Doc # 6.02.01 Page 201
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AMM
DA 40 Series
Detail Steps/Work Items Key Items/References
(6) Carefully remove the protective coating from the new window only where it will bond to the frame.
(7) Grind the bonding surface of the window. Use 120 grade abrasive paper.
(8) Make sure that the viewing area of the window is protected. Use masking tape with paper.
(9) Apply adhesive to the frame. Use Terostat 9380.
(10) Put the window in position in the frame. Hold the window with 3 mm pins through the 2 holes in the canopy.
(11) Removed unwanted adhesive.
(12) Allow the adhesive to cure for 24 hours.
(13) Remove the 2 pins.
(14) Apply a bead of white sealant to the gap between the edge of the window and the frame. Use Terostat 9380.
(15) Allow the sealant to cure. Follow the manufacturer’s instructions.
(16) Remove the protective covering from the window.
(17) Install the canopy or door. Only if you have replaced the canopy or door window. Refer to Section 52-10.
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3. Window Repairs
A. Damage Limits
Maximum crack length: 150 mm (6 in).
Do not repair cracks which are more than 150 mm (6 in) from the edge of the window.
B. Equipment
Item Quantity Part Number
Small high-speed rotary grinder. 1 Commercial
Filler: Acryfix 92 or Tensol cement No. 70. A/R Commercial
Masking tape. A/R Commercial
Plastic adhesive tape. A/R Commercial
Cold ultra-violet light source (only for Acryfix 92). A/R Commercial
Note: Fillers become smaller when they cure. Apply enough filler to be above the level of the window surface. Cut the filler back when it has cured.
If you repair a vertical crack, keep the filler in place with plastic adhesive tape. Apply a second coat of filler after the first coat has cured.
C. Temporary Repairs to Windows
Stop-drill the ends of short cracks. Use a 2.5 mm (3/32 in) drill. Refer to Figure 2.
Doc # 6.02.01 Page 203
Rev. 4 09 Jan 2003
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AMM
MaskingCrack Window
Tape 60-90° Outer Surface
Inner SurfaceSTEP 1
Cold UV Light
Filler
(Acryfix Filler Only)
STEP 2
Stop-drill 2.5 mm (3/32 in)
Outer
>1/3 Thickness
STEP 3
Tape
Cold UV Light (Acryfix Filler Only) STEP 4
Grind to Contour and Polish with Fine Abrasive Paper
STEP 5
Figure 2: Window Repairs
Page 204 Doc # 6.02.01 09 Jan 2003 Rev. 4
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AMM
D. Permanent Repairs to Windows
DA 40 Series
Detail Steps/Work Items Key Items/References
(1) Remove the canopy or door. Put the canopy or door on a firm working surface with the crack horizontal. Only if you will repair the canopy or door window. Refer to Section 52-10.
(2) Put protective covers over the inside of the cockpit. Only if you will repair the right fuselage window.
(3) Mask the area around the crack on both inner and outer surfaces.
(4) Cut a groove along the crack in the outer surface of the window. Refer to Figure 2, step 1.
(5) Countersink temporary stop-drill holes.
(6) Seal the stop-drill holes on the inner surface. Use plastic adhesive tape.
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