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KDU 1034
carbon
uni-directional
tape
380 0.40 24
AIRCRAFT
DA 40 Series
AMM
Standard Practices and
Structures
Doc # 6.02.01
Rev. 5 51-20-00 Page 215
20 Sep 2007
B. Class 3 Repairs
Small holes or cracks in the outer skin where there is no internal damage to the component, the
sandwich material, or the inner skin.
Detail Steps/Work Items Key Items/References
(1) Make sure that the area around the damage is
clean.
(2) Carefully examine the area around the damage.
Look specially for disbonding between the inner
laminate layers and any core material.
Do a coin tap test to find the extent of
any disbonding or delamination.
(3) Remove damaged/loose laminate until the edges
of the laminates bond together and to any core
material.
Refer to Figure 3.
Use a sharp knife or grinding disk.
(4) Scarf the edges of the repair area with a grinding
disk or block.
Refer to Table 2 for data about the scarf
size.
(5) Count the layers of fabric that you will need to
replace.
Refer to the lay-up drawing for the
related structure for data about the cloth
type and orientation.
WARNING: DO NOT GET ACETONE ON YOUR SKIN. ACETONE CAN CAUSE
SKIN DISEASE.
WARNING: DO NOT BREATHE ACETONE FUMES. ACETONE FUMES CAN
CAUSE DISEASE.
CAUTION: THERE MUST BE NO GREASE OR DUST ON THE REPAIR AREA.
GREASE AND DUST PREVENT A GOOD BOND.
(6) Clean the area of the repair. If you use acetone to remove any
grease or dirt then you must re-sand
the repair area.
AIRCRAFT
Standard Practices and
Structures
DA 40 Series
AMM
Page 216
20 Sep 2007 51-20-00 Doc # 6.02.01
Rev. 5
Scarf the Edges of the Repair Area
Repair the Laminate
Contour the Laminate
New Laminate
New Laminate
Laminate
Foam Core
Remove Damaged /Loose Laminate
Laminate
Scarf
Figure 3: Typical Class 3 Repair
AIRCRAFT
DA 40 Series
AMM
Standard Practices and
Structures
Doc # 6.02.01
Rev. 5 51-20-00 Page 217
20 Sep 2007
Detail Steps/Work Items Key Items/References
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) Repair the laminate. Use one of the 2 methods given in
Paragraph 5 of this Section.
(8) Pre-cure the repair. Refer to Paragraph 7 in this Section.
(9) Post-cure the repair. Refer to Paragraph 7 in this Section.
(10) When the repair is fully post cured, remove the
peel ply and sand smooth the surface of the
repair.
(11) Contour the repair so that the final surface level
of the repair is slightly lower than the original
surrounding area.
Use 150 grit sanding paper.
To allow for the paint coat.
(12) Apply filler(s) and paint coat. Refer to Paragraph 8 in this Section.
AIRCRAFT
Standard Practices and
Structures
DA 40 Series
AMM
Page 218
20 Sep 2007 51-20-00 Doc # 6.02.01
Rev. 5
Laminate
Laminate
Foam Core
Remove Damaged/Loose Laminate
Remove Damaged Foam Core and Scarf Laminate
min. 20 mm (0.8 in) min. 20 mm (0.8 in)
Scarf Scarf
Foam Insert
Foam Insert
Laminate
Laminate
Insert the Laminate and Foam Core into the Repair
Profile the Foam Core Insert
Laminate
Laminate
Repair the Laminate
Contour the Laminate
Figure 4: Typical Class 2 Repair
AIRCRAFT
DA 40 Series
AMM
Standard Practices and
Structures
Doc # 6.02.01
Rev. 5 51-20-00 Page 219
20 Sep 2007
C. Class 2 Repairs
Holes and cracks passing through both skins of a sandwich construction component. The core
damage must be able to be covered by a 75 mm (3 inches) diameter circle.
Detail Steps/Work Items Key Items/References
(1) Make sure that the area around the damage is
clean.
(2) Carefully examine the area around the damage.
Look specially for disbonding between the inner
laminate layers and the foam core.
Do a coin tap test to find the extent of
any disbonding or delamination.
(3) Remove exterior laminate which is damaged or
has become disbonded from the foam core. The
edge of the laminate must bond to the foam core.
Refer to Figure 4.
(4) Remove the damaged foam core. Remove sufficient foam core to give a
minimum of a 20 mm (0.8 inches) edge
around the outside of the damaged
area. Refer to Figure 4.
(5) Scarf the edges of the external laminate repair
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