Chapter 51 Standard Practices and Structures - General
Contents
1. Paint Manufacturer Supplier Type 285 100 929 73 352 91 EBERHARD Chemie GmbH Olpener Stra e 405 D 51109 K ln 91 Merheim Germany Cotton flakes Microballoons BJO 0930 GLASURIT GmbH Max Winkelmannstr 80 D 48165 M nster Hiltrup Germany WESSELS AG Pagenstecherstra e 121 D 49090 Osnabr ck Germany Glassodur Rapidf ller AC 85 0100 Glassodur MS H rter SC 29 0173 Glassodur Einstellzusatz SV 41 0391 PAGE DATE 31 January 1995 CHAPTER 51 PAGE 10 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 MATERIALS Composite Part Materials 51 30 02 IMPORTANT 1006 202 3 948 36 21 929 73 352 91 Glassit Spritzf ller SP 60 7023 Glassit H rterpaste rot SB 48 3360 Glassodur PUR Acryl Lack AD AE2 Glassodur MS H rter SC 29 0173 Glassodur Einstellzusatz SV 41 0391 Metal Components Only approved materials have to be used for the repair of metal components Steel tubing Manufacturer Supplier Type MHP Mannesmann Hoesch Prazisrohr GmbH Postfach 1713 D 59061 Hamm Germany HEINE BEISSWENGER Stiftung CO Postfach 1510 D 70705 Fellbach Germany WLB 1 7734 4 18mm x 1 0mm 20mm x 1 0mm 22mm x 1 0mm 22mm x 1 5mm 25mm x 1 5mm Steel sheet metal Manufacturer Supplier Type BOHLER Edelstahl GmbH M nchen Germany BOHLER Edelstahl GmbH Hansa Allee 321 D 40549 Diisseldorf Germany WLB 1 7734 4 1 0mm 1 5mm 2 0mm 3 0mm PAGE DATE2. to the repair area and lay on fabric in accordance to the layer sequence plans Ensure to use correct style and direction of fabric IMPORTANT Repair area must be clean of dirt dust and grease Lay out the required number and size of fabric pieces on a piece of colored plastic foil and soak wet them with resin mixture subsequently position them on the repair area IMPORTANT Remove the plastic foil after each positioning process For a repair of honeycomb sandwich parts you have to observe the following The repair area has to be cured under condition of vacuum bagging For vacuum bagging proceed as follows Apply peel nylon fabric on the last repair fabric layer Perforate a clean thin plastic foil with a thick needle max spacing of holes 20mm x 20mm mainly in the area of the honeycomb and lay it on the repair area Lay ajute cloth weave or equivalent bleeder cloth on this perforated plastic foil Lay anair tight plastic foil upon the jute weave and seal their edges to the surrounding surface using an adhesive tape Apply suction witha vacuum pump pressure approx 0 7 bar 10 psi Apply the thermal curing cycle Refer to Figure 3 Following the curing cycle remove vacuum bagging material and peel nylon fabric After the pre curing period at room temperature the re paired area has to be cured according the temperature cycle as shown on Figure 6 PAGE DATE 31 January 1995 CHAPTER 51 P
3. 31 January 1995 CHAPTER 51 PAGE 11 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 MATERIALS Metal Components 51 30 03 Paint Manufacturer Supplier Type 801 1552 965 32 2 21 1929 73 352 91 GLASURITGmbH Max Winkelmannstr 80 D 48165 M nster Hiltrup Germany WESSELS AG Pagenstecherstra e 121 D 49090 Osnabr ck Germany Glassofix Grundf ller EP AC 01 1492 Glassofix Harter EP SC 65 0322 Glassodur PUR Acryl Lack AD AE 2 Glassodur MS H rter SC 29 0173 Glassodur Einstellzusatz SV 41 0391 Aluminium Components Aluminium sheet metal Manufacturer Supplier Type Kaiser Aluminium amp Chem Corp Spokane Washington Westdeutscher Metallhandel Postfach 104245 45141 Essen WLB 3 1364 T3511 or 2024 T3 0 6mm 0 8mm 1 2mm Control rod tubings Manufacturer Supplier Type Aluminium AG CH 5737 Menziken Karstens amp Knauer GmbH amp Co D 28865 Lilienthal WLB 3 1354 T3 e 25x1mm PAGE DATE 31 January 1995 CHAPTER 51 PAGE 12 EXTRA FLUGZEUGBAU GmbH MATERIALS SERVICE MANUAL EXTRA 300 Aluminium Components Paint Manufacturer GLASURITGmbH Max Winkelmannstr 80 D 48165 Minster Hiltrup Germany Supplier WESSELS AG Pagenstecherstra e 121 D 49090 Osnabriick Germany Type Primer 283 150 Glassofix Grundf ller AB83 1150 352 228 Glassofix Zusatzl sung SC12 0228 Lacquer 21 Glassodur PUR Acryl Lack AD AE2 1929 73 Glassodur MS H
