MOD 91-0001-01 R2.pdf

USDA - Forest Service C23A

EXTERIOR MODIFICATION

NUMBER 91-0001-01

Title: PAINTING OF AIRCRAFT AND COMPONENTS

ATA CHAPTER: 11-10-00, 11-20-00, 51-22-00, 51-23-00, 51-24-00

APPLICABLE TO: MAINTENANCE, ENGINEERING

THIS MODIFICATION OUTLINES THE VARIOUS PROCEDURES AND EQUIPMENT USED FOR THE REMOVAL OF PAINT, PREPARATION, PRIMING, PAINTING, AND THE APPLICATION OF EROSION RESISTANT COATINGS ON THE USDA-FOREST SERVICE C-23A AIRCRAFT. THE INFORMATION PROVIDED, INCORPORATES

SHORT BROTHERS STRUCTURAL REPAIR MANUAL CHAPTERS

51-22-00 STRIPPING OF PAINT FROM ALUMINIUM ALLOY AND / OR COMPONENTS,

51-23-00 PAINTING OF AIRCRAFT AND COMPONENTS,

51-24-00 ALODINE / ALOCROM 1200-BRUSH APPLICATION.

THIS WILL ENSURE COMPATIBILITY WITH THE ORIGINAL PAINTING SPECIFICATIONS, BUT SHOULD ANY

FURTHER INFORMATION BE REQUIRED THEN REFERENCE CAN BE MADE TO SHORTS PROCESS

SPECIFICATION ( P. SPEC. 910, 911, 915, 916 & 918 ).

PAINT FACILITY SPECIFICATIONS ARE CALLED OUT IN 11-00-00 PAINT FACILITY SPECIFICATIONS

EXTERIOR PAINT SCHEME IS CALLED OUT IN 11-10-00 EXTERIOR AND MARKINGS.

EXTERIOR PLACARDS AND PLACEMENT ARE CALLED OUT IN 11-20-00 PLACARDS AND LABELS.

11-00-00 PAINT FACILITY SPECIFICATIONS.

11-10-00 EXTERIOR AND MARKINGS.

11-20-00 PLACARDS AND LABELS.

51-22-00 STRIPPING OF PAINT FROM ALUMINIUM ALLOY AND / OR COMPONENTS,

51-23-00 PAINTING OF AIRCRAFT AND COMPONENTS,

51-24-00 ALODINE / ALOCROM 1200-BRUSH APPLICATION.

FILING INSTRUCTIONS: USDA-FS INSERT THIS MODIFICATION AFTER CHAPTER 51-20-00, PAGE 6

OF THE C-23A STRUCTURAL REPAIR MANUAL. USDA-FS MICROFICHE

HOLDERS OF THE SD3-30 STRUCTURAL REPAIR MANUAL SHOULD

INSERT THIS MODIFICATION AT THE FRONT OF THEIR MICROFICHE FOLDER.

issued by: USDA - Forest Service Signed: __________________________________ Aircraft Maintenance Program Manager Pacific Northwest Region (R-6) Date: __________________________________ 1740 SE Ochoco Way Redmond, Oregon 97756-9506

USDA - Forest Service Signed: __________________________________ C23A Maintenance Program Specialist Pacific Northwest Region (R-6) Date: __________________________________ 1740 SE Ochoco Way Redmond, Oregon 97756-9506

ORIGINAL ISSUE: JUNE 06 91-0001-01

REVISION No.: 1 AUG 01/08 AUG 01/08

EXTERIOR MODIFICATION 91-0001-01

STRUCTURAL REPAIR MANUAL

: PAINT FACILITY SPECIFICATIONS :

: 1. INTRODUCTION :

: A. THIS SECTION DESCRIBES THE MINIMUM PAINT FACILITY REQUIREMENTS, TO INSURE AIRCRAFT :

: A. PAINTING MEETS USDA FOREST SERVICE C23A MAINTENANCE PROGRAM REQUIREMENTS. :

: 2. HANGAR :

: MINIMUM INSIDE DIMENSIONS: :

: A. 20 FEET HIGH. :

: B. 78 FEET WIDE. :

: C. 70 FEET LONG. :

: HANGAR CONSTRUCTION: :

: A. ALL METAL. :

: B. AUTOMATIC FIRE ALARM AND SPRINKLER SYSTEM. :

: C. CLEAN CEMENT FLOORS. :

: 3. EQUIPMENT :

: A. WASTE WATER / CHEMICAL TREATMENT SYSTEM :

: (1). MINIMUM 200 GALLON COLLECTION TANK INCLUDING A DRUM DRYER EVAPORATOR :

: (1). WITH A 190 CFM VENT BLOWER :

: (2). UNIT MOUNTED ON A CEMENT FLOOR. :

: 11-00-00 91-0001-01 :

: PAGE 1 OF 3 :

: JUN 19/08 :

EXTERIOR MODIFICATION 91-0001-01

STRUCTURAL REPAIR MANUAL

: B. CROSS FLOW UNIDIRECTIONAL VENTILATION SYSTEM :

: (1). MINIMUM OF TWO VERTICAL DIRECT FIRED GAS HEATED MAKEUP UNITS WITH A MAXIMUM :

: (1). CAPACITY OF 75'000 CFM AND 491 FPM FACE VELOCITY EACH COUPLED WITH 5 EXHAUST :

: (1). FANS WITH A MAXIMUM OF 29,000 CFM AND 191 FMP FACE VELOCITY. :

: 11-00-00 91-0001-01 :

: PAGE 2 OF 3 :

EXTERIOR MODIFICATION 91-0001

STRUCTURAL REPAIR MANUAL

: C. APPLICATION EQUIPMENT :

: (1). ELECTROSTATIC EQUIPMENT :

: A. GRASCO PROXs4 OR EQUIVALENT :

: B. COMPRESSED AIR DRYER SYSTEM WITH DOUBLE AIR FILTER SYSTEM. :

: 11-00-00 91-0001-01 :

: PAGE 3 OF 3 :

U.S.F.S. 1C-23A-4-11

EXTERIOR AND MARKINGS ( MOD 91-0001 )

FIGURE 0001

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FIG 0001

AUG 01/08

FIGURE 0002

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FIGURE 0003

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FIGURE 0004

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FIGURE 0009

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FIG 0009

FIGURE 0010

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FIG 0010

WING WALK-BLACK

EXTERIOR AND MARKINGS ( MOD 91-0001 )

FIGURE 0011

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FIG 0011

FIGURE 0012

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FIG 0012

FIGURE 0013

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FIG 0013

JUN 18/06

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FIGURE 0015

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FIG 0015

FIGURE 0016

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FIG 0016

PLACARDS AND LABELS ( MOD 91-0001 )

