(b)
Cure the laminate for 24 hours at room temperature, for two hours at 120 degrees F, or for 30 minutes at 180 degrees F.
S 358-046
(11) Let the part cool to 90 degrees F before you remove the vacuum pressure.
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747-400 MAINTENANCE MANUAL
TASK 25-00-00-308-021
8. Repair Polycarbonate (Lexan), ULTEM, and Declar Plastics
________________________________________________________
A. General
(1) The paragraphs that follow give instructions to repair cracks and gouges in decorative and nondecorative plastics.
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)
A50005 Hysol EE 1067 Resin
(b)
A00112 Hysol No. 3561 Hardener
(2)
G02022 Rubber - Silicone, Dow Corning Silastic
RTV B
(3)
G02024 Rubber - Silicone, RTV 93-079, Clear
(4)
G00034 Cheesecloth - Lint-free
(5)
Solvents
(a)
B00083 Aliphatic Naphtha, TT-N-95
(b)
B00149 Methylene Chloride
(6)
G00321 Fabric - Woven prepreg glass, BMS 9-3,
Type H, H-2, H-3, Class 3 or 4
(7)
Finish, Internal Decorative Water Emulsion,
BMS 10-55
(a)
C00375 Type I
(b)
C00377 Type II
(8)
Finish, Silk Screen Ink - BMS 10-73
(a)
C00367 Type I
(b)
C00368 Type II
(9)
C00040 Paint - Polyurethane, BMS 10-38 Type II
(10)
B00168 Paper - Abrasive, 400 grit
C. References
(1) 25-00-00/701, Equipment/Furnishings
D. Access
(1) Location Zone
200 Upper Half of the Fuselage
E. Repair Cracked Areas
S 348-148
(1)
Drill a 1/16-inch diameter hole at each end of the crack.
S 348-149
(2)
Remove material from the crack until the width of the crack is approximately equal to the thickness of the part.
(3)
Rub the surface with abrasive paper until the surface is not glossy.
S 348-150
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747-400 MAINTENANCE MANUAL
S 348-120
(4)
Clean the surface with aliphatic naphtha and a clean cheesecloth.
S 348-121
(5)
Mix the repair resin as follows:
(a) Mix one hundred parts of the No. 3561 hardener with 15 or 16 parts of the Hysol TE 1005 resin. .
S 348-151
(6)
Fill the crack with the repair resin.
S 348-123
(7)
Let the repair resin cure until it is hard.
S 348-152
(8)
Apply glass fabric that is soaked with the repair resin to make the repair stronger.
NOTE: If you want to repair a decorative part, put the fabric
____
in the side that is not decorative.
The glass fabric layers must be at least as thick as the part where the crack was. Taper the glass fabric 1/2 inch for each layer at each side. If the crack is at or near an edge, the taper is not necessary.
S 348-153
(9)
Remove all the unwanted resin.
S 348-154
(10)
Let the repair cure until it is hard at a temperature
between 70 and 130°F.
S 348-155
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