4. 5 5 6 6 5 7 7 5 Mass kg SAP ad E 3 z zo Trim tab D 2 5 1 5 A 70 80 90 100 110 120 130 140 Mass g Weights AilronLH W kg oe Aileron RH W kg ME Rudder OW kg mE m Elevator 0 Mann kg ad Trim Tab W kg M Nem m kg g m s r cm Moments AileronLH m kg 9 Ss NG Dc i oids Gn ME Ecos Nem AileronRH m KEI BUG S sia ou MM ne Nem Rudder Dh es KERN SEN ccs grates MM La ccce Nem Elevator mi ke t SINE Lanes Cini MIU Nem Trim Tab m kg i AE codes EM ee Nem Control Surface Weights and Moments Figure 4 PAGE DATE 15 December 1999 CHAPTER 51 PAGE 17 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 51 70 00 51 70 01 IMPORTANT IMPORTANT WARNING WARNING IMPORTANT REPAIRS Repair of Reinforced Glass and Carbon Fibre Components Repair of composite parts has to be carried out only by qualified and authorized personnel Ifthe aircraft is damaged proceed as follows First conduct a careful visual inspection of the surface and the damaged area Frequently the damage extends to futher components sometimes a fracture will continue invisible beneath the surface Perform the repair work with utmost care The external shell of the wing and empannage is stressed a failure of this bonded structure can lead to an aircraft crash In order to eliminate dangerous stress concentrations a
5. 9 b Large damage If the extent of the damaged area exceed 10 cm 4 inches a large damage repair is required Carefully trimm out the damaged portion to a circular or oval shape Prelaminate a backing plate from two layers of glass fibre fabric and resin mixture which must be approx 20 mm larger than the damaged area Apply peel nylon fabric as external layer Sandwich the resin wetted layers between two sheets of plastic foil Work the excess resin out and allow the plate to cure at elevated room temperature for 8 hours on a flat surface or a plasticfoil covered surface of the proper curvature near the damaged area or the same location on a comparable undamaged part Following the curing cycle remove plastic foil and peel nylon fabric Bond the backing plate to the inside using a mixture ofresin and cotton flocks and adapt to the contour Cure the bonding at elevated room temperature for 8 hours PAGE DATE 31 January 1995 CHAPTER 51 PAGE 27 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 REPAIRS Repair of Laminates IMPORTANT IMPORTANT NOTE IMPORTANT Subsequently scarf the edges of the damaged portion with sandpaper Minimum lenght ofscarfper fabric layer approx 20mm ratio laminate thickness scarf lenght approx 1 50 Following the scarf procedure clean the repair area thor oughly Remove the sanding dust with a pneumatic vacuum cleaner Clean the scarfed overlaps with carbon
6. of the laminate tickness One technique to learn about the number of layers is to burn a small piece taken from the damaged area The resin will burn off leaving the glass and or carbon fabric to be in spected for the number of layers and the type of fabric Creating a scarfed overlap takes time Sand away as much of the old material that the new fabric patches do not project beyond the contour In order to shorten the curing time a heater can be used to increase the ambient temperature Too high temperature will cause large air bubbles in the laminate Local overtemperature can be prevented by using a foil tent which leads the hot air stream The curing cycle must be maintained as stated Use a thermometer to monitor the temperature After repair of control surfaces check for proper bal ance refer to chapter 27 Flight Controls It is recommended to prepare test specimens at the same time as the actual repair is accomplished These can then be subject to a material test to establish the quality of the laminate in the repaired part To make this determination valid the specimens must be assembled with the same style of fabric and resin mixture Subsequently the specimens must be subject to the curing pressure temperature and time identical with those in the actual repair PAGE DATE 31 January 1995 CHAPTER 51 PAGE 19 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 REPAIRS 51 70 02 IMPORTANT Repa
7. tetrachloride or acetone in case of dirt or grease was introdued during the preparation of the overlap Repair area must be free of dirt dust and grease Wet all surfaces of the backing plate and the scarfed area with resin mixture Lay on prelaminated fabric layer in accordance to the layer sequence plan Ensure correct style and direction of fabric Lay out the required number and size of fabric pieces on a piece of colored plastic foil and wet them with resin mixture Subsequently position them on the repair area Remove the plastic foil after each positioning process The repair area has to be cured under condition of vacuum bagging Proceed as follows Apply peel nylon fabric on the last repair fabric layer PAGE DATE 31 January 1995 CHAPTER 51 PAGE 28 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 REPAIRS Repair of Laminates CAUTION 51 70 04 IMPORTANT Perforate a clean thin plastic foil with a coarse needle max spacing of holes 20mm x 20mm mainly in the area of the honeycomb and lay it on to the repair area Lay ajute cloth or equivalent bleeder cloth on this perforated plastic foil Layanairtight plastic foil upon the jute weave and seal their edges to the surrounding surface using an adhesive tape Apply suction with a vacuum pump pressure difference approx 0 7bar 10psi Curingcycle Following the curing cycle carefully remove vacuum bagging material and
