Attch 5 - 42F-1-2.pdf

REPAIR AND FABRICATION OF PAD ASSEMBLY

3.1. General.

A. This section contains the following procedures for repair and fabrication of mattress-crew-bunk pad assembly, also known as ″pad assembly″, and details for part number 17P1B2144-1 (ref. Figure 3-1).

B. Identify new pad assembly detail parts with the same part number and appropriate material specifica-tion.

C. Maintenance personnel should familiarize themselves with referenced drawings and drawing specifica-tions reference before starting this fabrication process.

D. Review applicable drawings to identify which Standard Method drawings defined (DPS, DPMS, etc.)

are applicable for fabrication. Standard Method drawings define the materials and process specifica-tions necessary to fabricate the desired pad assembly.

E. Figure 3-3 contains the illustration of the mattress-crew bunk pad assembly configuration, providing the parts material description and illustration reference.

(1) Number on the index column assigned to the part in order to determine an exact location and allow cross referencing between illustration and text.

(2) Drawing/part number listed under this column is either pad assembly configuration or part detail of the pad assembly configuration.

(3) Description, Gauge and Size column describe pad assembly or item. It also contains the assigned nomenclature that appears in the title block of the engineering drawing, along with the modifiers and descriptive information to completely identify the item.

(4) Material or Make From column contains the description of the material, specification, and information used to fabricate the part.

(5) Reference column contains boxed letter assigned to pad assembly configuration on text, to cross reference to illustration.

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Figure 3-1. Mattress-Crew Bunk Pad Assembly

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3.2. Check.

A. Inspect pad assembly:

(1) Repair pad assembly if thread stripping or cross-threading is observed.

(2) Examine assembly parts for wear, tear, obvious defects that could impair efficient pad assembly operation; repair or fabricate and replace pad assembly. .

3.3. Cleaning

A. Clean pad assembly cover, if needed using hand wipe cleaner.

3.4. Repair

A. General:

(1) Replace damaged strap.

(2) Replace damaged hook or loop tapes.

(3) Repair damaged stitching.

B. Repair:

(1) Repair pad assembly by replacing strap as follows:

a. Using suitable cutter, carefully remove stitching from sewn joint.

b. Remove strap (1, Figure 3-3) from cover (3).

c. Fabricate strap (1) in accordance with paragraph 3.5.B.(5).

d. Machine stitch strap (1) to cover (3) using nylon thread (6).

NOTE:

Stitch used is 5 to 7 stitches per inch per FED-STD-751, stitch type 301, seam type SSa-1.

(2) Repair pad assembly by replacing tape (8 or 9, Figure 3-3) as follows:

a. Using suitable cutter, carefully remove stitching from sewn joint.

b. Remove tape (8 or 9).

c. Clean faying surfaces with hand wipes.

d. Install loop tape (9) or hook tape (8) on cover (3) in accordance with paragraph 3.5.B.(5).

(3) Repair damaged stitching.

a. Using suitable cutter, remove old thread and using nylon thread (6), re-stitch.

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b. Determine type of stitching and seam used on location of repair (ref. Figure 3-2).

NOTE:

Stitching is 5 to 7 stitches per inch per FED-STD-751.

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Figure 3-2. Standard Stitching and Seam Method

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3.5. Fabrication

A. General:

(1) Inspect parts to be used to fabricate pad assembly for conformance to specification, requirements regarding dimensions, color, flaw resistance, and/or other special requirements.

(2) Inspect each roll of felt, cover, and foam for cuts, frayed edges, and defective or deteriorated fabric;

reject parts that fail to meet requirements.

B. Fabrication:

(1) Fabricate strap (1, Figure 3-3) as follows:

a. Cut webbing material into the shape required per engineering drawing.

b. Sear cut (heated sealed) ends of webbing with electrically heated knife (1, Table A-2).

c. Install closure hook tape (8, Figure 3-3) on prepared webbing material.

1. Cut closure hook tape material into the shape required per drawing.

2. Machine stitch closure hook tape to the webbing.

NOTE:

Stitching is 5 to 7 stitches per inch per FED-STD-751, Type 301, and seam type

SS A-1.

