Rockwell Commander 112 - Structural Repairs; Windshield and Windows

Rockwell Commander 112

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SECTION n

SERVICING

MAINTENANCE

MANUAL

ROCKWELL

COMMANDER

112iBiTCiTCA

AND

INSPECTION

Feather

the hole into

surrounding

gel

coat.

Do

not

undercut.

Proceed

to

step

k.,

if

this

repair

is

for

a

large

scratch

or

deep cavity.

h.

Pour

a

small

amount of

resin,

add

catalyst

and

mix thoroughly

using

a

cutting

motion

rather

than

stirring.

Do

not add

fibers.

i.

Use the tip of a putty knife

or

finger

tip and

fill

the hole to

lilS-inch

above the

surrounding

surface

with the

gel

coat

mixture.

j.

Lay a

piece

of

cellophane

over

the patch

area

to

start

the

curing

process.

Repeat

step

f.,

and

trim

patch when

partially

cured.

k.

After

trimming

the patch,

immediately

place

another

small

amount of

gel

coat

on one edge of the

patch

and

cover

with

cellophane.

Use a

squeegee

or

the

back

of a

razor

blade and

squeegee

the

area

level

around the patch.

Leave

the cellophane on

patch

for

two

hours

or

overnight

for

complete

cure.

1.

Allow the

patch

to

cure

for

24

hours.

Sand

patched

area

using a sanding

block

with fine wet

sand-

paper.

Finish

by

priming,

again sanding and apply-

ing

color

coat.

FIBERGLASS FRACTURE

AND

PATCH REPAIRS

a.

Remove wax,

oil

and

dirt

from

around

the

dam-

aged

area

with acetone

or

MEK (Methyl

Ethyl

Ketone)

or

equivalent.

b.

Cut away

ragged

edges

with a key hole

saw,

electric

saber

saw

or

sharp

lmife. Cut

back

to sound

material.

c.

Remove paint

three

inches

back

from

around

damaged

area.

d. Work

inside

the

structure

and

bevel

the

edges

to

approximately

a

30

degree

angle and rough

sand

the hole and the

area

around

it.

Use an 80-

grit

dry

sandpaper

and

feather

back

for

about two

inches

all

around the hole.

e.

Cover

a

piece

of

cardboard

or

metal

with

cello-

phane.

Tape

it

to the

outside

of the

structure

cover-

ing the hole

completely.

The

cellophane should

face

toward

the inside

of

the

structure.

If

the

repair

is

on

a

sharp

contour

or

shaped

area,

a

sheet

of

alum-

inum

formed

to a

similar

contour

may

be

placed

over

the

area.

The

aluminum should be

covered

with

cello-

phane.

f.

Prepare

a

patch

of

fiberglass

mat

and

cloth

to

cover

an

area

two

inches

larger

than

the hole.

g. Mix a

small

amount of

resin

and

catalyst,

enough to

be

used

for

one

step

at

a

time,

according

to

kit

instructions.

h. Thoroughly

soak

mat

and

cloth

with

catalyzed

resin.

Put

resin

on

mat

first

and

then on the

cloth.

Mat

should be

applied

against

structure

surface

with

cloth on top. Both

the

cloth

and

mat

may

be

spread

out and soaked on

cellophane

and

applied

as

a

sand-

wich. Enough

fiberglass

cloth

and

mat

reinforc

e-

ments

should be

used

to

replace

the

amount of

rein-

fore

ements

removed

in

order

to

maintain

the

original

strength.

If

damage

occurred

as

a

stress

crack,

an

extra

layer

or

two

of

cloth

may

be

used

to

strengthen

area.

i.

Place

patch

on the

inside

of

structure

over

the

hole.

Cover

with cellophane and

squeegee

from

center

to

edges

to

remove

all

air

bubbles and

assure

adhesion

around the edge of hole.

Air

bubbles in the patch will

appear

white and should

all

be worked out to the edge.

2-16

Remove

excess

resin

before

it

sets

up on the

part.

Allow

patch

to

cure

completely.

j.

Remove

cardboard

or

aluminum

sheet

from

out-

side

of hole and rough

sand

the

patch

and edge of hole.

Feather

edge the hole about two

inches

into undamaged

area.

k.

Mask

area

around

hole

with

tape

and

paper

to

protect

the

surface.

Cut

a

piece

of

fiberglass

mat

about one

inch

larger

than

the

hole

and

one

or

more

pieces

of

fiberglass

cloth

two

inches

larger

than

the

hole.

Brush

catalyzed

resin

over

hole.

Lay

mat

over

hole and

soak

it

with

catalyzed

resin.

Apply

additional

layers

of

fiberglass

cloth

to

build up

patch

area

to

the

surface

of

structure.

Soak

each

layer

thoroughly with

resin.

1.

With a

squeegee

or

broad

knife,

work

out

all

air

bubbles

in the patch.

Work

from

center

to edge,

press-

ing patch

firmly

against

the

structure.

m. Allow the

patch

to

cure

15

to 20

minutes

until

it

feels

rubbery

to the touch. Use a

sharp

lmive and

cut

away

extra

cloth

and

mat.

Cut on

outside

edge of

fea-

thering.

Strip

cut

edges

of

structure

before

cure

is

complete,

to

save

extra

sanding. Allow

patch

area

to

cure

overnight.

n.

Use

an

80-grit

sandpaper

on a

power

sander

or

sanding

block

and

blend

area

with

surrounding

surface.

If

any

air

pockets

appear

during

the sanding

operation,

puncture

the

air

pockets

and

fill

them

with

catalyzed

resin.

A

hypodermic

needle

may

be

used

to

fill

cavities.

Let

patch

area

cure

and

resand.

o. Mix

catalyzed

resin

and

work

it

into any

crevices.

p.

Cover

area

with cellophane and

squeegee

smooth.

Allow

patch

to

cure

completely

before

removing

cello-

phane.

Let

patcA

cure

and

resand.

q.

Brush

or

spray

a

coat

of

catalyzed

resin

to

seal

patch. Sand the

patch

and

finish

by

priming.

Sand

the

patch

and apply a

color

coat.

NOTE

Brush

and hands

may

be

c leaned with

Ren

RP-70.

If

not

available,

a

strong

solution

of

detergent

and

water

may

be

used.

STRUCTURAL

REPAIRS

Structural

repair

methods

should be

in

accordance

with

the

requirements

of

the

Federal

Aviation

Agency's

"Aircraft

Inspection and

Repair",

Manual

43.13-1

and

"Aircraft

Alterations",

Manual

43.13-2.

Any

skins,

frames

or

ribs

damaged beyond

repair

can be

ordered

from

the

Parts

Catalog.

WINDSHIELD AND WINDOWS

The

windshield and cabin

side

windows

are

made

from

plastic;

therefore,

care

must

be

exercised

when

ser-

vicing the

aircraft

to

prevent

scratching

or

otherwise

damaging the window

surfaces.

The

windshield and

cabin

windows may be

cleaned

by

carefully

washing

with a mild

commercial

soap and

clean

water.

Copyright Commander Owners Group 2013 All Rights Reserved

**unofficial copy**

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