8. AGE 21 EXTRA FLUGZEUGBAU GmbH REPAIRS SERVICE MANUAL EXTRA 300 Repair of Sandwich Material TC 80 60 40 20 mis m24 EN 8h 8h Curing cycle resin L20 SL Figure 6 After the curing process is completed the repair area can be sand level to the surrounding area CAUTION Sand only the edge thickness of repair laminate refer to Figure 7 ag sanding block IT Level Sanding of Surrounding Area Figure 7 NOTE For painting of the repair area refer to Chapter 51 70 06 b Damage of complete sandwich If the inner laminate is also damaged first remove the upper laminate within the area where no secure bond connection to the core material is suspected Trim out the complete damaged portion of core material to a circular or elliptical shape PAGE DATE 31 January 1995 CHAPTER 51 PAGE 22 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 REPAIRS Repair of Sandwich Material IMPORTANT WARNING IMPORTANT The damaged area of the inner laminate has to be taken out as well Make sure not to increase the disbond area by preparing the hole Preferably use a hand held milling machine In case of cutting with a saw the pulsation stress may peel of the inner laminate secondary damage If the extent of the disbon
9. EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 Chapter 51 Standard Practices and Structures General PAGE DATE 31 January 1995 CHAPTER 51 PAGE 1 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 Chapter 51 00 00 51 00 01 51 10 00 51 10 01 51 10 02 51 30 00 51 30 01 51 30 02 51 30 03 51 60 00 51 60 01 51 70 00 51 70 01 51 70 02 51 70 03 51 70 04 51 70 05 51 70 06 51 70 07 TABLE OF CONTENTS Title GENERAT uud 3 Access Panel Identification s 3 INVESTIGATION maa nee 6 Damage Classification 6 Repair Criteria and Limits s hh hs 7 MATERIALS s 8 Composite Parts usa 8 Metal Components nn ee oet D eO s 11 Aluminium Components s 12 CONTROL SURFACE BALANCING LU 14 Weighing and Determination of Control Surface Moments 14 REPAIRS ce quieti Oe enti Mud 18 Repair of Reinforced Glass and Carbon Fibre Components 18 Repair of Sandwich Material 20 Repair of Laminates s 25 Repair of Sparse 29 Structural Repair of Steel Components 30 Painting of Composite Parts s 31 Aluminium and Steel Components Refinishing 32 PAGE DATE 31 January 1995 CHAPTER 51 PAGE 2 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 51 00 00 51 00 01 NOTE GENERAL Access Panel Identification For the Extra 300 all removable covers and fairings are defined as access panels refer to Figure 1 and the adjacent chart If maintenance or repair is not restricted to a sma
10. amages Classes 2 3 and 4 may be repaired by qualified personnel In case of Damage Class 1 it has to be contacted EXTRA FLUGZEUGBAU GmbH According to the Luftfahrt Bundesamt Federal German Aviation Authority four damage classes are defined Damage Class 1 Large scale destruction requiring a partial reconstruction of the component or large scale repair Each destruction over 300 mm diameter and each damage ofa spar is a large scale destruction EXTRA FLUGZEUGBAU GmbH has to be contacted prior to repair Damage Class 2 Damageto primary structures and to secondary structures to the following extent Holes and fractures extending through asandwich component and a scale under 300 mm diameter Damage Class 3 Damageto primary structures and to secondary structures to the following extent Small holes or fractures in the external covering layers ifnot accompanied by damage to supporting layers or internal covering layers PAGE DATE 31 January 1995 CHAPTER 51 PAGE 6 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 INVESTIGATION Damage Classification 51 10 02 IMPORTANT IMPORTANT Damage Class 4 Erosion scratches or nicks not accompanied by fractures or breakages Damage to fairings belong to this class Repair Criteria and Limits Il damage of composite parts must first be classified prior to repair Refer to Chapter 51 10 01 Damage Classification Only the Damages Classes 2 3 and 4 may be re