FIGURE 0001

11-20-00 91-0001-01

FIG 0001

UNITS

FIG - PART NUMBER NOMENCLATURE EFFECT PER

ITEM 123456 FROM TO ASSY

0001-

- 1 A1829KIT PLACARDS EXTERIOR - MOD 91-0001 A 1

( A1829KIT ) AERO DECALS

10 A1825VMM LABEL EXTERIOR LT. - "MAX TOWING" A 1

20 A1814VBC LABEL EXTERIOR LT. - "STATIC VENTS" A 1

30 A1822VBY LABEL EXTERIOR LT. - "RESCUE" A 1

40 A1818VMM LABEL EXTERIOR LT. - "EMERGENCY EXIT" A 1

50 A1850VBW LABEL EXTERIOR LT. - "EXIT" A 1

60 A1804VBW LABEL EXTERIOR LT. - "CARGO DOOR" A 1

70 A1803VBW LABEL EXTERIOR LT. - "BAGGAGE DOOR" A 1

80 A1827VMM LABEL EXTERIOR LT. - "TIRE PRESSURE" A 1

A - SN: SH-3106, SH-3109, SH-3115,

SH-3116, SH-3119

AERO DECALS

1914 CANOVA STREET S.E. PALM BAY, FL. 32909

TELEPHONE: ( 321) 768-2114

11-20-00 91-0001-01

FIG 0001

FIGURE 0002

11-20-00 91-0001-01

FIG 0002

FIG - PART NUMBER NOMENCLATURE EFFECT PER

ITEM 123456 FROM TO ASSY

0002-

- 1 PLACARDS EXTERIOR - MOD 91-0001 A 1

( A1829KIT ) AERO DECALS

10 A1809VWB LABEL EXTERIOR RT. - "JET A" A 1

20 A1826VMM LABEL EXTERIOR RT. - "FUEL DRAIN" A 2

30 A1816VBC LABEL EXTERIOR RT. - "OXYGEN" A 1

50 A1818VMM LABEL EXTERIOR RT. - "EMERGENCY EXIT" A 1

60 A1821VBY LABEL EXTERIOR RT. - "RESCUE" A 1

70 A1817VBC LABEL EXTERIOR RT. - "AIR CONDITIONING" A 1

80 A1827VMM LABEL EXTERIOR RT. - "TIRE PRESSURE" A 1

90 A1825VMM LABEL EXTERIOR RT. - "MAX TOWING" A 1

100 A1815VBC LABEL EXTERIOR RT. - "GROUND SUPPLY" A 1

110 A1814VBC LABEL EXTERIOR RT. - "STATIC VENTS" A 1

A - SN: SH-3106, SH-3109, SH-3115,

SH-3116, SH-3119

AERO DECALS

1914 CANOVA STREET S.E. PALM BAY, FL. 32909

TELEPHONE: ( 321) 768-2114

11-20-00 91-0001-01

FIG 0002

FIGURE 0003

11-20-00 91-0001-01

FIG 0003

FIG - PART NUMBER NOMENCLATURE EFFECT PER

ITEM 123456 FROM TO ASSY

0003-

- 1 PLACARDS EXTERIOR - MOD 91-0001 A 1

( A1829KIT ) AERO DECALS

10 A1810VBC LABEL EXTERIOR - "JET A" A 2

20 A1812VBC LABEL EXTERIOR - "AFT TANK" A 1

30 A1813VBC LABEL EXTERIOR - "TANK 1" A 1

40 A1811VBC LABEL EXTERIOR - "TANK 2" A 1

50 A1806VWB LABEL EXTERIOR - "NO STEP" A 10

70 A1828VWB LABEL EXTERIOR - "OIL CAPACITY" A 2

80 A1808VBC LABEL EXTERIOR - "NO STEP OUTSIDE" A 5

81 A1807VWB LABEL EXTERIOR - "NO STEP OUTSIDE" A 4

90 A1821VBY LABEL EXTERIOR - "RESCUE" A 1

100 A1819VMM LABEL EXTERIOR - "EMERGENCY EXIT" A 1

A - SN: SH-3106, SH-3109, SH-3115,

SH-3116, SH-3119

AERO DECALS

1914 CANOVA STREET S.E. PALM BAY, FL. 32909

TELEPHONE: ( 321) 768-2114

11-20-00 91-0001-01

FIG 0003

FIGURE 0004

11-20-00 91-0001-01

FIG 0004

FIG - PART NUMBER NOMENCLATURE EFFECT PER

ITEM 123456 FROM TO ASSY

0004-

- 1 PLACARDS EXTERIOR - MOD 91-0001 A 1

( A1829KIT ) AERO DECALS

10 A1820VWB LABEL EXTERIOR - "STOW PLUG" A 1

20 A1823VMM LABEL EXTERIOR - "CAUTION" A 1

30 A1824VMM LABEL EXTERIOR - "RAMP DOOR" A 1

A - SN: SH-3106, SH-3109, SH-3115,

SH-3116, SH-3119

AERO DECALS

1914 CANOVA STREET S.E. PALM BAY, FL. 32909

TELEPHONE: ( 321) 768-2114

11-20-00 91-0001-01

FIG 0004

EXTEROR MODIFICATION 91-0001-01

STRUCTURAL REPAIR MANUAL

: STRIPPING OF PAINT FROM ALUMINUM ALLOY AND/OR COMPOSITE COMPONENTS :

: 1. INTRODUCTION :

: A. THIS SECTION DESCRIBES THE REMOVAL OF PAINT FROM ALLOY AND COMPOSITE COMPONENTS, :

: INCLUDING THOSE WHICH HAVE BEEN ADHESIVELY BONDED. :

: B. UNDER NO CIRCUMSTANCES SHALL PAINT STRIPPERS OTHER THAN THAT DETAILED IN THIS SECTION :

: BE USED IN PAINT REMOVAL OPERATIONS. :

: C. THIS SECTION DESCRIBES THE REMOVAL OF EPOXY PRIMER WHICH HAS BEEN APPLIED IN :

: ACCORDANCE WITH SHORTS P SPEC 910 AND POLYURETHANE FINISHES APPLIED IN ACCORDANCE :

: WITH SHORT P SPEC 911. :

: 2. SCOPE :

: THIS SECTION ESTABLISHES THE PROCEDURE FOR COMPLETE REMOVAL OF POLYURETHANE FINISH :

: AND/OR EPOXY PRIMER FROM:- :

: A. ALUMINUM ALLOY, WITHOUT REMOVING UNDERLYING CHEMICAL PRE-TREATMENT OR ADHESIVE :

: PRIMER ( WHERE EMPLOYED ). :

: B. CARBON FIBRE AND ARAMID COMPOSITE COMPONENTS. :

: 3. EQUIPMENT AND MATERIALS :

: A. PAINT STRIPPER :

: - ARDOX 230 - DEF 1443 - ARDOX LIMITED :

: - B & B 5075 NP - MIL - R - 81903A AMENDMENT 1, TYPE 111 - B & B CHEMICAL LTD. :

: B. PAINT STRIPPER APPLICATION :

: (1) BRUSH APPLICATION :

: SUITABLE STIFF BRISTLE BRUSHES - OPEN SOURCE. :

: (2) IMMERSION :

: STAINLESS STEEL OR OTHER SUITABLY LINED TANK - OPEN SOURCE :

: C. MISCELLANEOUS MATERIALS :

: A. MEK CLEANER ( METHYL ETHYL KETONE ) - OPEN SOURCE :

: GENKLENE CLEANER - BS 4487 - I.C.I LTD. :

: B. CLEAN LINT FREE CLOTHS - APPROVED SUPPLIER :

: C. PLASTIC SCRAPERS - OPEN SOURCE :

: D. PVC PROTECTIVE GLOVES - OPEN SOURCE :

: E. PVC PROTECTIVE APRONS - OPEN SOURCE :

: F. GOGGLES OR FACE SHIELDS - APPROVED SUPPLIER :

: 51-22-00 91-0001-01 :

: PAGE 1 OF 3 :

: JUN 19/06 :

STRUCTURAL REPAIR MANUAL

: 4. SAFETY PRECAUTIONS :

: A. PAINT STRIPPING MUST NOT BE CARRIED OUT IN CONFINED SPACES. ADEQUATE VENTILATION IS REQUIRED. :

: B. PAINT STRIPPERS CONTAIN CHLORINATE SOLVENTS AND PHENOLIC COMPOUNDS. AVOID CONTACT :

: WITH SKIN, EYES, AND CLOTHING. IN THE EVENT OF EYE CONTACT, WASH IMMEDIATELY AND GET :

: MEDICAL ATTENTION. FACE SHIELDS OR GOGGLES AND PVC SOLVENT-RESISTANT GLOVES AND APRONS :

: MUST BE WORN BY PERSONNEL. :

: C. SPILLAGE OR LEAKAGE OF PAINT STRIPPER SHOULD BE ABSORBED WITH SAND OR SAWDUST THEN TAKEN :

: TO A SAFE AREA OUT OF DOORS FOR SUBSEQUENT DISPOSAL. WASH SITE OF SPILLAGE WITH WATER AND :

: SOAP OR DETERGENT. :

: D. ARDOX 230 AND B AND B 5075 NP ARE FLAMMABLE AND NORMAL FIRE PRECAUTIONS MUST BE TAKEN. :

: 5. REQUIREMENTS :

: A. PAINT STRIPPER STORAGE :

: (1) DRUMS SHOULD BE STORED IN A COOL WELL VENTILATED AREA OUT OF DIRECT SUNLIGHT. :

: (2) THE DRUMS USED FOR STRANGE SHOULD BE SUFFICIENTLY STOPPERED TO PREVENT LOSS :

: OF SOLVENTS BY EVAPORATION. :

: 6. PROCEDURES :

: A. CLEANING :

: (1) WIPE OFF SURPLUS DIRT USING GENKLENE CLEANER OR MEK, AND CLEAN LINT FREE CLOTHS. :

: B. MASKING :

: REFER TO 51-23-00, PB1. ( PARA 5 A ). :

: (1) PAINT STRIPPERS WILL ATTACK NON-COMPOSITE PLASTICS, THEREFORE PLEXIGLASS ( PERSPEX ) :

: WINDOWS MUST BE PROTECTED BY MASKING. RUBBER WINDOW SEALS AND TYPES SHOULD :

: ALSO BE PROTECTED. :

: C. PAINT REMOVAL :

: NOTE: PAINT STRIPPER MUST NOT BE APPLIED TO AREA WHERE COMPLETE REMOVAL OF ALL TRACES :

: OF THE STRIPPER CANNOT BE ENSURED. ( E.G. ASSEMBLIES WHERE ENTRAPMENT MAY OCCUR) :

: (1) APPLICATION OF PAINT STRIPPER :

: TWO TYPES OF APPLICATION CAN BE EMPLOYED:- :

: (A) PAINT STRIPPER MUST BE APPLIED TO THE FOLLOWING AREAS USING BRUSH ONLY. :

: - AIRCRAFT :

: - ADHESIVE BONDED COMPONENTS :

: - COMPOSITE COMPONENT :

: (B) SMALL NON-BONDED ALUMINUM ALLOY DETAILS MAY HAVE PAINT REMOVED BY :

: COMPLETE IMMERSION IN PAINT STRIPPER. :

: 51-22-00 91-0001-01 :

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EXTEROR MODIFICATION 91-0001

STRUCTURAL REPAIR MANUAL

: (2) BRUSH APPLICATION :

: A LIBERAL COATING OF PAINT STRIPPER MUST BE APPLIED TO THE ARE TO BE STRIPPED :

: PARTICULAR ATTENTION BEING PAID TO CORNERS AND CREVICES. A MINIMUM DWELL TIME OF :

: 1 HOUR IS REQUIRED, WITH UP TO 16 HOURS MAXIMUM FOR MORE RESISTANT PAINT FINISHES. :

: PROCEED TO PARA. D. :

: (3) IMMERSION :

: ITEMS WHICH CAN BE STRIPPED BY THIS METHOD, SHALL BE WHOLLY IMMERSED FOR A :

: PERIOD SUFFICIENT TO LOOSEN THE PAINT. :

: A MINIMUM TIME 1 HOUR IS RECOMMENDED, HOWEVER, TO PREVENT EXCESSIVE SCUDDING :

