5C9 Soldering Iron Tips (Repair Method No. 3)
Feb 20/85 Figure 202 25-00-11
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BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.
E. Repair Method No. 4
(1)
General
(a) This method of repair is used to re-emboss small cuts and scratches where no base material is removed.
(2)
Equipment and Materials
(a)
Ungar soldering iron (with shaped tip)
(b)
Variable Autotransformer - Powerstat, Type 116-- See Table 1.
NOTE: Tip used will depend upon type and location of damage and skill of repairman.
(3) Repair: (Hot Point Embossing)
(a)
Use soldering iron with shaped tip and point heat fuse re-emboss small cuts and scratches in decorative part where no base material is removed.
(b)
After damaged material has been heated sufficiently to flow, part shall be re-embossed to produce correct surface texture by using stippling motion.
NOTE: Quality of re-embossing will depend upon skill of operator.
(4) Repair: (Cold Point Embossing)
(a)
Any appropriate tool may be used, such as leather working tools.
(b)
Re-emboss damaged material by pressing tool into surface with a stippling motion to produce correct surface texture.
F. Repair Method No. 5
(1)
General
(a) This method is used to repair cuts or tears which completely penetrate decorative material.
(2)
Equipment and Materials
(a)
Screws
(b)
Traffic Wax - Johnson's Heavy Duty, or equivalent
(c)
Decorative materials - similar to material being repaired
(d)
Wood frame
(e)
C-clamps
(f)
Hardener - Kish 50-AM
(g)
Resin - Kish 426-M
(h)
Mylar film
(i)
Metco SF Aluminum
(j)
Cloth - Osnaburg
(k)
Resin -Epibond 126
(l)
Hardener - HN 9812
(m)
Ferro No. 7005 (white titanium dioxide)
(n)
Calcium carbonate
(o)
X-Acto Knife No. 1 and X-Acto Blade No. 11
(p)
Bell jar and vacuum pump
(3)
Repair: (Epoxy Sweep - Fairing)
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(a) Splash Casting Procedure for Embossing Mylar Film.
1) With wood details, construct frame to one square foot (inside dimension). Nails or screws shall be used to hold frame together. Joints of frame must be tight as possible.
2) Apply heavy duty traffic wax to all side of wooden frame. Three coats shall be applied in order to form reliable parting surface to the wood.
3) Obtain piece of decorative material that will match surface texture of material to be repaired. Size of material must be at least 4 inches in excess of inside dimensions of wooden frame.
4) Clean decorative side of material with aliphatic naphtha (TT-N-95) in
accordance with cleaning Method 7.
5) Place decorative material texture side up on small surface table.
6) Apply parting film of heavy duty traffic wax to textured surface of vinyl. Remove
excess wax by polishing.
7) Place wood frame on decorative material and clamp to table surface with C clamps.
8) Accurately weigh and thoroughly mix the following materials: (Stir slowly. Do not
mechanically agitate.) 100 parts by weight - Kish 426M Resin 18 parts by weight - Kish 50AM Hardener
NOTE: Total volume of resin to be used will depend on size of splash casting required. This procedure is not limited to casting size. 12 x 12 inch casting described herein is an arbitrary dimension. Dimensions of splash castings are limited to platen size of press to be used for embossing mylar film.
9) Deaerate mixture for approximately 10 minutes using Bell jar and vacuum pump.
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Oct 20/86 BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. 25-00-11 Page 211
10) Pour resin slowly onto prepared surface of decorative material. Mixture shall be poured as close as possible to surface of decorative material in order to prevent air inclusions in the casting.
11) Casting shall be at least 1/4 inch in thickness.
12) Cure casting for 8 hours at room temperature or 4 hours at 120°F.
13) After cure, carefully remove wood frame and decorative material from casting.
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