11. aminated fabric layer in accordance to the layer sequence plan Ensure correct style and direction of fabric PAGE DATE 31 January 1995 CHAPTER 51 PAGE 23 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 REPAIRS Repair of Sandwich Material Bi ratio min 1 ie mn 20 mm inch IMPORTANT NOTE IMPORTANT Damage of Complete Sandwich Figure 8 Lay out the required number and size of fabric pieces on a piece of plastic foil and wet them with resin mixture Subsequently position them on the repair area Remove the plastic foil after each positioning process The repair area has to be cured under condition of vacuum bagging Proceed as follows Apply peel nylon fabric on the last repair fabric layer Perforate a clean thin plastic foil with a thick needle max spacing of holes 20mm x 20mm mainly in the area ofthe honeycomb and lay it on the repair area Layajute cloth or equivalent bleeder cloth on this perforated plastic foil Layasecond plastic foil uppon the jute weave and seal their edges to the surrounding surface using an adhesive tape Applysuction with a vacuum pump pressure approx 0 7bar 10psi Apply the thermal curing cycle Following the curing cycle carefully remove vacuum bagging ma
12. ate container of clean solvent CAUTION Do not spin bearing cones with compressed air 4 After cleaning thoroughly dry all metal parts with fil tered dry compressed air 5 It is recommended that all O rings backup rings and wipers be replaced at each overhaul However if neces sary O rings may be reused but should be put back into position from which removed 6 Wipe down O rings backup rings wipers or other rubber parts with a clean dry cloth Lubricate with a suitable O ring lubricant prior to installation PAGE DATE 31 January 1995 CHAPTER 51 PAGE 32 EXTRA FLUGZEUGBAU GmbH REPAIRS SERVICE MANUAL EXTRA 300 Aluminium and Steel Components Refinishing Paint Removal Disassemble components to the level required for repaint ing then proceed as follows WARNING Stripping solvents can be toxic and volatile Use only in well ventilated areas Avoid physical contact with solvent and do not inhale vapors Keep solvent containers covered when not in use CAUTION Before stripping parts remove all fittings O rings nuts bolts washers pistons bearingcups etc Parts must be totally immersed in solvent to maximize cleaning 1 Degrease part per degreasing paragraph 2 Totally immerse part in paint removing solvent Portions not totally covered by solvent will begin to corrode NOTE Stripping agents are commercially available for remov ing topcoat and primer Follow manufacturer s recom mendations for u
13. ded area on the inner laminate exceeds the prepared cut out increase the cut out of material and upper laminate Prepare a scarfed overlap of laminate around the circular cut out Overlap lenght of inner laminate should not be less than 20 mm Overlap lenght of the upper laminate should not be less than 1 50 ratio laminate thickness overlap lenght Prepare a replacement block of core material foam or honeycomb with equivalent diameter and thickness Cut it to fit snuggly in the trimmed hole In case of foam core coat one side with a mixture of resin and microballoons ratio 100 15 Apply prelaminated fabric layers required for the inner laminate on this side of the core filler block Ensure correct style and direction of fabric After precuring the laminate at elevated room temperature 30 C scarf the overlap and sand the upper overlapping core material down up to the surrounding core material Subsequently clean the repair area thoroughly as follows Remove the sanding dust with a pneumatic vacuum cleaner Clean the scarfed overlaps with carbon tetrachloride or acetone in case of dirt or grease was introdued during the preparation Carbon tetracloride or Acetone used for cleaning re pair areas are flamable liquids and should be used with proper ventilation and safety equipment Repair area must be free of dirt and grease Wet all surfaces of the backing plate and the scarfed area with resin mixture Lay on prel
14. eign materials Subsequently apply Glassodur Rapid Filler with a spray gun The Rapid Filler must be completely dry before the cov ering paint can be applied Forthe final sanding use 400 grade wet sandpaperto achieve asmooth clean surface Allow surface to dry Paint application of Glassodur Pur Acryl Lack AD AE 21 two component acryl paint is performed with a spray gun Paint can be mixed with small quantities of reducer After completion of the painting polish the repair area PAGE DATE 31 January 1995 CHAPTER 51 PAGE 31 EXTRA FLUGZEUGBAU GmbH REPAIRS SERVICE MANUAL EXTRA 300 51 70 07 Aluminium and Steel Components Refinishing Complete procedure necessary to remove existing paint from aluminium and steel components and then to repaint them as described in the following paragraphs Degreasing WARNING Cleaning solvents can be toxic and volatile Use only in well ventilated areas Avoid physical contact with sol vent and do not inhale vapors Keep solvent containers covered when not in use CAUTION Before stripping parts remove all fittings O rings nuts bolts washers pistons bearingcups etc 1 Clean all metal parts by immersing in a clean degreasing solution An alkaline based solution is recommended for aluminium and magnesium parts 2 Hardened dirt or grease may be removed with soft bris tle brush or by soaking in cleaning solution 3 Where necessary clean bearing cones carefully in a separ