: AND TO CONSERVE STRIPPER, THE ITEMS SHOULD NOT BE IMMERSED LONGER THAN :

: NECESSARY TO LOOSEN PAINT AND CARE MUST BE TAKEN TO REMOVE THE ITEMS FROM THE :

: STRIPPER WITHOUT EXCESSIVE DRAG OUT. :

: PROCEED TO PARA D. :

: D. STRIPPING :

: (1) AFTER APPLICATION OF STRIPPER BY EITHER OF THE METHODS DEFINED IN PARA C FOR THE :

: APPROPRIATE TIME , REMOVE LOOSE PAINT AND EXCESS PAINT STRIPPER WITH AN AIR/WATER :

: JET OR HIGH PRESSURE WATER. A PLASTIC SCRAPPER CAN BE USED TO COMPLETELY REMOVE :

: THE MORE RESISTANT AREAS OF PAINT, PARTICULARLY IN AWKWARD CORNERS AND CREVICES, :

: TAKING CARE NOT TO DAMAGE UNDERLYING TREATMENTS. TRAPPED STRIPPER CAN REMAIN :

: ACTIVE FOR A CONSIDERABLE PERIOD AND IT IS ESSENTIAL THAT IT IS ALSO REMOVED USING :

: CLEAN WATER AND A STIFF BRISTLE BRUSH. :

: (2) FINALLY RINSE THROUGHLY WITH HIGH PRESSURE WATER. :

: NOTE: IF PAINT HAS BEEN REMOVED FROM AN ANODIC COATING WHICH HAS NOT BEEN :

: PROTECTED BY AN ADHESION PRIMER THAN THIS SURFACE MUST EITHER: :

: - BE REACTIVATED BY USING ALOCOM1200. REFER TO 51-24-00, PB1. :

: - HAVE AN ETCH PRIMER APPLIED. REFER TO 51-23-00, PB 1. :

: 7. QUALITY REQUIREMENTS :

: THE QUALITY DEPARTMENT SHALL BE SATISFIED THE PROVISIONS OF THIS SECTION HAVE BEEN MET. :

: SPECIAL ATTENTION SHALL BE PAID TO THOSE DETAILED IN PARA 5. :

: INSPECTION SHALL VERIFY THE FOLLOWING:- :

: A. THE PAINT STRIPPER USED IS AS DETAILED IN THIS SECTION. :

: B. OPERATIONS PERFORMED HAVE BEEN CORRECTLY SELECTED AND APPLIED AS DESCRIBED IN PARA 6. :

: C. PARTS WHICH HAVE HAD PAINT REMOVED SHALL COMPLY TO THE FOLLOWING APPEARANCE:- :

: (1) ALL TRACES OF PAINT SYSTEM HAVE BEEN REMOVED BACK TO THE CHEMICAL PRETREATMENT OR TO :

: ADHESIVE PRIMER ( WHERE EMPLOYED ) IN THE CASE OF ALUMINUM ALLOY, OR TO THE BARE SURFACE. :

: (2) ALL TRACES OF PAINT STRIPPER HAVE BEEN COMPLETELY REMOVED, PARTICULARLY FROM :

: JOINTS AND CREVICES. :

: 51-22-00 91-0001-01 :

: PAGE 3 OF 3 :

STRUCTURAL REPAIR MANUAL

: PAINTING OF AIRCRAFT AND COMPONENTS :

: 1. INTRODUCTION :

: THIS SECTION OUTLINES THE VARIOUS PROCEDURES AND EQUIPMENT USED FOR THE REMOVAL OF :

: PAINT, PREPARATION, PRIMING, PAINTING, AND THE APPLICATION OF EROSION RESISTANT AND HEAT :

: RESISTANT COATINGS ON THE C-23A AIRCRAFT. THE INFORMATION PROVIDED, WILL ENSURE :

: COMPATIBILITY WITH THE ORIGINAL PAINTING SPECIFICATIONS, BUT SHOULD ANY FURTHER :

: INFORMATION BE REQUIRED THEN REFERENCE CAN BE MADE TO SHORTS PROCESS SPECIFICATION :

: ( P. SPEC. 910, 911, 915, 916 & 918 ). :

: 2. GENERAL :

: (1) PAINT MATERIALS FROM DIFFERENT SUPPLIERS MUST NOT BE MIXED TOGETHER, EVER :

: THOUGH RELEASED TO THE SAME SPECIFICATIONS. :

: (2) IN ANY PAINT SCHEME A PRIMER COAT IS ESSENTIAL FEATURE. IN ADDITION TO SERVING AS :

: AN ADHESIVE LINK BETWEEN THE UNDERLYING MATERIAL AND ANY TOP OR FINISH COATS IT :

: IS CHIEFLY RESPONSIBLE FOR THE PROTECTIVE VALUE OF THE FINISHING SCHEME. :

: (3) FOR AIRCRAFT INTERIOR SURFACES SUFFICIENT PROTECTION IS NORMALLY AFFORDED BY :

: THE PRIMER ONLY, BUT THE EXTERIOR SURFACES RECEIVE ADDITIONAL TOP OR FINISH :

: COATS TO PROVIDE THE DESIRED AESTHETIC EFFECT AND ALSO TO AUGMENT THE PROTECTIVE :

: VALUE OF THE FINISHING SCHEME. EPOXY PRIMERS ARE COMPATIBLE WITH POLYURETHANE AS :

: WELL AS EPOXIDE BASED FINISHES. :

: (4) THE PRIMER COAT SHOULD PREFERABLE FOLLOW IMMEDIATELY AFTER THE PREPARATORY :

: OPERATIONS DESCRIBED IN PARA 8. :

: (5) SIMILARLY THE FINISH COAT SHOULD PREFERABLY FOLLOW IMMEDIATELY AFTER PRIMING, AS :

: THIS WILL REDUCE PREPARATORY WORK. :

: (6) SURFACES WHICH HAVE BEEN PRIMED FOR LONGER THAN 48 HOURS MAY HAVE DETERIORATED :

: DUE TO AGEING, CONTAMINATION OR DAMAGE, AND WILL REQUIRE A REFRESHER COAT OF :

: PRIMER IN ACCORDANCE WITH PARA 8.F. :

: 3. ENVIRONMENTAL CONDITIONS :

: TEMPERATURE AND HUMIDITY IN THE PAINT SHOP MUST BE CONTINUOUSLY RECORDED, AND BE :

: WITHIN THE FOLLOWING RANGE:- :

: TEMPERATURE: 14 TO 29 EC :

: HUMIDITY: 35 TO 80% :

: THE HUMIDITY IN THE AREA WHERE THE PAINT IS MIXED MUST NOT FALL BELOW 35% OR EXCEED 80%, :

: AND MUST, BE WITHIN " 5% OF THE LEVEL IN THE PAINT SHOP. :

: THE TEMPERATURE DIFFERENCE BETWEEN THE PAINT SHOP AND THE MIXING AREA MUST NOT BE :

: GREATER THAN "2EC. :

: 4. EQUIPMENT MATERIALS :

: OTHER EQUIPMENT AND MATERIALS MAY BE USED IN LIEU OF THOSE LISTED BELOW PROVIDED THAT :

: THEIR QUALITY AND PERFORMANCE IS NOT INFERIOR, AND THAT THEY COMPLY WITH THE RELEVANT :

: SPECIFICATIONS AND HAVE BEEN APPROVED BY BOMBARDIER ( BELFAST ) QUALITY AND MATERIALS :

: TECHNOLOGY DEPARTMENTS. :

: 51-23-00 91-0001-01 :

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STRUCTURAL REPAIR MANUAL

: A. EQUIPMENT FOR PAINT MIXING :

: SPATULA, 100 MM ) :

: MECHANICALLY OPERATED PAINT STIRRER/MIXER ) :

: 100 MESH SCREEN FILTER. PHOSPHOR ) :

: BRONZE, BRASS OR STAINLESS STEEL, ) COMMERCIALLY AVAILABLE :

: ( BS 410, APPENDIX C ) ) :

: VISCOMETER. BS B3 CUP. ( BS 3900 ) ) :

: STOP CLOCK ) :

: THERMOMETER. 0 TO 50 C ) :

: B. EQUIPMENT FOR PAINT SPRAYING AND PAINT FILM MEASUREMENT :

: PAINT SPRAY GUN. SUCTION TYPE. ) :

: WITH NO. 30 AIR CAP AND EX FLUID TIP AND NEEDLE. ) :

: KREMLIN AIRMIX PAINT EQUIPMENT 16.35 ) COMMERCIALLY AVAILABLE :

: PAINT FILM MEASURING METER ) :

: ( PERMASCOPE TYPE 3E2 TAN B ) ) :

: C. FILLERS AND STOPPERS :

: STATIC CONDITIONER FILLER 28 - C - 1 DEXTER CORP. USA :

: STOPPERS AND SURFACES :

: FOR APPROVED STOPPERS AND SURFACES. REFER TO TABLE 1. :

: D. PAINT AND PRIMER :

: FOR APPROVED POLYURETHANE FINISHES. REFER TO TABLE 1. :

: FOR APPROVED ETCH PRIMERS. REFER TO TABLE 2. :

: FOR APPROVED EPOXY PRIMERS. REFER TO TABLE 3. :

: E. CLEANED MATERIALS :

: TDL 2000 60009 CLEANING FLUID ) :

: CN 45 ( AFS 1826 ) CLEANING FLUID ) :

: WHITE CLEANING CLOTHS, GENERAL PURPOSE ) COMMERCIALLY AVAILABLE :

