3. Fairing Compound - Approved Repairs
A.
In the case of a repair covering a large part of the fairing compound surface, the installed fairing compound must be a flat plane within 0.00士0.03 inch around the entire periphery of the window. The method used in manufacture is to make up a faceplate, with a surface as nearly as possible corresponding to that of the replacement window, and clamp or bolt it in position. For very small areas of repair the compound should be smoothed off with a hand tool as evenly as possible.
B.
In the case of all partial repairs the window frame should be prepared as described in par. D.(1)(a). If the old fairing compound has been completely removed, new compound should be applied to the window frame as described in par. D.(1)(b).
C.
Equipment and Materials
(1)
Sandpaper, 400 grit
(2)
Cleaning Solvent - BMS 11-7
(3)
Cheesecloth, lint and oil-free, or equivalent
(4)
Aliphatic Naphtha - TT-N-95A, Type II
NOTE: Freon-TF, or equivalent may be used in lieu of aliphatic naphtha, TT-N-95A, Type II, for general cleaning of windows.
(5)
Fairing Compound - EC-3587-1/4, EC-3587-1 or Tereco 175M (Ref 20-30-11)
(6)
Spatula - Or Semco Model 250 Sealant Gun, or equivalent
(7)
Teflon pressure sensitive tape, or Ivory soap and a soft bristle brush
(8)
Mold faceplate (for large repairs)
500
56-11-0 Page 802 BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. May 01/01
Sealant Shape-Windows With Z Channel Seal
Figure 801
500 Sealant Shape-Windows Without Z Channel Seal
Feb 15/79 Figure 802 56-11-0
Page 803
BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.
T54637 T54638
Sealant Cure Times 500
56-11-0 Page 804 Figure 803 BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. May 15/77
D. Prepare Window Frame and Fairing Compound for Repair
(1) Prepare Window Frame
NOTE: The procedures which follow assume that the extent of the area being repaired justifies the use of a faceplate as a forming tool. If the area is small enough to be repaired by a hand tool, it is less necessary to ensure that the newly applied compound is fully hardened before the window is installed.
(a) Prepare window frame for replacement of missing portion of fairing compound.
1) Clean affected portion of window frame surface by lightly sanding. It is not necessary to remove old fairing compound if in good condition or unless a new window being installed cannot be flushed up with the skin.
2) Wipe off sanded surface with a clean cloth soaked in cleaning solvent, just prior to application of fairing compound. Avoid use of excess solvent.
WARNING: SOLVENT CLEANER IS FLAMMABLE.
(b)
Prepare window frame from which old fairing compound has been completely removed. 1) Clean surface of window frame with cloth soaked in BMS 11-7 solvent and wipe
off, while wet, with a clean dry cloth. 2) Continue cleaning and drying until no soil is visible on the final drying cloth.
(c)
Wipe faying surface of faceplate with a clean cloth soaked in aliphatic naphtha. The cleaner should be wiped off, while wet, with a clean, dry cloth. The use of excessive cleaner must be avoided.
WARNING: ALIPHATIC NAPHTHA IS FLAMMABLE.
(d)
To ease removal, mask the contacting surface of the faceplate with one of the following: Teflon tape, baked on Teflon, room temperature cured Teflon, or a brush coat of Ivory soap applied with a soft bristle brush,
500
Feb 15/80 BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. 56-11-0 Page 805
(2) Prepare Fairing Compound
(a) The fairing compounds are available in pre-measured two-part kits; Tereco 175 is also supplied in one-part ready-to-use frozen cartridges. (Refer to Table I for characteristics of the different materials.)
WARNING: FAIRING COMPOUNDS AND SOLVENT CLEANER ARE TOXIC AND FLAMMABLE. AVOID PROLONGED OR REPEATED CONTACT WITH THE SKIN. DO NOT GET IN EYES. KEEP AWAY FROM SOURCES OF IGNITION.
CAUTION: MINIMIZE ENTRAPEMNT OF AIR DURING MIXING.
E. Repair Fairing Compound on Window Frame
(1)
Apply fairing compound with a spatula or an extrusion gun to the uneven surfaces, gaps and voids of window frame and fair to the desired contour and smoothness. Care must be exercised to avoid air entrapment and the formation of surface air bubbles during application of the fairing compound.
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