15. ently position them on the repair area Remove the plastic foil after each positioning process After the curing process is completed remove the peel nylon fabric The repair area can be sand level with the surrounding area Sand only the edge thickness of repair laminate Refinish the surface according chapter 51 70 05 Painting PAGE DATE 31 January 1995 CHAPTER 51 PAGE 25 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 REPAIRS Repair of Laminates IMPORTANT IMPORTANT If the extent of the damaged area exceed 10 cm 4 inches a large damage repair is required Carefully trim out the damaged portion to a circular or oval shape Prelaminate a backing plate from two layers of glass fibre fabric and resin mixture which must be approx 20 mm larger than the damaged area Apply peel nylon fabric as external layer Sandwich the resin wetted layers between two sheets of plastic foil Work the excess resin out and allow the plate to cure at elevated room temperature for 8 hours on a flat surface or a plasticfoil covered surface of the proper curvature near the damaged area or the same location on a comparable undamaged part Following the curing cycle remove plastic foil and peel nylon fabric Bond the backing plate to the inside using a mixture of resin and cotton flocks and adapt to the contour Cure the bonding at elevated room temperature for 8 hours Subsequently scarf the edges of the damaged portion w
16. ir of Sandwich Material Two types of core materials are used for sandwich on the EXTRA 300 PVC hard foam Honeycomb both with glass or carbon fibre shells The following section describes the repair of both types of sandwich Different processing techniques for these mate rials if necessary are also described a Minor surface damage Around a visible crack the laminate may be separated from the core material Determine the extent of this area by coin tapping Remove the separated laminate carefully using a sanding disk sanding block or a sharp knife Prepare a scarfed overlap of the laminate around the damaged area Overlap lenght per fabric layer min 20 mm Ratio laminate thickness overlay lenght min 1 50 refer to Figure 5 ze min 1 VES IER Minor surface damage Figure 5 NINI AT After preparing the scarfed overlap clean the repair area thoroughly as follows Remove the sanding dust with a pneumatic vacuum cleaner Clean the scarfed overlaps with carbon tetrachloride or acetone in case of dirt or grease was introdued during the preparation Damaged core material has to refilled with a mixture of resin and microballoons weightratio 100 15 Apply resin mixture PAGE DATE 31 January 1995 CHAPTER 51 PAGE 20 EXTRA FLUGZEUGBAU GmbH REPAIRS SERVICE MANUAL EXTRA 300 Repair of Sandwich Material
17. ith sandpaper Minimum lenght ofscarfper fabric layer approx 20mm Ratio laminate thickness scarf lenght approx 1 50 Following the scarf procedure clean the repair area thor oughly Remove the sanding dust with a pneumatic vacuum cleaner Clean the scarfed overlaps with carbon tetrachloride or acetone in case of dirt or grease was introdued during the preparation of the overlap Repair area must be free of dirt dust and grease Wet all surfaces of the backing plate and the scarfed area with resin mixture Lay on prelaminated fabric layer in accord ance to the layer sequence plan Ensure correct style and direction of fabric PAGE DATE 31 January 1995 CHAPTER 51 PAGE 26 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 REPAIRS Repair of Laminates NOTE IMPORTANT Lay out the required number and size of fabric pieces on a piece of colored plastic foil and wet them with resin mixture Subsequently position them on the repair area Remove the plastic foil after each positioning process The repair area has to be cured under condition of vacuum bagging Proceed as follows Apply peel nylon fabric on the last repair fabric layer Perforate a clean thin plastic foil with a thick needle max spacing of holes 20mm x 20mm mainly in the area of the honeycomb and lay it on the repair area ratio min 1 50 pa Repair of minor damage Figure
