. Sandpaper (Norton 220 Grit Or Equivalent) Razor Blades (Single Edge, Safety) Felt Blacks (4x45 in.) ZUD® Cleanser With Ovalic Acid / Pumice / Cerium Oxide CK163 "HUMP SEAL’ Tool MATERIALS PROCURRED LOCALLY: Aliphatic Naphtha Or Methyl Ethy! Ketone (MEK) Isopropyl Alcohol (100%) Water INSTRUCTIONS: ‘A. Outboard Glass and Fiberalass Strap Surface Preparation +1. Mask off the outer glass surface of the window up to the inside edge ofthe existing outboard moisture seal. This taping is to insure protection of the glass surface during removal of the damaged sealant and fiberglass strap. 2. Completely mask the metal window retainer from the inside edge of the retainer to the outside edge ‘3. When the masking is completed as detailed in steps t and 2, an open work area the width of the existing seal should exist. 4, Carefully remove any damaged, debonded or deteriorated sealant or fiberglass with a single edge safety razor blade by shaving along the surface. This is made easier by slightly bending the razor blade at center to insure that the comers do net scratch or cot into the cutboard glass surface. 5 After removal of the damaged sealant, sand the exposed surface of the remaining intact fiberglass strap with 220 grt sandpaper. CAUTION: BE CAREFUL NOT TO ABRADE OR SCRATCH THE OUTER GLASS PLY ‘SURFACE WITH THE SANDPAPER. 6. After sanding fiberglass strap(s), remove the masking tape and thoroughly clean the exposed glass surface and remaining fiberglass strap using a clean cloth saturated ‘with aliphatic naphtha or methyl ethyl Ketone (MEK). Degrease the work area utilizing progressive cleaning procedure by cleaning a small area at a time followed by PAGE 20F 8CUSTOM KIT NO. 163 isopropyl rinse to remove solvent residue, then dry with a clean cloth. Discard soiled cloths regularly o prevent redepositing contaminants. 7. Apply masking tape as shown in Figure 1. After taping, an open work area of approximately 1.00 inch should exist. 8, Soak a block of clean felt with water and using a slurry of either pumice, cerium oxide of ZUD® cleanser and water, polish the exposed glass surface by hand all around until ‘observing @ water-break free surface. A water-break free surface completely "wets" or “sheets over the glass surface with no signs of drawing up into droplets showing dry areas in betwesn. Continue polishing until the water-break free surface is obtained ‘Achieving the water-break free surface is critical to insure adhesion of the sealant to the outer glass surface. This stop is critical to achieving proper bond of the PR 1425 B- 4112 to the glass since complete removal of the PPG surface seal in the bond area is required. 9. After a water-break free surface is obtained, remove tape from glass and clean the entire area with isopropyl alcoho! (100%) and allow to air dry. Repeat the cleaning operation charging cloths frequently until no residue is visible on the surface of cloth 40. Apply 1" masking tape to the outboard glass surface as shown in Figure 2. One layer of tape shouldbe applied 25 inch from the edge of the fiberglass strap using the "pump" seal forming tool as a template, Build up the thickness using multiple layers of tape 50 inch from the edge of the fiberglass strap to form a guide for the "nump" seal forming tool. After masking, an open area of 25 inch should exist between the inside fedge of the fiberglass strap and the outside edge of the first layer of masking tape. Mask the remeining area of glass (daylight opening) to protect glass surface during repair operaticn, Figure 3 and Figure § show configuration of repaired "hump' seal Figure 4 shows configuration of OEM *hump* seal +14. Wearing powder free rubber gloves, repeat the cleaning operation with clean cloths saturated with isopropyl alcohol (100%). Take care not to soak the masking tape ‘and contaminate the qlass with adhesive from the tape. Again, wipe the surfaces Unlitno residue is visible on the cloth. Allow surtace to air dry a minimum of five minutes, 42. After a thorough cleaning of the area to be repaired has been accomplished, apply the ew sealant pr the following detailed moisture seal application procedure, B. Moisture Ses! Application Procedure General Instructions 4. Follow all esteblished safety rules and practices. 