DG Flugzeugbau DG-1000M Manual Perbaikan - Halaman 12

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5.4 Repair of outer and inner skin of a sandwich panel

See section 5.3. Additionally remove as much foam as is needed so that the

entire damage to the inner skin can be seen, plus enough undamaged inner

skin as is required for overlapping. If the inner skin still holds together,

sand properly and lay up the new cloth over it. Insert a suitable cut piece of

foam, 1-2 mm (0.04 to 0.08 in.) thinner than the original, glued in with

microballoons-resin.

Should the inner skin be so damaged that the above process cannot be used,

the inner skin fabric should be applied to the foam first and left to harden

before inserting into the repair area. Microballoons-resin should once again

be used.

For lay up of the fabric to the foam, a layer of microballoons-resin should

be applied first to eliminate the formation of airbubbles.

Apply the outer layers as in section 5.3.

5.5 Repair of a sandwich panel with tubus core (fuselage)

The repair method is similar to a foam core with the following differences:

1. The outside skin can't be pressed into the tubus core. An accurate scarf is

necessary.

2. To get a good bonding to the skin you have to fill the holes of the tubus

core with microballon-resin mixture.

5.6 Repairing small dents in a sandwich panel skin (no cracks in the

gelcoat)

Small dents can usually be removed by heating up to 60° to 70° C (140° -

158°F). Use a hot air blower to heat the area of the dent. The crushed foam

will then spring back to its original form, so that the dent will hardly be

seen. Final sanding with wet sandpaper grade 600 should finish the job. In

more severe cases, one coat of gelcoat will remove all trace of the dent.

Issued December 2010

Repair manual DG-1000

1-3 mm

0.04 – 0.12 in.

outer skin

foam

inner skin

resin thickened with

microballoons

5.2