18. ll area it is advisable to remove all access panels before beginning work or checks Access panels partly overlap Remove the front panels first All panels are screwed For the removal installation of the wing tip panels refer to Chapter 57 Prior to unscrewing of the air inlet screen remove bottom half ofthe engine cowling not to lose the attachment stopnuts and washers PAGE DATE 31 January 1995 CHAPTER 51 PAGE 3 EXTRA FLUGZEUGBAU GmbH GENERAL SERVICE MANUAL EXTRA 300 Access Panel Identification e2 e3 Access Panel Identification Figure 1 PAGE DATE 31 January 1995 CHAPTER 51 PAGE 4 EXTRA FLUGZEUGBAU GmbH GENERAL SERVICE MANUAL EXTRA 300 Access Panel Identification 2 bottom covering sheet LH wing tip panel RH wing tip panel PAGE DATE 31 January 1995 CHAPTER 51 PAGE 5 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 51 10 00 51 10 01 WARNING WARNING INVESTIGATION Damage Classification All damage of composite parts must first be classified by qualified personnel In case of doubt with regard to the classification of damage if a clear definition of the extent of damage is not possible or if a repair of dam age inspite of the valid manufacturer documentation is doubtful contact EXTRA FLUGZEUGBAU GmbH Only the D
19. om plished by icensed personnel Consult EXTRA FLUGZEUGBAU GmbH in case of doubt about a re pair not specifically mentioned there If welding work must be performed use only the TIG procedure Tungsten Inert Gas Use steal welding wire 1 7734 2 for welding additive PAGE DATE 31 January 1995 CHAPTER 51 PAGE 30 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 REPAIRS 51 70 06 WARNING WARNING NOTE Painting of Composite Parts Coating materials may cause sensitization by inhala tion and skin contact Hardeners and coating materials ready for use can have an irritant and sensitizing effect upon the skin and respiratory tracts and cause allergic reactions Provide for a continuous supply of fresh air during and also after the application do not inhale the vapours and wear a breathing mask during the spray application of these materials Persons suffering from an allergy or being prone to diseases of the respiratory tracts must not get in contact with coating materials Refer to the manufacturer technical information sheet After curing cycle the surface of repared area can be sanded with sandpaper 80 grade Indentations are filled with white polyester filler Subsequently achieve a surface as uniformly rough as possible using a finer dry sandpaper 150 or 320 grade Prior to paint application the surface of the repair areamustbecleanedthoroughly ofall sanding dust separation compounds and otherfor
20. paired by qualified personnel In case of Damage Class 1 it has to be contacted EXTRA FLUGZEUGBAU GmbH The decision whether to repair or replace a major unit of structure will be influenced by factors such as time and labor available and by comparison oflabor costs with the price of replacement assemblies Past experience indicates that replacement in many cases is less costly than major repair Certainly when the aircraft must be restored to its airworthy condition within limited time replacement is preferable PAGE DATE 31 January 1995 CHAPTER 51 PAGE 7 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 51 30 00 MATERIALS This Section describes metallic and non metallic materials used in the repair of the Extra 300 and gives the sources of supply manufacturers and supplier 51 30 01 Composite Parts IMPORTANT Only approved materials have to be used for the repair of composite parts Epoxy system Manufacturer RUTGERS BAKELITE Aktiengesellschaft Varzinerstr 49 D 47138 Duisburg 12 Germany Resin R tapox L20 Hardener Riitapox SL Ratio of comp 100 parts L20 34 parts SL weight ratio Glass fibre fabrics Manufacturer INTERGLAS Interglas AG S flinger Stra e 246 Postfach 3820 D 89077 Ulm Germany WLB No weave LN 9169 erste patterns 8 4505 60 plain 8454860 twill 2 2 8455160 twill 2 2 8455160 twill 2 2 All glass fabric is made of alkali free E gla