: WET AND DRY ABRASIVE PAPER. 320 AND 400 GRIT ) :

: SCOTCHBRITE SHEET. FINISHING TYPE 'A' VERY FINE ) :

: TAK RAGS ) :

: 51-23-00 91-0001-01 :

: PAGE 2 OF 20 :

STRUCTURAL REPAIR MANUAL

: F. MISCELLANEOUS MATERIALS :

: PRESSURE SENSITIVE ADHESIVE PAPER TAPE IN 0.75, 1.0 AND ) :

: 1.5 INCH WIDTHS ) :

: BROWN KRAFT PAPER IN 30 & 36 INCH WIDTHS ) :

: COTTON AND RUBBER GLOVES ) :

: DUST SUIT ) COMMERCIALLY AVAILABLE :

: AIRFED PROTECTIVE HELMETS ) :

: RUBBER COVERED ROLLER. 4 1/2 POUND ) :

: SOLVENT SAFETY CAN/DISPENSER ) :

: ( APPROVED TO FACTORY INSPECTORATE OF APPROVAL :

: CERTIFICATE NO. 1 ) :

: PRESSURE SENSITIVE TAPE 1.0 INCH WIDE CODE 250 3M LTD. :

: 51-23-00 91-0001-01 :

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STRUCTURAL REPAIR MANUAL

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STRUCTURAL REPAIR MANUAL

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STRUCTURAL REPAIR MANUAL

: 5. HEALTH AND SAFETY PRECAUTIONS :

: A. AIRCRAFT SAFETY :

: (1) THE AIRCRAFT BATTERIES ARE TO BE REMOVED OR DISCONNECTED. :

: (2) THE AIRCRAFT SHALL BE ELECTRICALLY GROUNDED. :

: (3) BLANK OFF ALL OPENINGS IN AREA TO BE PAINTED TO PREVENT ENTRY OF DUST AND PAINT :

: SPRAY IE STATIC VENTS. ETC. :

: (4) MASK OFF AREAS TO PROTECT FROM UNDESIRABLE PAINT SPRAY ON WORKING SURFACES SUCH :

: AS FLAP TRACKS, INSULATORS, WINDOWS, DE-ICER BOOT, LANDING GEAR, ETC. :

: (5) THE SEQUENCE OF OPERATIONS FOR THE MOVEMENT OF FLAPS AND AIR - IN - TAKE DEFLECTORS :

: SHALL BE CARRIED OUT AFTER PAINTING THESE SYSTEMS OR IN THOSE AREAS. :

: B. PAINT SPRAYING AREA AND PERSONNEL SAFETY :

: (1) NO OPEN FLAMES OR NAKED LIGHTS, ARE ALLOWED IN THE PAINTING AREA. :

: (2) THE USE OF INFRARED OR OTHER HEAT LAMPS IN THE PAINTING AREA IS PROHIBITED. :

: (3) SMOKING OR EATING IS PROHIBITED IN THE PAINT SPRAYING AREA. :

: (4) PRIMERS AND PAINTS SHALL BE STORED IN ACCORDANCE WITH THE MANUFACTURERS IN INSTRUCTIONS. :

: (5) SOLVENT CONTACT WITH THE SKIN MUST BE AVOIDED. :

: (6) SOLVENTS MUST BE KEPT IN AN APPROVED SAFETY STORAGE CAN/DISPENSER. :

: (7) CLOTHS SATURATED WITH SOLVENTS MUST BE DISPOSED OF IN METAL CONTAINERS WITH CLOSE :

: FITTING LIDS. THE CONTAINERS MUST BE EMPTIED DAILY. :

: (8) ENSURE CORRECT SAFETY EQUIPMENT IS USED. WORKING OVERALLS, RUBBER GLOVES AND :

: SUITABLE AIRFED HELMETS SHOULD BE USED AT ALL TIMES DURING OPERATIONS. :

: (9) VOLATILE SURFACES AND FILLERS, CAN BE HARMFUL BY INGESTION AND BY INHALATION OF THEIR :

: VAPORS, AND THE MAJORITY ARE ALSO FLAMMABLE. IT IS THEREFORE ESSENTIAL THAT ADEQUATE :

: VENTILATION IS PROVIDED AT ALL TIMES, AND THAT NECESSARY FIRE PRECAUTIONS ARE OBSERVED. :

: SPRAY DUST WHICH HAS ACCUMULATED IN VENTILATION DUCTS OR SPRAY BOOTHS MUST BE :

: REMOVED BY FREQUENT CLEANING. :

: (10) VENTILATION DUCT, FILTERS ETC, MUST BE SERVICED REGULARLY. :

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: (11) ALL ELECTRICAL EQUIPMENT, SWITCH GEAR AND LIGHTING MUST COMPLY WITH BS 5345 ( BASEFA :

: STANDARD ), OR US ELECTRICAL STANDARD 00 - 25 - 172 ( INTRINSICALLY SAFE ELECTRICAL :

: EQUIPMENT. :

: 6. REMOVAL OF PAINT :

: PARTIAL OR COMPLETE REMOVAL OF PAINT FROM ALUMINUM AND COMPOSITE SURFACES. REFER TO :

: 51 - 22 - 00, PB1. :

: 7. REPAINTING OF AIRCRAFT :

: THE TWO SYSTEMS EMPLOYED BY BOMBARDIER AEROSPACE ( BELFAST ) FOR AIRCRAFT REPAINTING ARE:- :

: SYSTEM 1 - REFER TO 51-22-00, PB1. OVERALL CHEMICAL STRIPPING ( IN ACCORDANCE WITH :

: BACK TO BARE METAL, FOLLOWED BY THE APPLICATION OF A CHEMICAL CONVERSION :

: COATING, EPOXY PRIMING AND TOP-COATING. :

: SYSTEM 2 -MECHANICALLY ABRADING AND PARTIAL STRIPPING, ( WHERE NECESSARY), FOLLOWING :

: REPAINTING OVER THE EXISTING SCHEME. :

: NOTE: SYSTEM 2 INCURS AN ADDITIONAL WEIGHT PENALTY TO THE AIRCRAFT. :

: A. SYSTEM 1 :

: SYSTEM 1 IS THE MOST DEMANDING AND TIME CONSUMING METHOD OF PAINT REMOVAL. ITS IS HOWEVER :

: THE ONLY METHOD APPROVED BY BOMBARDIER AEROSPACE ( BELFAST ) TO COMPLETELY REMOVE PAINT. :

: OPERATORS MAY FIND THAT CHEMICALLY STRIPPING AN AIRCRAFT TO BARE METAL IS A DIFFICULT AND :

: HAZARDOUS OPERATION, BUT MAY BE NECESSARY FOR INSPECTION FOR CORROSION, SURFACE OR :

: STRUCTURAL DAMAGE. IT SHOULD BE NOTED THAT ON SOME AREAS OF THE AIRCRAFT, IE WING AND :

: FUSELAGE AREAS, AN ADHESIVE PRIMER EG BSL 101 ( RED COLOR ) IS APPLIED DURING BONDING :

: MANUFACTURE. ADHESIVE PRIMERS ARE ALMOST IMPOSSIBLE TO REMOVE, AND SHOULD IF POSSIBLE BE :

: LEFT INTACT AS THEY WILL PROVIDE AN EXCELLENT SURFACE FOR SUBSEQUENT REPAINTING, :

: AFTER PAINT STRIPPING THE FOLLOWING PROCEDURES SHOULD BE APPLIED:- :

: (1) NO OPEN FLAMES OR NAKED LIGHTS, ARE ALLOWED IN THE PAINTING AREA. :

: (2) EPOXY PRIME OVERALL IN ACCORDANCE WITH PARA. 9 A. THROUGH 9.E. :

: (3) FINISH TOPCOAT AS REQUIRED IN A ACCORDANCE WITH PARA. 9. F. :

: B. SYSTEM 2 :

: SYSTEM 2 IS EMPLOYED WHERE A CHANGE OF LIVERY IS REQUIRED, AND WHERE INSPECTION FOR :

: CORROSION, SURFACE OR STRUCTURE DAMAGE IS NOT NECESSARY OR THE TIME, FACILITIES AND :

: EXPENSE PROHIBIT THE USE OF SYSTEM 1. :

: THE SUCCESS OF THIS SYSTEM DEPENDS ON THE EXTENT OF THE ABRADING AND REPAINTING, WHICH :

: IN TURN WILL INFLUENCED BY THE EXISTING COLOURS ON THE AIRCRAFT. :

: IF THE AIRCRAFT IS MAINLY WHITE, WITH A MINIMUM OF COLOUR, CHEAT LINES AND LOGO, THE REPAINT :

: WILL BE RELATIVELY STRAIGHTFORWARD. HOWEVER, DIFFICULTY MAY BE EXPERIENCED IN COVERING DARK :

: COLOURS SUCCESSFULLY. IN SUCH CASES LOCAL CHEMICAL STRIPPING IS ADVISED. :

: IF THE EXISTING LIVERY IS PREDOMINATELY COLOURED, IT WILL REQUIRE OVERALL ABRADING, AND THE :

: FOLLOWING PROCEDURES SHOULD THEN BE APPLIED. :

: (1) ABRADE IN ACCORDANCE WITH PARA. 8.E. :

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: (2) PRIMER PAINT ( AS REQUIRED ) IN ACCORDANCE WITH PARA. 9.A. THROUGH 9.E. :

: (3) FINISH COAT AS NECESSARY IN ACCORDANCE WITH PARA. 9 (6). :

