TM 1-1500-204-23-11
extend through the full thickness of the laminate.
This repair procedure is not necessarily applicable
to a particular weapon system. The applicability of
this repair depends upon additional factors such as
Failure to properly cure adhesive in accor-
loading conditions and laminate thickness. Consult
dance with the speciied cure cycle will result in
the system speciic technical manual or engineering
reduced repair strength may not be detectable
for further guidance. Refer to igure 7-51 for the
by visual or nondestructive inspection. This
Process Flow Diagram for Fill and Drill Fastener Hole
may result in loss of structural integrity.
Repair.
(f)
Set Filler.
1
Apply release ilm, a metal caul
plate and contact pressure to the
repair using either an external
weight or clamp.
Allow iller to set at room temper-
2
ature for 8 hours before removing
weights or clamps. If clamps were
used, the adhesive/iller may be set
using a heat lamp. Use the cure
cycle in the system speciic techni-
cal manual to set the adhesive/iller.
Figure 7-51. Process Flow Diagram for Fill and
Operate heat lamps per paragraph
Drill Fastener Hole Repair
(1) Facilities, Equipment and Materials. The
Remove caul plate and release
3
following equipment and materials are required: Vac-
ilm.
Very carefully remove
uum Cleaner, HEPA Filter, Marking Pen, Weights, Shot
installed fastener so as not to
Bags, Clamps, Drill Motor, 2000 RPM, Drill Guide,
cause damage.
Drill Bit, Countersink Cutter, Piloted, Microstop Cage,
Silicon Carbide Abrasive Paper, Wiping Cloth, Spat-
(g) Reinish.
ula, Adhesive, Liquid (See System Speciic Technical
Manual), Release Film, Fabric (See System Spe-
Sand the area smooth with 180 grit
1
ciic Technical Manual), Aluminum Sheet Stock, 0.063
abrasive paper. Vacuum sanding
inches or thicker (Local Procurement), Cotton Tipped
dust from repair area. Wipe with
Applicator, Solvent, Flash breaker Tape, Mylar.
clean, dry wiping cloth to remove
sanding residue.
(2) Fill and Drill Repair Procedure.
Apply inish system in accordance
2
(a) Remove dirt, grease and aircraft luids
with paragraph 7-13b or the sys-
from repair area as described in para-
tem speciic technical manual. Use
care not to apply inish system in
fastener hole or countersink area.
c. Fill And Drill Repair. This repair is applicable
DO NOT use oil or oil based materials
to damaged, misdrilled or elongated fastener holes.
as NDI couplants on advanced composite
It is limited to lightly loaded fastener holes used on
components. Use only water or water based
non-structural access covers and doors. For repairs
materials. Disbonds may result and loss of
to load bearing fastener holes, use the potting, fabric
structural integrity may occur.
repair, swagged grommet or captive bushing method
per paragraphs 7-10d, 7-10e, 7-10f, or 7-10h. This
(b) Inspect damaged fastener hole for
method uses a two-part resin illed with chopped
delaminations using NDI according to
ibers to restore damaged fastener holes and part
paragraph 5-2 and the system speciic
surfaces. It is used to repair over-sized countersinks
technical manual. If delaminations are
and gouged surfaces which are caused by fastener
present, irst repair the delaminations
wear around the head and/or fastener removal. This
per paragraph 7-10f.
method is intended only for damage that does not