21. peel nylon fabric After the pre curing period at room temperature the re paired area has to be cured according the temperature cycle as shown on Figure 3 After the curing process is completed the repair area can be sand level to the surrounding area Sand only the edge thickness of repair laminate Refinish the surface according chapter 51 10 09 Painting Repair of Spars The spars consists of carbon roving caps glass or carbon fibre webs and PVC foam cores The spars are higly stessed a failure of this bonded struc ture can result in loss of the aircraft In all cases the repair of a spar must be considered as a large scale re pair with a Damage Class 1 Refer to Chapter 51 10 01 Damage Classification EXTRA FLUGZEUGBAU GmbH has to be contacted prior to repair PAGE DATE 31 January 1995 CHAPTER 51 PAGE 29 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 REPAIRS 51 70 05 IMPORTANT IMPORTANT NOTE Structural Repair of Steel Components Restoration of a damaged fuselage to its original design strength shape and alignment involves careful evaluation of the damage followed by exacting workmenship in performing the repairs Should structural repairs practicable on the aircraft be necessary refer to Aircraft Inspection and Repair FAA AC 43 13 1A and Aircraft Alterations Accept able Methods Techniques and Practices FAA AC 43 13 2A Alterations or repair of the airplane must be acc
22. rol Surface Moments Put the control surfaces on the balancing mandrels use a wire for the trim tab Weigh by means of a conventional spring balance kg g indication at the given weighing points Figure 3 and enter the weight m in Figure 4 Measure distance of hinge center line to weighing point r and enter the value in Figure 4 Calculate the control surface moment M in Figure 4 Reinstall the control surfaces only if the weight and moment values fall within the permissible values stated in Figure 4 PAGE DATE 1 June 1996 CHAPTER 51 PAGE 15 EXTRA FLUGZEUGBAU GmbH CONTROL SURFACE BALANCING SERVICE MANUAL EXTRA 300 Weighing and Determination of Control Surface Moments Aileron hinge center axis hinge center axis Elevator hinge center axis wire e Trimm tab er weighing point m Determination of Control Surface Moments Figure 3 PAGE DATE 31 January 1995 CHAPTER 51 PAGE 16 EXTRA FLUGZEUGBAU GmbH CONTROL SURFACE BALANCING SERVICE MANUAL EXTRA 300 Weighing and Determination of Control Surface Moments Permissible Weights and Moments 250 aks Elevator feed sa ae incl mass balance 200 A Rudder o DIE 4a Z 150 incl mass ae SS AE 8 Sie iz 4 Aileron 100 incl mass balance and spade EB 50 0 44 5
23. rter SC 29 0173 352 91 Glassodur Einstellzusatz SV 41 0391 Aluminium hardware metal brackets pedestals castings etc Paint Manufacturer Parker amp Anchem Ambler PA 19002 Supplier Aircraft Spruce Chem coating Alodine No 1201 MIL C 5541 Lacquer see above PAGE DATE 31 January 1995 CHAPTER 51 PAGE 13 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 51 60 00 51 60 01 CONTROL SURFACE BALANCING Weighing and Determination of Control Surface Moments All weighing of control surfaces is performed with surface removed from aircraft Weighing and determination ofcon trol surfaces moments is necessary after repairs or painting Weigh the control surfaces including the mass balances in disassembled condition The aileron weight includes the spade Copy page 31 enter the values W m r there and check whether the surface weights or moments are within the given tolerances If they are not contact the manufac turer for advice For the determination of control surface moments follow the steps as described below and use two balancing mandrels like shown in the Figure 2 8 mm 12 mm Balancing Mandrels Figure 2 Procedure 1 Remove the control surface refer to chapter 27 2 Reinstall the bolts in two brackets PAGE DATE 31 January 1995 CHAPTER 51 PAGE 14 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 CONTROL SURFACE BALANCING Weighing and Determination of Cont
24. se and disposal of stripping solutions 3 Remove part from solvent and rinse thoroughly with water heated to 160 to 180 F 71 to 82 C Flush solvent from all cavities and threaded holes where en trapment might occur 4 Thoroughly dry part with filtered dry compressed air 5 Where applicable refer to inspections procedures given in the respective chapters for specific parts to locate possible defects NOTE Refinishing should be completed as soon as possible unprotected parts will begin to corrode PAGE DATE 31 January 1995 CHAPTER 51 PAGE 33 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 REPAIRS Aluminium and Steel Components Refinishing Repainting Paint all surfaces exept those which are subjected to friction bearing surfaces anchor bolt bores etc Proceed as follows 1 Parts to be repainted should be cleaned and stripped per instruction in degreasing and paint removal paragraphs Aluminium parts should have a protective barrier be tween the topcoat and base metal It is recommended they be treated with solutions listed in Chapter 51 30 Apply solution liberally and evenly Allows it to set from 1 to 5 minutes The solution must completely wet the surface and overlap onto the adjoining anodize Remove excess coating by flushing with clean water Paints parts with one coat of wash primer Allow to dry thoroughly Paint parts with one coat of lacquer listed in Chapter 51 30 Allow to dr