: NOTE: WHEN REPAINTING THE FLYING CONTROL SURFACE, IF THE EXISTING PAINT SYSTEM HAS NOT BEEN :

: ABRADED PRIOR TO REPAINTING ( AS NOTED ABOVE AT PARA. 7. B. REFER TO STEP (1)), THEN THE :

: ADDITIONAL WEIGHT PENALTY INCURRED MAY BE SUFFICIENT TO DISRUPT THE BALANCE CONDITION :

: IN SUCH CIRCUMSTANCES REBALANCING WILL BE NECESSARY. :

: 8. SURFACE PREPARATION FOR METALLIC & COMPOSITE COMPONENTS :

: A. GENERAL :

: ALL AREAS NOT REQUIRING PRIMING OR PAINTING SHALL BE PROTECTED AS FOLLOWS:- :

: (1) CONSTRUCT, USING BROWN KRAFT PAPER, A MASK OF REQUIRED SHAPE AND SIZE. :

: (2) SECURE MASK OVER THE SPECIFIED AREA WITH PRESSURE SENSITIVE ADHESIVE PAPER TAPE. :

: (3) FOR SMALL AREAS, MASKING TAPE ONLY MAY BE USED. :

: B. PAINT STRIPPING :

: REFER TO 51 - 22 - 00, PB 1. :

: C. DE-NIBBING :

: USING CLEAN BROWN KRAFT PAPER AS A MILD ABRASIVE TO REMOVE MINOR SURFACE IRREGULARITIES. :

: D. SOLVENT CLEANING :

: WIPE AREAS AS REQUIRED WITH CLEAN WHITE CLOTHS DAMPENED WITH MEK, OR ACETONE CLEANING :

: FLUID, EXPOSING FRESH CLOTH SURFACES AS NECESSARY, UNTIL ALL CONTAMINATION HAD BEEN REMOVED. :

: ALWAYS ADD SOLVENT TO CLOTH. DO NOT DIP CLOTH INTO FLUID. DO NOT ALLOW DAMPEN CLOTH :

: DIRECTLY FROM THE MAIN CLEANING FLUID CONTAINER. USE ONLY AN APPROVED SAFETY CAN/ :

: DISPENSER CORRECTLY LABELED WITH FLUID TYPE. AFTER USE DISCARD THE USED CLOTHS IN A METAL :

: SAFETY BIN. :

: AFTER SOLVENT CLEANING PARTS MUST NOT BE HANDLED WITH BARE HANDS. WEAR CLEAN WHITE COTTON :

: GLOVES. :

: E. ABRADING :

: DRY ABRADE USING 320 OR 400 GRIT ABRASIVE PAPER. REMOVE SANDING RESIDUE BY WIPING WITH :

: CLEAN TAK RAGS. IF SMOOTHING FILLER USE WATER OR A CLEANING FLUID TO LUBRICATE THE ACTION OF :

: THE ABRASIVE PAPER SO AS TO PRODUCE A SMOOTH, LEVEL, FINE GRAINED SURFACE. REMOVE ALL TRACES :

: OF ABRASIVE AND SLUDGE, PARTICULARLY FROM CREVICES. IF WATER OR SOLVENT IS USED ALLOW AT :

: LEAST ONE HOUR DRYING TIME BEFORE SUBSEQUENT OPERATIONS. :

: NOTE: IF ABRADING COMPOSITE SURFACES TAKE CARE NOT TO EXPOSE THE COMPOSITE FIBRES. :

: WET ABRASION IS NOT PERMITTED ON PRIMED PART, UNLESS THE EPOXY PRIMER HAS BEEN :

: APPLIED FOR MORE THAN 7 DAYS. :

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: F. REFRESHER PRIMING :

: WHENEVER A PRIMER SURFACE HAS AGED OR BECOME CONTAMINATED IT IS NECESSARY TO RETURN IT :

: TO A SUITABLE CONDITION FOR SUBSEQUENT FINISH COATING. IF ONLY SLIGHT DETERIORATION HAS :

: TAKEN PLACE SOLVENT CLEANING WITH OR WITHOUT MILD ABRASION MAY SUFFICE TO REACTIVATE THE :

: SURFACE, IN MORE SEVERE CASES, HOWEVER, IT IS ADDITIONALLY NECESSARY TO APPLY A VERY LIGHT COAT :

: OF EPOXY PRIMER. THIS 'REFRESHES' THE SURFACE AND PROVIDES A GOOD FOR SUBSEQUENT PAINT. THE :

: PRIMER IS PREPARED IN THE NORMAL MANNER, ( PARA. 9.C.), AND APPLIED AS LIGHTLY AS POSSIBLE :

: CONSISTENT WITH SURFACE WETTING. :

: G. PRIMED CLEAN SURFACES LESS THAN 48 HOURS OLD. :

: (1) MASK AS REQUIRED. ( PARA. 8.A ) :

: (2) DE-NIB. ( PARA. 8.C.) :

: (3) SOLVENT LEAN. ( PARA. 8. D.) :

: (4) APPLY FINISH COATING. ( SECTION 9. F. ) :

: H. PRIMED SURFACES MORE THAN 48 HOURS OLD AND/OR CONTAMINATED. :

: (1) MASK AS REQUIRED. ( PARA. 8.A ) :

: (2) LIGHTLY ABRADE. ( PARA. 8.E. ) :

: (3) SOLVENT CLEAN. ( PARA. 8.D. ) :

: (4) APPLY A REFRESHER COAT OF PRIMER ( PARA. 8. F. ) AND ALLOW TO DRY FOR 4 HOURS MINIMUM. :

: (5) SOLVENT CLEAN. ( PARA. 8.D. ) :

: (6) APPLY FINISH COATING. ( PARA. 9. F. ) :

: I. FILLED AND FLATTED SURFACES EITHER MORE THAN 48 HOURS OLD AND/OR CONTAMINATED. :

: (1) MASK AS REQUIRED. ( PARA. 8.A ) :

: (2) LIGHTLY ABRADE. ( PARA. 8.E. ) :

: (3) SOLVENT CLEAN. ( PARA. 8.D. ) :

: (4) APPLY FINISH COATING. ( SECTION 9. F. ) :

: J. FINISHED SURFACES REQUIRING ADDITIONAL COATING OR THE ADDITION OF MARKINGS AND PLACARDS. :

: (1) MASK AS REQUIRED. ( PARA. 8.A ) :

: (2) LIGHTLY ABRADE. ( PARA. 8.E. ) IF MORE THAN 200 HOURS OLD. :

: (3) SOLVENT CLEAN. ( PARA. 8.D. ) :

: (4) APPLY ADDITIONAL FINISH COAT OR MARKING AND PLACARDS AS REQUIRED. ( PARA. 9F.) :

: K. METALLIC COMPONENTS :

: BARE ALUMINUM SURFACES ESPECIALLY THOSE EXPOSED FOLLOWING CHEMICAL STRIPPING OF/OR :

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: MECHANICAL ABRADING CAN BE SUITABLY TREATED USING THE ALODINE/ALOCROM 1200 CHEMICAL :

: CONVERSION COATING, REFER TO 51 - 24- 00. PB 1. :

: PARTS WHICH REQUIRE THE ALODINE/ALOCROM TREATMENT FOLLOWED BY EPOXY PRIMING CAN BE :

: CATEGORIZED AS FOLLOWS:- :

: (1) PARTS ULTIMATELY FORMING PART OF THE OUTSIDE PROFILE OF THE AIRCRAFT. :

: (2) PARTS WHICH DO NOT FORM PART OF THE OUTSIDE PROFILE, BUT COULD BE PAINTED WITHIN 16 :

: HOURS OF ALODINE/ALOCROM TREATMENT. :

: (3) PARTS WHICH BECAUSE OF TIME CONSUMING OPERATIONS SUBSEQUENT TO ANODISING CANNOT BE :

: PAINTED WITHIN 16 HOURS OF ANODISING. :

: PARTS IN CATEGORY (A) MUST BE PAINTED IN ACCORDANCE WITH PARA. 9. E. AND 9.F. SHOULD 16 HOURS :

: ELAPSE BEFORE PAINTING THE PARTS MUST BE STRIPPED, RE-ALODINED AND PAINTED WITHIN :

: THE NEXT 16 HOUR PERIOD. REFER TO 51 - 22 - 00, PB. ETCH PRIMER MUST NOT BE USED. :

: PARTS IN CATEGORY (B) MAY OF COURSE BE PAINTED WITHIN 16 HOURS OF ANODISING. SHOULD 16 HOURS :

: BE EXCEEDED THE PARTS MUST BE ETCHED BEFORE EPOXY PRIMING. :

: PARTS IN CATEGORY (C) ARE TO BE ETCH PRIMED IN ACCORDANCE WITH PARA. 9.A. THROUGH 9.E. :

: L. COMPOSITE COMPONENTS :

: (1) GENERAL :

: LAMINATE AND HONEYCOMB COMPOSITE SURFACES REQUIRE CAREFUL PREPARATION PRIOR TO PRIMING :

: SO THAT THE REQUIRED STANDARD AND APPEARANCE IS ACHIEVED WHEN FINAL TOP COATING IS :

: CARRIED OUT. :

: THE COMPOSITE SURFACES PREPARED IN ACCORDANCE WITH THIS SECTION, INCLUDE EXTERIOR, :

: INTERIOR, STRUCTURE AND NON-STRUCTURAL COMPONENTS, PRIOR TO THE APPLICATION OF EPOXY :

: PRIMER IN ACCORDANCE WITH PARA. 9. :

