25-01-12
ALL ú ú 01 Page 718 ú Nov 12/01
BOEING PROPRIETARY - Copyright (C) - Unpublished Work - See title page for details.
A
737-300/400/500MAINTENANCE MANUAL
EQUIPMENT/FURNISHINGS - APPROVED REPAIRS
________________________________________
1. General________
A. This procedure contains instructions to do approved repairs on the following items:
(1)
Crushed-core and sandwich panels.
(2)
Decorative surfaces.
(3)
Nomex honeycomb sandwich panels with a decorative tedlar cover.
(4)
Tedlar covers of aluminum laminates.
(5)
Perforated panels.
(6)
Polycarbonate (Lexan), ULTEM, and Declar plastics.
(7)
Urethane foam.
(8)
Insulation blankets and covers.
(9)
Aluminum trim
TASK 25-01-12-308-009
2. Repair Crushed-Core and Sandwich Panels________________________________________
A. General
(1)
This procedure gives instructions to repair crushed-core and sandwich panels that have these types of damage:
(a)
Small scratches and dents
(b)
Large dents in thin crushed-core panels
(c)
Small holes and gouges
(d)
Damage that is more than 0.5 square inch but has no core damage
(e)
Damage that is more than 0.5 square inch with core damage
(2)
Make sure the area you want to repair is smaller than 100 square inches. If the area is larger than 100 square inches, you must replace the part.
B. Standard Tools and Equipment
(1)
Heat Gun - 1200 to 1500 watts
(2)
Saw - Hole
C. Consumable Materials
(1)
Adhesives
(a)
A00000 Filler - BMS 5-136, Ad Tech 15-3
(b)
A00216 BMS 5-28, Epocast 1618A/B
(c)
A00292 BMS 5-105, Type II, Class I, EC 3532A/B
(d)
A00905 BMS 8-201, Type II
(2)
B00083 Solvent - Aliphatic Naphtha, TT-N-95
(3)
B00168 Paper - Abrasive, 400-600 grit
(4)
G00034 Cheesecloth - Lint-free
(5)
G00077 Foam - BMS 8-133
(6)
G00129 Fabric - Woven prepreg glass, BMS 9-3 class 7
(7)
G00368 Tape - Mylar, Permacel No. 92
D. References
(1) AMM 20-10-27/201, Heat Guns, Soldering Guns, and/or Soldering Irons
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25-01-12
ALL ú ú 02 Page 801 ú Mar 12/02
BOEING PROPRIETARY - Copyright (C) - Unpublished Work - See title page for details.
A
737-300/400/500MAINTENANCE MANUAL
E. Access
(1) Location Zone
200 Upper Half of the Fuselage
F. Repair Small Scratches and Dents
NOTE: Use this procedure to repair panels that have damage that does
____
not go into the fiberglass or carbon skins.
For panels that are 0.25-inch thick or more, use this procedure to repair scratches and small surface dents that are not more 0.10-inch deep. For panels that are less than 0.25-inch thick, use this procedure to repair scratches and small surface dents that are not more than 0.005-inch deep.
S 348-048
(1)
Fill the damaged area with BMS 5-136 filler to make a crown above the adjacent area.
S 348-049
(2)
After the filler is hard, rub it with abrasive paper to the same level as the surface of the panel.
S 348-050
(3)
If this is a decorative panel, do the procedure to repair the decorative surface.
G. Repair Large Dents in Crushed-Core Panels
NOTE: This procedure is for panels less than 0.25 inch thick with
____
dents that are more than 0.005-inch deep.
S 888-054
CAUTION: BE CAREFUL WHEN YOU APPLY HEAT NEAR MATERIALS THAT CAN BURN.
_______ THE TEMPERATURE OF THE TEDLAR MUST NEVER BE MORE THAN 200°F OR THE TEMPERATURE AT WHICH THE TEDLAR DISTORTS, WHICHEVER IS LOWER. TOO MUCH HEAT CAN CAUSE DAMAGE TO THE TEDLAR.
(1) On the side that does not have dents, increase the temperature of the panel. Use a standard 1200 to 1500 watt handgun, until the panel is approximately 200°F.
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