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AFS-640

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AFS-640 ( afs-640 )

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9/8/98 AC 43.13-1B (1) It may be necessary when routing a tapered section such as an aileron to use a wedge-shaped block between the routing tem­ plate and the upper surface. This will allow the router to cut the core material parallel with the lower surface. (See figure 3-14.) (2) Select the appropriate potting adhe­ sive as recommended by the manufacturer. Mix a sufficient quantity of filler to fill the hole and add microballoons if they are needed to serve as a filler. When the resin and filler are thoroughly mixed according to the manu­ facturer’s recommendations, pour the mixture into the hole filling all of the cells, then work out all of the bubbles with a toothpick. If per­ forming an overlay repair fill the core cavity to slightly above the part’s surface. If performing a flush repair, fill the core cavity to slightly above the original core. (3) Cure the compound according to the manufacturer’s directions. Trim the top of the cured potting compound flush with the surface, for the type of repair you are performing. h. A core plug repair replaces damaged core material with a shaped piece of similar core material. (1) Complete removal of core material to the opposite face generally requires some hand-cutting with a core knife. Figure 3-15 shows core material being removed with a core knife. The core can be peeled away from the skin bond using duckbill pliers. Sanding is then required to remove irregular accumula­ tions of adhesive from the undamaged inner face. Remove only enough adhesive to pro­ duce a smooth finish. CAUTION: Care should be used when peeling core material from thin- skin sandwich face sheets, because the skin can be damaged by pulling on the core. Par 3-10 FIGURE 3-12. Cross section of bonded and bolted over­ lap repairs. FIGURE 3-13. Honeycomb core removal. FIGURE 3.14  Removing honeycomb core from a tapered control surface. FIGURE 3-15. Removal of core with core knife. Page 3-11

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