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Structures
B. Class 3 Repairs
Small holes or cracks in the outer skin where there is no internal damage to the component, the sandwich material, or the inner skin.
Detail Steps/Work Items Key Items/References
(1) Make sure that the area around the damage is clean.
(2) Carefully examine the area around the damage. Look specially for disbonding between the inner laminate layers and any core material. Do a coin tap test to find the extent of any disbonding or delamination.
(3) Remove damaged/loose laminate until the edges of the laminates bond together and to any core material. Refer to Figure 3. Use a sharp knife or grinding disk.
(4) Scarf the edges of the repair area with a grinding disk or block. Refer to Table 2 for data about the scarf size.
(5) Count the layers of fabric that you will need to replace. Refer to the lay-up drawing for the related structure for data about the cloth type and orientation.
WARNING: DO NOT GET ACETONE ON YOUR SKIN. ACETONE CAN CAUSE SKIN DISEASE. WARNING: DO NOT BREATHE ACETONE FUMES. ACETONE FUMES CAN CAUSE DISEASE. CAUTION: THERE MUST BE NO GREASE OR DUST ON THE REPAIR AREA. GREASE AND DUST PREVENT A GOOD BOND.
(6) Clean the area of the repair. If you use acetone to remove any grease or dirt then you must re-sand the repair area.
Doc # 6.02.01 Page 215
Rev. 4 09 Jan 2003
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Structures
AMM
Laminate
Foam Core Laminate
Remove Damaged /Loose Laminate Scarf
Scarf the Edges of the Repair Area
New Laminate
Contour the Laminate
Figure 3: Typical Class 3 Repair
Page 216 Doc # 6.02.01 09 Jan 2003 Rev. 4
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Structures
Detail Steps/Work Items Key Items/References
WARNING: DO NOT GET RESIN ON YOUR SKIN. RESIN CAN CAUSE SKIN DISEASE. WARNING: DO NOT GET RESINS, HARDENERS OR SOLVENTS IN YOUR MOUTH OR IN YOUR EYES. THESE CHEMICALS CAN CAUSE DISEASE.
(7) Repair the laminate. Use one of the 2 methods given in Paragraph 5 of this Section.
(8) Pre-cure the repair. Refer to Paragraph 7 in this Section.
(9) Post-cure the repair. Refer to Paragraph 7 in this Section.
(10) When the repair is fully post cured, remove the peel ply and sand smooth the surface of the repair.
(11) Contour the repair so that the final surface level of the repair is slightly lower than the original surrounding area. Use 150 grit sanding paper. To allow for the paint coat.
(12) Apply filler(s) and paint coat. Refer to Paragraph 8 in this Section.
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Structures
AMM
Remove Damaged/Loose Laminate Scarf Scarf
min. 20 mm (0.8 in) Remove Damaged Foam Core and Scarf Laminate
Insert the Laminate and Foam Core into the Repair
Laminate Profile the Foam Core Insert
Repair the Laminate
Contour the Laminate
Figure 4: Typical Class 2 Repair
Page 218 Doc # 6.02.01 09 Jan 2003 Rev. 4
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