: THE STOPPER AND SURFACER MATERIALS SHALL BE USEABLE FOR A PERIOD OF 6 MONTHS FROM THE DATE :

: OF RECEIPT WHEN STORED AT A TEMPERATURE OF 20" 2 EC. MATERIAL WHICH HAVE EXCEEDED THE :

: ABOVE STORAGE TIME MAY BE RE-LIFTED AT THE DISCRETION OF THE LOCAL CONTROLLING LABORATORY. :

: (2) PROCEDURES :

: (A). OPERATIONAL SEQUENCE :

: REFER TO TABLE . :

: THE FOLLOWING PROCEDURES MUST BE APPLIED IN CONTINUOUS SEQUENCE. NO SINGLE :

: OPERATION MAY BE OMITTED. :

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: (B). ABRADING :

: LIGHTLY DRY ABRADE THE SURFACE OF THE COMPOSITE COMPONENT USING 320 OR 400 GRIT :

: ABRASIVE PAPER, TAKING CARE NOT TO EXPOSE THE COMPOSITE FIBRES. :

: (C). SOLVENT CLEANING :

: WIPE AREAS AS REQUIRED WITH CLEAN WHITE CLOTHS DAMPENED WITH CLEANING FLUID, :

: EXPOSING FRESH CLOTH SURFACES AS NECESSARY, UNTIL ALL CONTAMINATION HAS BEEN :

: REMOVED. ALWAYS ADD SOLVENT TO CLOTH. DO NOT DIP CLOTH INTO FLUID. DO NOT ALLOW THE :

: FLUID EVAPORATE TO DRYNESS ON THE SURFACE, BUT DRY BY WIPING WITH CLEAN WHITE :

: CLOTHS. DO NOT DAMPEN CLOTH DIRECTLY FROM THE MAIN CONTAINER. USE ONLY :

: AN APPROVED SAFETY STORAGE CAN/DISPENSER CORRECTLY LABELED WITH FLUID TYPE. AFTER :

: USE DISCARD THE USED CLOTHS IN A METAL SAFETY BIN. :

: AFTER SOLVENT CLEANING PARTS MUST NOT BE HANDLED WITH BARE HANDS. WEAR CLEAN WHITE COTTON :

: GLOVES. :

: (3) PINHOLE FILLING :

: DO NOT USE PINHOLE FILLER AS A SMOOTHING AGENT. A CONTINUOUS LAYER IS DETRIMENTAL TO :

: SUBSEQUENT PRIMER ADHESION. :

: (A). STIR THE FILLER TO A UNIFORM CONSISTENCY. :

: (B). PREPARE THE SURFACE TO BE FILLED IN ACCORDANCE WITH PARA. 8.L (2) (A), AND (C) :

: (C). APPLY THE FILLER TO THE CLEANED SURFACE USING HAND PRESSURE TO FORCE THE MATERIAL INTO :

: ANY PINHOLES. :

: (D). ALLOW TO DRY UNTIL CONDITIONER TURNS WHITE. ( APPROXIMATELY 30 MINUTES AT 21 TO 32EC). :

: (E). THROUGHLY WIPE OFF EXCESS MATERIAL WITH A CLEAN WHITE DRY CLOTH. SCOTCHBRITE SHEET, :

: FINISHING TYPE A MAY ALSO BE USED. DO NOT USE WATER OR CLEANING FLUID AS THEY :

: WOULD REMOVE THE STATIC CONDITIONER ON CONTACT. :

: (F). DETERMINE IF SURFACE FILLING IS REQUIRED. IF NECESSARY APPLY THE FILLER, IN ACCORDANCE :

: WITH THE APPROPRIATE PART OF PARA. 8.L. (4) (B) WITHIN 24 HOURS. :

: (4) SURFACE FILLING :

: REFER TO TABLE 4. :

: SMALL IRREGULARITIES INDENTATIONS, ETC. OTHER THAN PINHOLES MUST BE FILLED WITH AN :

: APPROVED STOPPER AS LISTED, AND IN ACCORDANCE WITH THE FOLLOWING PROCEDURES. :

: NOTE: USE ONLY STATIC CONDITIONER FILLER 28 - C - 1 FOR PINHOLE FILLING. ( REFER TO STEP (3) ). :

: (A). POLYESTER KNIFING STOPPER :

: REFER TO TABLE 4. MIX STOPPER COMPONENTS IN THE RATIOS SPECIFIED, AND LABEL THE :

: CONTAINER IMMEDIATELY AFTER MIXING WITH THE DATE AND TIME OF MIXING AND THE POT LIFE :

: EXPIRY TIME. :

: NOTE: MATERIAL WHICH HAS EXCEEDED ITS POT LIFE MUST BE DISCARDED. :

: ABRADE BY FILLING THE SURFACE IRREGULARITIES WITH THE MIXED FILLER AND SMOOTH WITH A :

: SPATULA, USING FIRM HAND PRESSURE. :

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: REFER TO TABLE 4. ALLOW TO CURE. :

: ABRADE TO ORIGINAL PROFILE, ( STEP (2) (B)) TAKING CARE TO OBSERVE THE TIME BEFORE :

: ABRADING. REFER TO TABLE 4. :

: REMOVE SANDING RESIDUE BY WIPING WITH CLEAN TAK RAGS. :

: (B). LAMINAR X 500 OFF-WHITE SURFACER :

: WHEN LAMINAR X 500 IS SPECIFIED BY THE ENGINEERING DRAWING IT MAY APPLIED BY BRUSHING OR SPRAYING. :

: THE PROCEDURES ARE AS FOLLOWS:- :

: 1 MIX THE SURFACER COMPO NENETS IN THE RATIOS SPECIFIED AND ADD REDUCER AS REQUIRED :

: TO GIVE BRUSH OR SPRAY VISCOSITY. :

: 2 APPLY A SINGLE BRUSH COAT, OR APPLY A SINGLE CROSS COAT USING A PAINT SPAY GUN. :

: NOTE : IF FURTHER COATS ARE NECESSARY, ALLOW TO DRY FOR 10 MINUTES AT :

: 18 TO 25EC BETWEEN EACH COAT. :

: 3 ALLOW TO CURE. REFER TO TABLE 4. :

: 4 LIGHTLY ABRADE, IF REQUIRED, TO ORIGINAL PROFILE ( STEP (2) (B) ) TAKING CARE TO OBSERVE :

: THE TIME BEFORE ABRADING. REFER TO TABLE 4. :

: 5 REMOVE SANDING RESIDUE BY WIPING WITH CLEAN TAK RAGS. :

: (5) QUALITY REQUIREMENTS. :

: THE QUALITY DEPARTMENT SHALL BE SATISFIED THAT THE REQUIREMENT OF THIS SECTION HAVE BEEN :

: COMPLIED WITH, AND THAT PRIOR TO PRIMING, THE SURFACES OF THE COMPONENTS AND ASSEMBLIES :

: ARE SMOOTH AND FREE FROM DEFECT, SUCH AS DENTS, CRACKS, AND OTHER SURFACE IRREGULARITIES. :

: 9. APPLICATION OF PRIMERS AND POLYURETHANE FINISH COATING :

: THE FOLLOWING PRIMING AND PAINTING PROCEDURES ARE TO BE APPLIED IN A CONTINUOUS SEQUENCE. :

: NO SINGLE OPERATION SHOULD BE OMITTED. :

: A. PREPARATION :

: (1) THE PRIMER SHOULD BE PREPARED 30 MINUTES BEFORE USE. IT MUST BE DISCARDED 8 HOURS AFTER :

: MIXING. :

: (2) THE POLYTHENE PAINT MUST BE USED WITHIN THE POTLIFE STATED. REFER TO TABLE 1. :

: (3) BEFORE OPENING THE CONTAINERS:- :

: (A) CHECK IDENTITIES OF CONTENTS. :

: (B) SHAKE, UP-END ETC. FOR SEVERAL MINUTES TO MIX CONTENTS :

: (C) WIPE DUST ETC. FROM CONTAINERS :

: (D) OPEN CONTAINERS AND STIR CONTENTS, USING A HAND HELD STIRRER UNTIL EACH COMPONENT :

: APPEARS HOMOGENEOUS. USE A SEPARATE STIRRER FOR EACH COMPONENT. :

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: B. MIXING :

: (1) MIXING OF PAINT AND PRIMER IS TO BE CARRIED OUT IN ADEQUATELY VENTILATED AREAS. :

: (2) MIX PAINT AND PRIMER COMPONENT IN THE RATIOS SPECIFIED:- :

: (A) POLYURETHANE FINISHES. REFER TO TABLE 1. :

: (B) APPROVED ETCH PRIMERS. REFER TO TABLE 2. :

: (C) APPROVED EPOXY PRIMERS. REFER TO TABLE 3. :

: (3) MIX THROUGHLY FOR 1 TO 3 MINUTES USING A MECHANICAL STIRRER, OR FOR 4 TO 6 MINUTES :

: IF MIXING BY HAND. :

: (4) DETERMINE THE VISCOSITY AS SPECIFIES:- :

: (A) POLYURETHANE FINISHES. REFER TO TABLE 1. :

: (B) APPROVED ETCH PRIMERS. REFER TO TABLE 2. :

: (C) APPROVED EPOXY PRIMERS. REFER TO TABLE 3. :

: (5) IF NECESSARY ADJUST MIXTURE WITH THE APPROPRIATE THINNER TO OBTAIN THE REQUIRED VISCOSITY. :

