TASK 25-01-12-308-006
4. Repair Nomex Honeycomb Sandwich Panels that have a Decorative Tedlar Cover
__________________________________________________________________________
A. General
(1) This task gives instructions to repair damage that went through the decorative tedlar laminate into the honeycomb sandwich panels.
NOTE: 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. Consumable Materials
(1) Adhesives
(a) BMS 5-126, Type II, Class 1
1) A00273 Component A Formulation a) Epon 828 or DER 331 b) Heloxy 68
2) A00050 Component B Formulation a) Versamid 115 b) Versamid 125
(b) A00042 Scotchcast 5126
(2) G00034 Cheesecloth - Lint-free
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737-300/400/500MAINTENANCE MANUAL
(3)
B00083 Solvent - Aliphatic Naphtha, TT-N-95
(4)
A00044 Adhesive - TUF-ON P-24A
(5)
Finish - Silk Screen Ink, BMS 10-73, Applicable
color as necessary
(a)
C00367 Type I
(b)
C00368 Type II
(6)
G00077 Foam - HETROFOAM, BMS 8-133, Type I,
Grade 20, Form A
(7)
G00000 Laminate - Decorative tedlar
(8)
G00380 Paper - Abrasive, 240-320 grit
(9)
G02022 Rubber - Silicone, Dow Corning Silastic
RTV B
(10)
G02024 Rubber - Silicone, RTV 93-079, Clear
(11)
Tape
(a)
G00123 Doublebacked, 2 inches wide -Permacel No. 94
(b)
G00147 Masking, 1 or 2 inches wide -Permacel No. 718
C. Access
(1) Location Zone
200 Upper Half of the Fuselage
D. Repair Flat Panels or Simple Contoured Panels with Large Radii
S 348-027
(1) Use these steps to make a silicone embossing pad of the surface that is adjacent to the area you will repair:
(a)
Clean the surface with aliphatic naphtha.
(b)
Make a frame, approximately 3/8-inch wide by 1/2-inch high, around the clean surface.
NOTE: Use wood, clay, or high temperature vacuum sealant tape
____
for the frame.
(c) Apply a thin layer of prepared silicone rubber on the textured surface in the frame with a brush. Continue to use the brush until you cannot see air bubbles.
NOTE: Almost all brands, types, or colors of castable silicone
____ rubber are satisfactory, but not the dark red types which contain finely divided iron oxide. Dow Corning Silastic RTV "B", "E", 587, or 93072, and General Electric RTV41 or RTV61 are preferred. Prepare the silicone rubber with the manufacturer's instructions.
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737-300/400/500MAINTENANCE MANUAL
(d) Pour the remaining silicone rubber on the brushed surface until it is 1/4 inch thick. Let it cure at room temperature for 48 hours.
NOTE: One pound of prepared silicone rubber will make a
____ 10-inch-by-10-inch-by-1/4-inch replica.
(e) When the silicone is dry, remove the embossing pad from the surface.
S 348-154
(2) Attach a template with the correct hole diameter on the damaged area with the double-backed tape. Use the hole saw to remove the damaged area.
NOTE: Use a guard to make sure you do not cut the aft surface
____
of the panel.
S 348-029
WARNING:_______DO NOT TOUCH THE ADHESIVES OR BREATHE THE VAPORS. THE ADHESIVE COMPOUND CONTAINS EPOXY RESINS. THE ADHESIVE CAN CAUSE INJURY TO PERSONS.
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