DG Flugzeugbau DG-800S Repair Manual - Page 11

Browse online or download pdf Repair Manual for Aircrafts DG Flugzeugbau DG-800S. DG Flugzeugbau DG-800S 14 pages.

Print Page

5.3.4 Repairing the outer skin of a sandwich panel

Cut out the damaged area, remove the gelcoat over the overlap area +10

mm (0.4 in.) around the damaged area. Fill the damaged foam area with

resin thickened with microballoons (microballoons-resin), let harden.

Sand down. With a round headed hammer tap the outer skin around the

hole so that the foam is somewhat compressed, therefore heat this area to

ca. 60°C (140°F). Apply the new cloth.

5.3.5 Repair of outer and inner skin of a sandwich panel

See sect. 5.3.4. 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 use,

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 sect. 5.3.4.

Issued: April 1997

Repair manual DG-800S

0.04 – 0.12 in.

outer skin

foam

inner skin

resin thickened with

microballoons