TECHNICAL DESCRIPTION, OPERATING, MAINTENANCE AND REPAIR MANUAL
Now the projecting inner laminate is cleaned of any foam and feathered. If the hole in the
foam is smaller than a fist then glue with Patex a thin plywood or polyester plate from
the inside to the laminate, lay on the inner laminate ( 2 layers 92110 diagonal ) and fill
the hole in the foam with microballoons mixed with Styropor kernels or crumbled
Styropor. After hardening ( appr. 8 hrs at 20°C ) the damaged area should be smoothed,
sanded and apply the outer patches ( 2 layers 92110 diagonal ).
A tip on gluing the plywood plate – the hole in the inner laminate should always be a bit
oblong so as to insert the plywood backing plate. Before inserting the plywood drive
through the middle of the ply a pin or nail by which it can be drawn against the inner
shell. With additional nails or pins it is in this manner possible to close very large holes
to the proper contour to lay the cloth patch on. Basically it is possible to repair also
larger shell parts in the foregoing manner. Because of weight you should use a plug of
foam in place of the microballoons and Styropor kernels. In these case you cut or sand a
plug of foam to fit the hole, spread the inner laminate. The inner laminate must harden
before doing further work. If the hardening is completed at least progressed so that the
laminate does not separate from the foam, then glue the plug in the hole with thickened
resin ( chopped cotton wool, microballoons ). The foam with laminate on one side is
flexible so that it can be fitted to the repair place contour ( if necessary warm the foam
with hairdryer and bend ). Once the foam is glued it can be smoothed, puttied with
microballoons and the outer laminate applied ( 2 layers 92110 diagonal ).
Date: 01.03.2002 WT-9 Dynamic Section 4 Page 4 - 5
Outer laminate 2 layers 92110 diagonal
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