: (6) AFTER MIXING HAS BEEN COMPLETED THE PRIMER BE PASSED THROUGH A 100 MESH SCREEN :

: FILTER INTO A CLEAN CONTAINER. :

: (7) ALLOW MIXED PRIMER TO STAND FOR 30 MINUTES IN THE PAINT SHOP ENVIRONMENT PRIOR TO USE. :

: C. APPLICATION OF ETCH PRIMER. :

: (1) USE PAINT SPRAYING EQUIPMENT ( PARA. 4.B) ENSURING THAT CORRECT WORK PRESSURES ARE :

: EMPLOYED. :

: NOTE: FOR SUCTION TYPE EQUIPMENT 40 PSI IS REQUIRED AT THE GUN. :

: (2) APPLY ONE LIGHT COAT OF ETCH PRIMER, WHICH ,WHEN DRY, SHALL BE WITHIN THE THICKNESS :

: STATED. REFER TO TABLE 2. :

: (3) RECORD THE DATE AND TIME OF APPLICATION. :

: (4) ALLOW TO AIR DRY FOR NOT LESS THAN 2 HOURS AND NOR MORE THAN 8 HOURS BEFORE :

: APPLICATION OF EPOXY PRIMER. :

: (5) EXAMINE FOR APPEARANCE AND CHECK FOR ADHESION. ( PARA. 11 ). :

: D. APPLICATION OF EPOXY PRIMER. :

: (1) USE PAINT SPRAYING EQUIPMENT ( PARA. 4.B) ENSURING THAT CORRECT WORK PRESSURES ARE :

: NOTE: FOR SUCTION TYPE EQUIPMENT 40 PSI IS REQUIRED AT THE GUN. :

: (2) APPLY ONE DOUBLE TRACK COAT OF EPOXY PRIMER, WHICH ,WHEN DRY, SHALL BE WITHIN THE :

: LIMITS STATED. REFER TO TABLE 2. :

: (3) RECORD THE DATE AND TIME OF APPLICATION. :

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: (4) AIR DRY FOR NOT LESS THAN 4 HOURS AND NOT MORE THAN 24 HOURS PRIOR TO APPLICATION OF :

: FINISH COAT. :

: (5) EXAMINE FOR APPEARANCE AND CHECK FOR ADHESION. ( PARA. 11 ). :

: NOTE: THE FINIAL COAT OF EPOXY PRIMER MUST NOT BE WET ABRADED PRIOR TO THE :

: APPLICATION OF POLYURETHANE FINISH. :

: E. APPLICATION OF POLYURETHANE FINISH :

: ALLOW AT LEAST 24 HOURS FOR THE AIRCRAFT STRUCTURE TEMPERATURE TO REACH THAT OF THE :

: SURROUNDINGS IN THE PAINT SHOP BEFORE PAINTING. DURING THIS PERIOD THE AIRCRAFT SURFACE :

: CAN BE PREPARED FOR PRIMING. :

: NOTE: THE ENVIRONMENTAL CONDITIONS QUOTED IN PARA. 3 AND 5. MUST BE OBSERVED. :

: TO REMOVE DUST ETC. PERIODICALLY WIPE THE SURFACE BEING PAINTED WITH A TAK RAG. :

: USE ONLY NEW TAK RAGS IMMEDIATELY PRIOR TO FINISH COATING. :

: (1) USE PAINT SPRAYING EQUIPMENT ( PARA. 4.B) ENSURING THAT CORRECT WORK PRESSURES ARE :

: EMPLOYED. :

: NOTE: FOR SUCTION TYPE EQUIPMENT 40 PSI IS REQUIRED AT THE GUN. :

: (2) FOR ALL FINISHES, EXCEPT FE 115, APPLY ONE LIGHT COAT, ALLOW TO DRY FOR 30 TO 60 MINUTES, :

: AND THEN APPLY A WET DOUBLE TRACK COAT WHICH, WHEN DRY, SHALL BE WITHIN THE LIMITS :

: STATED. REFER TO TABLE 1. :

: (3) TO OBTAIN THE REQUIRED DRY FILM THICKNESS FOR FE115 EROSION RESISTANT PAINT, PROCEED :

: AS FOLLOWS:- :

: (A) APPLY TWO WET DOUBLE TRACK COATS, AND ALLOW TO DRY FOR 1 TO 3 HOURS. REPEAT :

: THIS PROCEDURE 3 OR 4 TIMES TO GIVE DRY FILM THICKNESS AS SPECIFIED. REFER TO TABLE 1. :

: (B) RECORD THE DATE AND TIME OF APPLICATION OF EACH COLOUR. :

: (C) ALLOW TO AIR DRY FOR 16 HOURS MINIMUM PRIOR TO TAPING, MASKING AND APPLICATION OF :

: OVERCOAT OR MARKINGS IF REQUIRED. :

: (D) FOLLOWING FINAL PAINTING OF AIRCRAFT ALLOW 3 DAYS MINIMUM BEFORE OUTSIDE EXPOSURE :

: AND 7 DAYS MINIMUM BEFORE FLIGHT. :

: NOTE: IF AN AIRCRAFT IS SUBJECTED TO RAIN WITHIN 7 DAYS OF PAINTING IT MUST BE DRIED OFF AS :

: SOON AS POSSIBLE. :

: (E) EXAMINE FOR APPEARANCE AND CHECK FOR ADHESION. ( PARA 11.) :

: (4) DURING FINAL PAINTING OF AIRCRAFT, MATT DOWN COMPOSITE COMPONENTS, ( PREVIOUSLY :

: PREPARED IN ACCORDANCE WITH PARA. 8.L. AND APPLY A LIGHT COAT OF EPOXY PRIMER. :

: DRY AS PER PARA 9. (5) (D) AND APPLY FINISH COATING. :

: 10. REPAIRS TO DAMAGED FINISH COATINGS :

: A. DAMAGE SLIGHT - FINISH COAT ONLY AFFECTED :

: (1) LIGHTLY ABRADE. (PARA. 8.E. ) :

: (2) SOLVENT CLEAN ( PARA. 8.D. ) :

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: (3) APPLY FINISH COATING, ( PARA 9.F. ) :

: B. DAMAGE MODERATE - FINISH AND PRIMER COAT AFFECTED :

: (1) LIGHTLY ABRADE. (PARA. 8.E. ) TO EXPOSE PRIMER LAYER :

: (2) SOLVENT CLEAN ( PARA. 8.D. ) :

: (3) APPLY REFRESHER COAT OF PRIMER ( PARA. 8.F. ) :

: (4) APPLY FINISH COATING. ( SECTION 9. F. ) :

: C. DAMAGE SEVERE - PENETRATION TO SUBSTRATE SURFACE :

: (1) STRIP PAINT :

: (2) BRUSH ALODINE/ALOCROM 1200 ON ALUMINUM ALLOY COMPONENTS. REFER TO 51-24-00. PB 1. :

: (3) EPOXY PRIME. ( PARA. 9. E. ) :

: (4) APPLY FINISH COATING. ( SECTION 9. F. ) :

: 11. INSPECTION FOR APPEARANCE, ADHESION, AND THICKNESS :

: A. APPEARANCE :

: PRIMED AND/OR PAINTED AREAS AEW TO BE UNIFORM IN COLOUR AND TEXTURE. SWELLING, WRINKLING, :

: ORANGE PEEL' EFFECT, SPRAY DUST, ROUGHNESS, SAGS OR RUNS ARE ABSENT. THE PRIMER AND/OR :

: PAINT ARE TO BE FREE FROM ENTRAPPED PARTICLES AND SHOW NO EVIDENCE OF 'BLUSHING'. :

: B. ADHESION TEST :

: NO ADHESION FAILURE IS TO TAKE PLACE WHEN TESTED AS FOLLOWS:- :

: (1) PRIMER :

: FIRMLY PRESS 6 INCHES OF 1.0 INCH WIDE PRESSURE SENSITIVE TAPE, CODE 250, ON TO A :

: SELECTED AREA. AGE OF TAPE NOT TO EXCEED SIX MONTHS. REMOVE THE TAPE WITH A SINGLE, FIRM :

: ABRUPT PERPENDICULAR MOTION. EXAMINE THE TAPE AND THE BARED AREA FOR EVIDENCE OF :

: PRIMER FAILURE. :

: (2) FINISH PAINT :

: ADHESION TEST SHALL BE MADE ON THE COMPLETED EXTERIOR FINISH OF THE PAINTED AREA AFTER :

: DRYING FOR A PERID PREFERABLY AT LEAST 48 HOURS ON A SUFFICIENT NUMBER OF SELECTED AREA :

: TO ASSURE THAT A SATISFACTORY LEVEL OF ADHESION HAS BEEN MAINTAINED OVERALL. :

: TAPE A PIECE OF CLOTH TO THE AREA UNDER INSPECTION. THE TEST AREA SHALL BE KEPT SOAKED FOR :

: 24 HOURS MINIMUM WITH TAPE OR DISTILLED WATER. THE TEST AREA SHALL HAVE A MINIMUM AREA OF :

: THREE INCHES. :

: REMOVE THE WET CLOTH AND BLOT UP THE SURFACE WATER. IMMEDIATELY APPLY A ONE INCH STRIP OF :

: PRESURE SENSITIVE TAPE, CODE 250, ADHESIVE SIDE DOWN. AGE OF TAPE NOT TO EXCEED SIX :

: MONTHS. PRESS THE TAPE DOWN, USING TWO PASSES OF A 4 -1/2 POUND RUBBER COVERED ROLLER :