25. ss with Volan A finish or with finish I 550 PAGE DATE 31 January 1995 CHAPTER 51 PAGE 8 EXTRA FLUGZEUGBAU GmbH MATERIALS SERVICE MANUAL EXTRA 300 Composite Parts Carbon fibre fabrics Manufacturer CCC C Cramer GmbH amp Co KG Postfach 209 D 48619 Heek Nienborg Germany WLB No weave SUIS KC DIN 65147 Usestyle patterns 8 350780 plain 8 3520 80 twill 2 2 cross twil WLB Werkstoff Leistungsblatt according to German standard DIN WL Glass rovings Manufacturer GEVETEX Textilglas GmbH Postfach 426 D 5100 Aachen Germany Supplier Lange amp Ritter GnbH Postfach 100321 D 7016 Gerlingen Germany Type Vetrotex EC14 2400 P185 Carbon rovings Manufacturer Tenax Fibers GmbH amp Co KG Kasinostr 19 21 D 42103 Wuppertal Supplier Tenax Fibers GmbH amp Co KG Kasinostr 19 21 D 42103 Wuppertal Type TENAX J HTA 5131 1600tex f24000 t 0 WLB 8 3614 85 PAGE DATE 31 January 1995 CHAPTER 51 PAGE 9 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 MATERIALS Composite Parts Core material a PVC Foam Manufacturer Supplier Type b Honeycomb Manufacturer Type DIAB Divincell International Gmbh Max von Laue Stra e 7 D 30966 Hemmingen Germany see above Divinycell HT 50 EURO COMPOSITES S A B P 95 Zone Industrielle L 6401 Echternach Luxembourg ECA I R 4 8 29 R Filler material for resin Manufacturer Type
26. terial and peel nylon fabric After the pre curing period at room temperature the repaired area has to be cured according the tempera ture cycle as shown on Figure 6 After the curing process is completed the repair area can be sand level to the surrounding area Sand only the edge thickness of repair laminate PAGE DATE 31 January 1995 CHAPTER 51 PAGE 24 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 REPAIRS 51 70 03 CAUTION NOTE IMPORTANT CAUTION For painting of the repair area proceed like mentioned in Chapter 51 70 06 Repair of Laminates a Minor damage Scarf the edges of the minor damage area with sandpaper Minimum lenght of scarf per fabric layer approx 20 mm ratio laminate thickness scarf lenght approx 1 50 Following the scarf procedure clean the repair area thor oughly Remove the sanding dust with a pneumatic vacuum cleaner Clean the scarfed overlaps with carbon tetrachloride or acetone in case of dirt or grease was introdued during the preparation Repair area must be free of dirt dust and grease Wet the prepared scarfed areas with resin mixture Lay on prelaminated fabric layer in accordance to the layer se quence plan Ensure correct style and direction of fabric Apply peel nylon fabric on the last repair fabric layer Lay out the required number and size of fabric pieces on a piece of colored plastic foil and wet them with resin mixture Subsequ
27. void changes in cross sectional areas The resin hardener mixture ratio must be precisely maintained 0 5 Clean cups and tools must be used The weight ratio of glass fabric to resin mixture should be approximately 50 50 Immediately prior to applying the wet laminate sand and vacuum clean the repair area so that no dirt and dust is involved which could prevent a secure adhesion Sanding carbon and glass fibre laminates gives off a fine dust that may cause skin and or respiratory irritation unless suitable skin and resiration protection is used Carbon tetracloride or Acetone used for cleaning re pair areas are flamable liquids and should be used with proper ventilation and safety equipment As with plywood grain the direction of the various fi bres longitudinal or diagonal is of great importance for the stability PAGE DATE 31 January 1995 CHAPTER 51 PAGE 18 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300 REPAIRS Repair of Reinforced Glass and Carbon Fibre Components CAUTION IMPORTANT The number of layers required to restore the stability in the damaged area can be taken from the layer sequence place ment plan Refer to the respective Chapters Itis necessary to know the number and direction oflayers in the damaged area in order to be able to replace them with the original number In all cases the thickness of the laminate has to be measured with a vernier calliper for the exact determination
28. y thoroughly before reassembly PAGE DATE 31 January 1995 CHAPTER 51 PAGE 34
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