2. Read material safety data sheets for each material to be used. 3, Wear powder free clean rubber gloves during all sealant applications to avoid contamination of the bonding surfaces and to prevent chemical contact with skin. PAGE 3 OF 8CUSTOM KIT NO. 163 C. Moisture Seal Application Procedure > 4. Apply 1 inch masking tape to the outboard metal retainer from the inside edge of the ‘outboard metal retainer as shown in Figure 2. 2. Using @ gauze pad, apply a thin coat (encugh to cover without running or dripping) of the PR 142 primericleaner to the cleaned glass surface to be bonded, Allow PR 142 to dry per manufacturers requirement. 3, Sealant must be applied to windshield immediately after the cleaning operation and primer application to prevent dust particles and other airborne contaminants from Setting on the cleaned surfaces. Any contaminant on the surface can adversely effect the adhesion of the sealant to the substrate. Note: Apply mixed sealant after allowing primer to dry. (See manufacturers" instructions). ‘4, Thoroughly mix the contents of the SEMKIT containing the appropriate sealant until no streaks of either material are visible. Mix components for a minimum of five minutes, COMPLETE MIXING IS ESSENTIAL Follow the miking instructions on the side of the SEMKIT package: ‘a) Wear safety glasses and gloves while mixing and dispensing ) Hold cartridge and pull dasher rod back approximately 1/4 of the way up the cartridge c) Insert ramtod into hollow ef dasher rod. Move piston and inject about 1/8 of the contents of the rod into the cartridge, CAUTION: USE FIRM BUT EVEN PRESSURE. DO NOT FORCE, TAP, POUND OR JOLT RAMROD, IF PISTON DOES NOT MOVE READILY. 4d) Repeat steps b and c until all the contents of the rod are emptied into the cartridge. Remove ramrod, 6) Hand mix Mix material for the total number of strokes listed (40 strokes! 20 strokes per minute). A stroke is one complete in and out cycle. Hold cartridge and rotate rod £0 degrees in a spiral clockwise motion with each stroke. Each stroke should extend from the nack end of the cartridge to the plunger end of the cartridge. Accepted procedure is 30 strokes per minute 5, Remove the mixed sealant from the SEMKIT tube by the following procedure a) Remave bottom cap. 4 ) Push dasher rod to plunger end of cartridge. Grasp cartridge firmly at plunger end and detacr dasher rod from mixing dasher by turning counter clockwise Pace 40F8CUSTOM KIT No. 163 Remove the dasher rod from cartridge, Using the dasher rod, push/extrude contents of ‘SEMKIT tube onto the surface to be sealed 6. Using a plastic spatula or air gun, spread the sealant on the cleaned and primed ‘outboard glass surface to be bonded. 7. Form the outboard "hump" seal using hump seal tool as shown in Figure 6. The width of the formed "hump" seal should be 1 inch, The thickness of the formed seal should be 0.10 inch +.02 inch. See Figure 3 and Figure 5 for view of "hump" seal after repair. Figure 4 shows view of OEM moisture seal After completing forming of "hump" seal immediately remove the masking tape from the glass and metal surface while the sealants sill wet” (uncured). Be careful not to touch the "wet" (uncured) sealant during tape removal 9, Smooth the surface of the "wet" sealant by rubbing the surface of the sealant very lightly and briskly with a cellulose sponge saturated with water or isopropyl alcohol (100%. Note: Use light pressure only. 40. Allow the sealant to cure. Tackfree cure time for PR 1425 8-1/2 is accomplished at room temperature (75 degrees F /50% relative humidity) in 8 hours. Cure time to 35 Rex hardness is 24 hours, For every 10°-15°F. rise in temperature (to @ maximum of 140° F] the cure times are cut in half, for every 10°-15? F. decrease in temperature, the cure time is doubled. 11. After the sealant has cured, inspect for voids and repair as necessary, PAGES OF 8‘CUSTOM KIT NO. 163 FIGURE 4 ‘TAPE FOR CLEANING MULTIPLE LAYERS OF MASKING TAPE MASKING TAPE 10 REF. FiGURE 3 PROPOSED HUNP SEAL FIELD REPAIR PAGE 6 OF 8elbows x sano was dwn O01 £91 X9 291 “ON Lm WoLsno