NOTE: Thickness should be same or slightly less than the honeycomb core to be replaced.
(b)
Bond a piece of decorative laminate of proper color, design and texture to the foam.
(c)
Using a hole saw, cut out damaged area. Set cutter depth so fiberglass on back surface of panel is not cut.
(d)
Cut out a plug from the bonded foam of step (b).
NOTE: The outside diameter of the saw used in step (c) must be equal to the inside diameter used to remove the plug from step (d).
(e)
Remove all core remaining in area from which damage was cut.
(f)
Sand plug and hole to remove all burrs.
(g)
Check plug for fit, alignment, design, color, texture, thickness, and diameter.
NOTE: The only visible defect in a properly fitted plug will be a fine transition line between plug and panel.
(h)
Coat the nondecorative portion of plug with BAC5010, type 71 adhesive. Use only enough adhesive to ensure a completely wetted bond area.
(i)
Position coated plug in panel aligned per step (g) and immediately remove any resin which may have gotten on the decorative panel using a chlorinated solvent.
NOTE: Steps (h) and (i) are to be performed within 4 minutes maximum, due to short adhesive pot life.
(j)
Secure plug in position and realign if necessary (aggressive tack adhesive tape may be used to secure plug).
(k)
Allow adhesive to cure per BAC5010, type 71.
(l)
After adhesive has cured, sand area around plug perimeter to smooth transition area between plug and panel.
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BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.
(m)
Color match BMS 10-73 ink and apply to repair with an artist brush. Allow to dry for 15 minutes.
(n)
When perforated panels are repaired, the above steps thru (m) should be followed and holes, which have been filled with adhesive or ink, should be drilled out. Excessive ink or adhesive significantly increases repair time.
(6) Large Area Repair
(a)
Carefully remove the damaged decorative surface and bond ply from panel.
(b)
Replace any damaged honeycomb.
(c)
Obtain a new decorative laminate having the proper design, color and texture.
(d) Reprocess panel per BAC5524. AJ. Repair Method No. 34
(1)
General
(a) This repair method is for the repair of edge delamination of vinyl decorative facing.
(2)
Equipment and Materials
(a)
Solvent - Aliphatic Naptha-TT-N-95
(b)
Abrasive paper - 400 grit or finer
(c)
Adhesive - 3M 77
(3)
Repair Procedure
(a)
Moisten gauze pad with solvent.
(b)
Rub soiled area with gauze pad.
(c)
Dry with clean gauze pad.
(d)
Use abrasive paper to remove persistent contamination.
(e)
Apply adhesive to both surfaces. Allow solvent to flash off. Use only enough adhesive to wet surfaces.
(f)
Bond surfaces eliminating any bubbles or adhesive ridges.
505
Feb 20/86 BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. 25-00-11 Page 247
AK. Repair Method No. 35 to No. 37 (NOT APPLICABLE) AL. Repair Method No. 38
(1)
General
(a) This method is for scratch or minor indentation damage to Tedlar covered aluminum.
(2)
Equipment and Materials
(a)
Abrasive paper - 240 to 600 grit
(b)
Scotchbrite pad, type A
(c)
Soft cloth - Rymple
(d)
Surfacing putty - Ditzler, Red Cap spot putty
(e)
Surfacing putty - Duratite, Ad Tech 15-3
(f)
Solvent - Methyl ethyl ketone (MEK)
(g)
Gauze pad
(h)
Spring gun - Binks Model No. 15
(i)
Artist brush
(j)
Ink
(3)
Repair Tedlar Covered Aluminum
(a)
Sand damaged area with adhesive paper or Scotchbrite.
NOTE: Limit sanding of Tedlar to frayed or damaged edges only. Do not sand Tedlar surface to be bonded.
(b)
Moisten soft cloth with MEK.
(c)
Pat soiled area with cloth.
(d)
Dry with gauze pad.
(e)
Repeat (c) and (d) if necessary.
(f)
Fill scratch or indentation with Duratite, Ad Tech 15-3 and feather edges. Ditzler, Red Cap Spot putty may be used for pin holes or light surfacing.
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