: OR EMPLOY FIRM PRESSURE WITH THE HAND. :

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: REMOVE THE TAPE IN ONE ABRUPT MOTION AND EXAMINE THE TESTED AREA FOR ANY PAINT DAMAGE :

: SUCH AS REMOVAL OF PAINT AT ONE OF THE LAYERS OF THE FINISH SYSTEM, OR REMOVAL OF THE :

: ENTIRE SYSTEM FROM THE PAINTED SURFACE. :

: C. THICKNESS :

: WHEN MEASURED WITH A SUITABLE INSTRUMENT, EG A PERMASCOPE, THE POLYUETHANE FINISH :

: THICKNESS SHALL BE WINTHIN THE LIMITS STATED. :

: (A) POLYUETHANE FINISHES. REFER TO TABLE 1. :

: (B) APPROVED ETCH PRIMERS. REFER TO TABLE 2. :

: (C) APPROVED EPOXY PRIMERS. REFER TO TABLE 3. :

: NOTE: THE ACCURACY OF THE PERMASCOPE MUST BE CHECK AT SIX MONTH INTERVALS. :

: WHEN CALCULATING THE FINISH COATING THICKNESS, ALLOWANCE SHOULD BE MADE FOR THE ETCH :

: PRIMER ( IF APPLICABLE ) AND THE SPOXY PRIMER THICKNESS. :

: 12. APPLICATION FOR EROSION RESISTANT COATINGS :

: A. GENERAL :

: REFER TO FIGURE 1 AND FIGURE 2. :

: EROSION RESISTANT PAINT IS APPLIED TOGETHER WITH, OR OVER, THE DECORATIVE PAINT SCHEME, TO :

: REDUCE EROSION DAMAGE IN THE IMPINEMENT AREAS OF THE AIRCRAFT. REFER TO FIGURE 1 AND FIGURE :

: 2, FOR SPECIFIC AREAS OF EROSION COATING. :

: B. PREPARATION :

: (1) FOR AREAS PRIMED REDAY FOR PAINTING, IN ACCORDANCE WITH PARA. 9.A. TO 9.E., THE EROSION :

: RESISTANT PAINT IS TO BE APPLIED AS SOON AS POSSIBLE AFTER THE MINIMUM DRTING TIME :

: SPECIFIED IN TABLE 3. :

: (2) FOR AIRCRAFT ALREADY PAINTED WITH POLYURETHANE FINISH COAT, THE AREA TO BE COVERED MUST :

: FIRST BE SOLVENT WIPED IN ACCORDANCE WITH PARA. 8.D. DRY ABRADE THE SURFACE USING 320 OR :

: 400 GRADE ABRASIVE PAPER. REMOVE SANDING RESIDUE BY WIPING WITH CLEAN TAK RAGS. :

: APPLY REFRESHER COAT OF PRIMER IN ACCORDANCE WITH PARA. 8.F. :

: C. APPLICATION :

: REFER TO FIGURE 1 AND FIGURE 2. :

: EROSION PAINT ( FE 115 ) TO BE APPLIED AS 3 OVERLAPPING COATS TO DIMENSIONS SHOWN ( SECTIONS :

: A-A, B-B, OR D-D ) IN ACCORDANCE WITH PARA. 9. REFER TO TABLE 1. :

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: ALODINE / ALOCROM 1200 - BRUSH APPLICATION :

: 1. GENERAL :

: THE BRUSH ALODINE ALOCROM PROCESS IS DESIGNED FOR TREATING ALUMINUM ALLOY :

: SURFACES WHICH ARE TOO LARGE FOR NORMAL DIP OR SPRAY ALODIZING AND FOR TOUCHING :

: UP ABRADED OR DAMAGED AREAS ON PREVIOUSLY ANODIZED OR ALODIZED SURFACES. :

: ALODINE/ALOCROM 1200 PRODUCES A PROTECTIVE COATING ON ALUMINUM AND RANGES IN COLOR :

: FROM LIGHT GOLDEN IRIDESCENT, THROUGH TAN TO LIGHT BROWN. THE PROCESS IS OPERATED AT :

: ROOM TEMPERATURE AND REQUIRES ONLY ONE CHEMICAL FOR MAKE-UP AND REPLENISHMENT. THE :

: COATING PRODUCED PROVIDES EXCELLENT SURFACE PROTECTION FOR UNPAINTED ALUMINUM AND :

: ACTS AS A GOOD PAINT BOND. ALODINE/ALOCROM 1200 MEETS ALL THE REQUIREMENTS OF MIL -C -5541. :

: 2. EQUIPMENT AND MATERIALS :

: ACID RESISTANT CONTAINER :

: NOTE: THE CONTAINER MUST BE CONSTRUCTED OF STAINLESS STEEL, PLASTIC, RUBBER, OR OTHER :

: ACID RESISTANT MATERIAL. DO NOT USE LEAD, GLASS, TIN OR GALVANIZED IRON CONTAINERS. :

: STORING AND SOLUTION IN MILD STEEL CONTAINERS WOULD RESULT IN A SLOW DECOMPOSITION :

: ALODINE/ALOCROM 1200 :

: DEOXIDINE NO. 624, SPECIFICATION DEOXIDINE MIL - M - 10578 OR METHYL ETHYL KETONE :

: ( MEK ) OR GENKLENE CLEANER ( ICI LTD ). :

: SCOTCHBRITE PADS, TYPE A :

: A. SAFETY PRECAUTIONS :

: REFER TO 51 - 23 - 00, PB1. ( PARA 5 ). :

: 3. PROCEDURE :

: A. PREPARE ALODINE/ALOCROM 1200 SOLUTION :

: (1) IN ACID RESISTANT CONTAINER, ADD THREE OUNCES OF POWDER FOR EACH GALLON OF WATER USED. :

: (2) STIR WELL UNTIL POWDER IS DISSOLVED. :

: NOTE: A SMALL AMOUNT OF MATERIAL THAT MAY SETTLE OUT OF SOLUTION MAY BE DISREGARDED. :

: (3) ALLOW SOLUTION TO STAND FOR AT LEAST ONE HOUR BEFORE USE. :

: B. PREPARE SURFACE :

: (1) SEAL OR PLUG ALL HOLES TO PREVENT ENTRY OF SOLUTION INTO ASSEMBLIES CONTAINING :

: HONEYCOMB OR FORMED PLASTIC COMPONENTS. :

: (2) REMOVE GREASE, OIL AND CORROSION PRODUCTS USING WASH-OFF TYPE DEOXIDINE NO. 624, :

: SPECIAL DEOXIDINE MIL - M - 10578, OR GENKLENE CLEANER. WHEN NO CORROSION IS PRESENT, :

: CLEAN THE SURFACES USING MEK. :

: (3) WHERE DEOXIDINE CLEANING HAS BEEN CARRIED OUT, FLUSH AFFECTED AREA USING CLEAN WATER :

: TO REMOVE EXCESS SOLUTION AND SOIL. ALLOW TO DRY. :

: (4) SMOOTH AFFECTED AREA USING SCOTCHBRITE PAD TYPE A OR A FINE ABRASIVE CLOTH. WIPE :

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: OFF DUST PARTICLES WITH A CLEAN LINT-FREE CLOTH. WIPE THE AREA WITH A CLEAN LINT-FREE :

: CLOTH DAMPENED WITH MEK: REPEAT UNTIL AREA SURFACE IS COMPLETELY CLEAN. :

: C. APPLY ALODINE/ALOCROM 1200 SOLUTION :

: WARNING: DO NOT ALLOW RAGS, SPONGES, SWABS, OR BRUSHES USED FOR APPLYING :

: OR REMOVING SOLUTION TO DRY OUT. IF ALLOWED TO DRY, THEY CONSTITUTE :

: A FIRE HAZARD. IMMEDIATELY AFTER USE, WASH THROUGHLY BEFORE DISCARDING. :

: (1) APPLY ALODINE/ALOCROM 1200 EVENLY AND LIBERALLY USING SCOTCHBRITE PADS :

: OR A NYLON BRISTLE BRUSH. :

: (2) ALLOW SOLUTION TO REMAIN ON SURFACE FOR SIX TO EIGHT MINUTES. PREVENT AREA :

: FROM DRYING DURING THIS PERIOD BY GENTLY BLOTTING WITH A SPONGE OR CLEAN, :

: LINT-FREE RAG MOISTENED WITH THE SOLUTION. :

: (3) RINSE TREATED AREA WITH CLEAN WATER. :

: (4) DRY THE TREATED AREA BY ONE OF THE FOLLOWING METHODS: :

: - WARM OR HOT AIR DRYING :

: - BLOWING DRY CLEAN FILTERED COMPRESSED AIR. :

: - WIPING DRY WITH CLEAN, LINT-FREE CLOTHS. :

: - AIR DRYING. :

: 4. QUALITY REQUIREMENTS :

: CHECK THAT TREATED AREA IS FREE FROM IMPERFECTIONS AND BLOTCHES. THE ALODINE/ALOCROM :

: COATING MUST HAVE GOOD ADHERENCE TO THE METAL SURFACE. POWDERING DEPOSITS ARE NOT :

: ACCEPTABLE. :

: 5. FINISH AND HANDLING :

: ON COMPLETION OF PROCESS, APPLY FINAL FINISH OR COMMENCE ADHESIVE BONDING AS SOON AS :

: POSSIBLE AFTER DRYING. HANDLE PARTS WITH CLEAN GLOVES AND KEEP PARTS CLEAN AND DRY TO :

: AVOID SURFACE CONTAMINATION. :

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