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AC 43.13-1B 9/8/98 (2) A core plug should be fabricated as follows. Select the core density. Cell size and ribbon direction and thickness should be at least the same as that used in the original con struction. Trim the sides of the plug to a loose fit in the routed cavity. Trim the plug height so the top of the plug sits .001 inch higher than the level of the original surface. The core will compress and set during cure thereby requiring the extra height. Carefully remove the trimmed core plug from the machined cavity. Use a vacuum cleaning device to remove any dust or particles remaining on the core plug or in the repair area. Clean the core plug by rinsing with an approved solvent and wrap the plug in a clean polyethylene bag until needed for assembly. CAUTION: When handling film ad- hesives, prepreg fabrics, or parts with prepared surfaces, latex gloves must be worn. (3) Using a film adhesive, the core plug should be installed as follows. Select the ap propriate adhesive film. Cut one disk of adhe sive to the same shape and size as the perime ter of the repair cutout if the repair extends through the entire core thickness. Cut two disks if a partial depth core repair is being made. Cut one strip of core splice adhesive to wrap around the core perimeter to its full depth. For a partial depth core repair, also cut out a fiberglass or aluminum disk, again matching the size and the shape of the repair cutout. Figure 3-16 shows the details of a par tial depth core repair. Preassemble the pieces. (4) Wipe the bottom and sides of the cutout area with solvent. Allow the area to dry. Insert the core plug assembly with splice adhesive applied to the perimeter into the core cutout. Ensure the core plug ribbon direction matches that of the parent core. In the case of a partial depth core repair, the plug and disk FIGURE 3-16. Details of core repair. may be cured to save time. Some restraining method, such as vacuum bagging, may be de sirable over the core splice adhesive as this material usually foams up and out during cure. Cure the adhesive according to the manufac turer’s directions and allow the area to cool. (5) Trim the top of the cured core plug flush with either the original core or the mold line, depending on the type of laminate repair to be performed. Proceed with laminate repair. 3-11. FINISHING. The type of finish coating applied to a metallic sandwich repair will normally be determined by the exposed material and the application of the part or as sembly. Rain erosion of plastic parts, the need for electrical or dielectric properties, and/or the necessity for anti-corrosion coatings must be considered when the choice of finish is made. Plastic-faced parts such as radomes are fin ished primarily for rain erosion while alumi num- or other metal-faced laminates are Page 3-12 Par 3-10PDF Image | AFS-640
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