THE NEW PIPER AIRCRAFT, INC.
PA-32-301FT / 301XTC
MAINTENANCE MANUAL
PAGE 4
Jun 1/03
4D8
51-00-00
(6) Allow gel to cure 10 to 15 minutes until it feels rubbery to touch. Remove cellophane and trim
flush with surface, using a sharp razor blade or knife. Replace cellophane and allow to cure
completely for 30 minutes to an hour. Patch will shrink slightly below structure surface as it
cures. (If wax paper is used, ascertain wax is removed from surface.)
(7) Rough up bottom and edges of hole with electric burr attachment or rough sandpaper. Feather
hole into surrounding gel coat, do not undercut.
(8) Pour out a small amount of resin, add catalyst and mix thoroughly, using a cutting motion
rather than stirring. Use no fibers.
(9) Using tip of putty knife or fingertips, fill hole to about 1/16 inch above surrounding surface with
gel coat mixture.
(10) Lay piece of cellophane over patch to start curing process. Repeat paragraph (6), above,
trimming patch when partially cured.
(11) After trimming patch, immediately place another small amount of gel coat on cut edge of patch
and cover with cellophane. Then, using a squeegee or back of a razor blade, squeegee level
with area surrounding patch, leave cellophane on patch for one or two hours or overnight, for
complete cure.
(12) After repair has cured for 24 hours, sand patched area using sanding block with fine wet sand-
paper. Finish by priming, again sanding and applying color coat.
B. Fiberglass Fracture and Patch Repairs
(1) Remove wax, oil and dirt from around damaged area with acetone, methylethyketone or
equivalent.
(2) Using a key hole saw, electric saber saw, or sharp knife cut away ragged edges. Cut back to
sound material.
(3) Remove paint three inches back from around damaged area.
(4) Working inside structure, bevel edges to approximately a 30 degree angle and rough-sand
hole and area around it, using 80-grit dry paper. Feather back for about two inches all around
hole. This roughens surface for strong bond with patch.
(5) Cover a piece of cardboard or metal with cellophane. Tape it to outside of structure covering
hole completely. Cellophane should face toward inside of structure. If repair is on a sharp
contour or shaped area, a sheet of aluminum formed to a similar contour may be placed over
area. Aluminum should also be covered with cellophane.
(6) Prepare a patch of fiberglas mat and cloth to cover an area two inches larger than hole.
(7) Mix small amount of resin and catalyst, enough to be used for one step at a time, according to
kit instructions.
(8) Thoroughly wet mat and cloth with catalyzed resin. Daub resin on mat first, and then on cloth.
Mat should be applied against structure surface with cloth on top. Both pieces may be wet out
on cellophane and applied as a sandwich. Enough fiberglas cloth and mat
reinforcements should be used to at least replace amount of reinforcements removed in order
to maintain original strength. If damage occurred as a stress crack, an extra layer or two of
cloth may be used to strengthen area.
(9) Lay patch over hole on inside of structure, cover with cellophane, and squeegee from center to
edges to remove all air bubbles and assure adhesion around edge of hole. Air bubbles will
show white in patch and they should all be worked out to edge. Remove excess resin before it
gels on part. Allow patch to cure completely.
(10) Remove cardboard or aluminum sheet from outside of hole and rough-sand patch and edge of
hole. Feather edge of hole about two inches into undamaged area.
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