(2) Cement polyurethane foam (4, Figure 3-3) onto polyvinyl chloride (PVC) foam (5).

a. Cut foams (4, 5) into the shapes required per engineering drawing.

b. Clean foam surfaces by blowing with clean, dry compressed air (30 psi).

c. Using a brush, apply adhesive (No. 3, Table A-1) to foams faying surfaces.

d. Allow adhesive to dry until tacky.

NOTE:

Time allowance is 5 to 10 minutes minimum to dry before joining.

e. Join foams (4, 5) with firm hand or roller pressure.

f. Dry for two hours at room temperature before handling.

(3) Fabricate felt or liner (2, Figure 3-3).

a. Cut muslin cloth material into the shapes required per engineering drawing.

NOTE:

Felt or liner will completely encase bonded foams.

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b. Machine stitch felt or liner (2) using spun para-aramid thread (7) using stitching type EFb-1 (ref. Figure 3-2) to cover bonded foams (4, 5).

(4) Fabricate cover (3, Figure 3-3).

a. Cut cloth into the shapes required per engineering drawing.

b. Machine stitch cloth using nylon thread (6) as indicated per drawing.

NOTE:

● Cover should be sewn to fit snugly over felt or liner cover foams. Seam locations are optional.

● Stitch type 301, Seam type SSv-1, with 5 to 7 stitches per inch is used.

(5) Install loop tape (9, Figure 3-3) and hook tape (8) on cover (3).

a. Cut tape into the size required per engineering drawing.

NOTE:

Loop and hook tape lengths to be installed between foam cut-outs are full pad width.

b. Machine stitch loop tape (9) to cover (3) using nylon thread (6) as indicated per drawing.

NOTE:

Stitch used is 5 to 7 stitches per inch, FED-STD-751 type 301, seam type SSa-1.

c. Machine stitch hook tape (8) to cover (3) using nylon thread (6) as indicated per drawing.

NOTE:

Stitch used is 5 to 7 stitches per inch, per FED-STD-751 type 101, stitch type EFB-1.

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Figure 3-3. Mattress-Crew Bunk Pad Assembly Part Number 17P1B2144-1 (Sheet 1 of 2)

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Index Drawing/Part Number

Description, Gauge and Size Material or Make From

Reference

17P1B2144-1 Pad Assy, Mattress - Crew Bunk [A] 1 17P1B2144-9 Strap [1] [2] 2 17P1B2144-5 Felt 30.00 in. wide x 60.00 in. long [3] 3 17P1B2144-7 Cover 32.00 in. wide x 185.00 in. long [4] 4 17P1B2144-3 Foam 1.25 in. Thk x 26 in. wide x 26 in. long [5] 5 17P1B2144-9 Foam 0.25 in. Thk. x 26 in. wide x 26 in. long [6] 6 17P1B2144-15 Thread 50 Yd. [1] [7] 7 17P1B2144-17 Thread 50 Yd. [1] [8] 8 17P1B2144-11 Tape .625 in. wide x 56 in. long [1] [9] 9 17P1B2144-13 Tape .625 in. wide x 56 in. long [1] [10]

[1] Number of pieces and length to be determined on assembly.

[2] Webbing, Nylon, Uncoated. Material per MIL-W-4088, Type 15.

[3] Cloth, Muslin, Unbleached. Material per Commercial Plus Treatment to meet requirements of DMS 1511.

[4] Cloth, Interior. Color is to be dark gull gray per FED-STD-595, color no. 36231. Material per DMS 1959, Class 2.

[5] Sheet Foam, Polyurethane. Material per DMS 1929, Type 1, Class 1, Grade C.

[6] Sheet, Polyvinyl Chloride (PVC), Color opt. Material per MIL-P-15280, Form S, Material to meet Requirement of

DMS 1511.

[7] Thread, Nylon, Color to match assembly. Material per V-T-295, Type 2, Class A, Type E.

[8] Thread, Spun Para-Aramid, Intermediate Modulus, Material per MIL-T-44100, Size T-50, Color Optional.

[9] Tape, Closure Element, Hook. Material per DMS 1982, Type 1.

[10] Tape, Closure Element, Loop. Material per DMS 1982, Type 2.

