TM 5-3800-205-23-1
CONTAINER REPAIR - CONTINUED
0164 00
REPAIR OF FACE SKIN DAMAGE (ALUMINUM-BONDED MATERIAL) - CONTINUED
d.
Cut and remove core material to opposite face sheet.
e.
File edges of cutout smooth using fine cut half round file or rotary file chucked in 1/4 in. (6.35 mm) drill.
f.
On opposite side of panel, cut out damaged area in face sheet. Make cutout identical in size and directly oppo-
site cutout made in step b.
g.
File edges of cutouts in both face sheets smooth using fine cut, half round file or rotary file chucked in 1/4 in.
(6.35 mm) drill.
h.
Remove paint from both panel faces around cutout for distance of 1-1/4 in. (31.75 mm). Paint may be sanded
off. All traces of paint must be removed.
i.
If patches are not available, cut two patches from unpainted Aluminum Alloy Sheet Stock (6061-T6) (QQ-A-
250/11). Make patches 1 in. (25.40 mm) larger all around than panel cutout . Patch thickness shall be 0.050 or
0.063 in. (1.27 or 1.60 mm).
j.
Lay out hole pattern in patches. Use 3/8 in. (9.53 mm) edge distance and 1 in. (25.40 mm) spacing. Drill holes
using no. 30 (0.1285 in) or no. 31 (0.1200 in.) drill.
k.
On one side of panel, center patch over cutout and drill through face sheet using predrilled holes in patch as
guide. Use temporary 1/8 in. (3.18 mm) sheet fasteners to secure patch in place while drilling.
l.
Position patch in cutout face sheet and back drill through patch using predrilled holes in patch as guide. Use
temporary 1/8 in. (3.18 mm) sheet fasteners to secure in place while drilling.
m.
Repeat procedures in step j and k to drill patch and patch on opposite side of panel.
n.
Remove patches and remove burrs from all drilled holes.
o.
Cut section of new core material to fit snugly into core cutout.
p.
Prepare bonding surfaces of face sheet patches by sanding until oxide film is removed and bright surface is
exposed.
WARNING
Dowclene EC is flammable and harmful to eyes, skin, and breathing passages. Observe all fire precau-
tions. Use only with adequate ventilation and with approved personal protective equipment. Failure to
follow this warning may result in injury or death to personnel. Failure to follow this warning may result
in injury or death to personnel.
q.
Wipe surfaces with clean cloth soaked in Dowclene EC and immediately wipe solvent from surfaces with
clean cloth. Wear gloves to avoid contaminating cleaned surfaces with dirt, oil or fingerprints.
WARNING
EA9324 adhesive is flammable and harmful to eyes, skin, and breathing passages. Observe all fire pre-
cautions. Use only with adequate ventilation and with approved personal protective equipment. Keep
away from open flames or other sources of ignition. Failure to follow this warning may result in injury
or death to personnel.
r.
Mix sufficient quantity of EA9324 adhesive for repair. The adhesive has limited pot life so repair must be
completed within that period of time.
s.
Apply liberal layer of adhesive to both sides and all edges of new core material and position core material in cut-
out.
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