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(11) If necessary, apply a vacuum bag to the laminate. Refer to the lay-up drawing and/or
repair drawing.
AIRCRAFT
Standard Practices and
Structures
DA 40 Series
AMM
Page 204
20 Sep 2007 51-20-00 Doc # 6.02.01
Rev. 5
B. Laminating on a Table
Detail Steps/Work Items Key Items/References
(1) Prepare the damaged area for laminating. Make
sure that the repair is clean and free from
contamination.
Refer to the relevant repair procedure in
this Section.
(2) Protect the area of the structure around the repair
from contamination by the repair materials.
Use plastic/polythene sheet material
held in place by self adhesive tape.
(3) Put a layer of clean transparent plastic/polythene
sheet over the repair and hold it in place with self
adhesive tape.
(4) Use an indelible felt marker to:
S Trace onto the plastic sheet the extreme
outline of the repair.
S Trace onto the plastic sheet the contour lines
of each layer of cloth in the structure.
The outer layer of the structure must be
tapered to avoid stress risers and to
give a good finish.
(5) Remove the transparent sheet from the structure
and place it upside down on a work table.
Note: The cloth layers are laid in reverse order when you laminate on a table. You
must take care to put the cut cloth layers in the correct order and that the fibers
in each cloth layer point in the correct direction.
(6) Cut the layers of cloth to fit the contour lines that
you traced onto the transparent sheet.
WARNING: DO NOT GET RESIN ON YOUR SKIN. RESIN CAN CAUSE SKIN
DISEASE.
WARNING: DO NOT GET RESINS, HARDENERS OR SOLVENTS IN YOUR
MOUTH OR IN YOUR EYES. THESE CHEMICALS CAN CAUSE
DISEASE.
(7) Apply a thin coat of resin to the transparent
sheet.
(8) Apply the first inner layer of cloth to the
transparent sheet and trim to the correct size.
Make sure that the fibers in the cloth
point in the correct direction.
AIRCRAFT
DA 40 Series
AMM
Standard Practices and
Structures
Detail Steps/Work Items Key Items/References
Doc # 6.02.01
Rev. 5 51-20-00 Page 205
20 Sep 2007
(9) Use a roller, squeegee and a stipple brush to
remove all trapped air. Make sure that the cloth is
completely impregnated with resin. If necessary,
add more resin.
(10) When the excess resin has been brought to the
surface with the rolling and stippling process,
apply the next layer of cloth. Trim the cloth to the
correct size.
Make sure that the fibers in the cloth
point in the correct direction.
(11) Do steps 9 and 10 as necessary until all the
layers of cloth are in place.
(12) Apply a thin coat of resin to the area of the repair
on the structure where you will attach the
laminate patch.
(13) Put the laminate patch carefully into position on
the structure using the transparent sheet.
Make sure that the fibers in the cloths
point in the correct direction.
(14) Carefully remove the transparent sheet from the
laminate patch.
(15) Use a roller to make sure that the laminate patch
is firmly in position and that any excess resin is
removed from the repair laminate.
(15) Put a layer of peel ply over the laminate.
(16) If necessary, apply a vacuum bag to the laminate. Refer to the lay-up drawing and/or
repair drawing.
AIRCRAFT
Standard Practices and
Structures
DA 40 Series
AMM
Page 206
20 Sep 2007 51-20-00 Doc # 6.02.01
Rev. 5
Table 1 - Bonding Paste Mixing Table
Material Weight in Grams
Mixed Resin 50 100 150 200 250 300 350 400 450
Cotton Flocks 6 11.5 17 23 29 34.5 40 46 52
Aerosil 1.4 2.8 4.2 5.5 6.9 8.3 9.7 11.1 12.5
AIRCRAFT
DA 40 Series
AMM
Standard Practices and
Structures
Doc # 6.02.01
Rev. 5 51-20-00 Page 207
20 Sep 2007
6. Bonding Paste (Thickened Resin)
% CAUTION: TO BOND PARTS MADE OR REPAIRED WITH SELF EXTINGUISHING
% RESIN, YOU MUST USE SELF EXTINGUISHING RESIN TO MIX THE
% BONDING PASTE (REFER TO SECTION 51-30).
Use bonding paste to bond GFRP/CFRP components together and in the repair of
sandwich cores. Resin and thickening fillers make bonding paste. Table 1 gives you the
proportions by weight of resin to thickening fillers. You can change the proportions of
Aerosil and Microballoons relative to each other but you must keep the total weight of the
Aerosil/Microballoon mix constant.
7. Curing
You must cure a composite structure to make it strong. If you do not cure a composite structure
correctly it may fail. Curing is a 2 part process, pre-curing and post-curing. The following procedure
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