Figure 3-3. Mattress-Crew Bunk Pad Assembly Part Number 17P1B2144-1 (Sheet 2)

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REPAIR AND FABRICATION OF CURTAIN ASSEMBLY

4.1. General.

A. This section contains the following procedures for repair or fabrication of curtain assembly for the fol-lowing Part Number(s):

Part Number CAGE Code Noun, Description

17B1E1013-517, -519, and -521 0ACH0 Curtain Assembly, Rear Access, Main Avionics Rack

17P1B1085-503, -505, and, -509 88277 Curtain Assembly, Flight Deck

17P1B2141-1 and -2 88277 Curtain Assembly, Crew Berth

17P1B2153-1 88277 Curtain, Window

B. Identify new curtain assembly detail parts with the same part number and appropriate material specifi-cation.

C. Maintenance personnel should familiarize themselves with referenced drawings and specifications be-fore starting the fabrication or repair process.

D. Review applicable drawings to identify which Standard Method drawings defined (DPS, DPMS, etc.)

are applicable. Standard Method drawings define the materials and process specification necessary to fabricate the desired part(s) or to repair material(s).

E. Figures 4-2 thru 4-4 contain the illustration of curtain assembly configurations, providing the parts ma-terial descriptions and illustration references where applicable.

(1) Number on the index column assigned to the part in order to determine an exact location and allow cross referencing between illustration and text.

(2) Drawing/part number listed under this column is either curtain assembly or part detail of the curtain assembly configuration.

(3) Description, Gauge and Size column describe each curtain assembly or item. It also contains the assigned nomenclature that appears in the title block of the engineering drawing, along with the modifiers and descriptive information to completely identify the item.

(4) Material or Make From column contains the description of the material, specification, and information used to fabricate the part.

(5) Reference column contains boxed letter assigned to curtain assembly configuration on text, to cross reference to illustration.

F. Figure 4-5 contains the illustration of main avionics rack curtain assembly, providing the references for repairs.

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4.2. Check.

A. Inspect curtain assembly.

(1) If curtain has been cut and solvents or flammable agents have been absorbed, fabricate and replace assembly In Accordance With (IAW) paragraphs 4.3 and 4.4.

(2) Examine assembly parts for wear, tear, obvious defects that could impair efficient curtain assembly operation; fabricate and replace curtain, or repair curtain assembly IAW paragraphs 4.3 and 4.4.

(3) Check all stitching for broken threads.

(4) Examine curtain for damage.

(5) Examine zipper for damage and proper operation where applicable.

4.3. Repair.

A. General

(1) Fabricate and replace curtain assembly, if damaged, IAW paragraph 4.4. Repair is not applicable to the following curtain assemblies:

Part Number CAGE Code

Noun, Description

17P1B1085-503, -505, and, -509 88277 Curtain Assembly, Flight Deck

17P1B2141-1 and -2 88277 Curtain Assembly, Crew Berth

17P1B2153-1 88277 Curtain, Window

(2) Repair is applicable to the following curtain assemblies:

Part Number CAGE Code

Noun, Description

1MA1115 (88277 SPEC CONT DWG

17B1E1013-517)

0ACH0 Curtain Assembly, Rear Ac-cess, Main Avionics Rack

1MA1116 (88277 SPEC CONT DWG

17B1E1013-519)

0ACH0 Curtain Assembly, Rear Ac-cess, Main Avionics Rack

1MA1117 (88277 SPEC CONT DWG

17B1E1013-521)

0ACH0 Curtain Assembly, Rear Ac-cess, Main Avionics Rack

B. Repair of Main Avionics Rack Curtain Assembly is limited to repairing the zipper (ref Figure 4-5). Dam-age such as cuts, wear, tears, and absorption of flammable agents cannot be repaired and the curtain assembly must be replaced.

(1) Repair zipper (1) that has become separated as follows:

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a. Using suitable cutter, make a small cut in back side of curtain fabric (2, Figure 4-5, continued) to expose the zipper stop (3).

b. Peel back curtain fabric (2) to gain access to zipper stop (3).

c. Pry up and straighten the zipper stop barbs (4) and remove the zipper stop (3).

d. Re-engage zipper (1) and ensure proper operation.

e. Inspect zipper stop (3) and zipper barbs (4) for serviceability. Discard unserviceable zipper stop (3) if barbs (4) are too weak, broken or cannot be reformed over zipper (3).

f. Install serviceable zipper stop (3) and reform barbs (4) on zipper stop (3) around zipper (1).

g. Using thread (No. 24, Table A-1) and needle (No. 3, Table A-2), wrap a minimum of 4 times around base of zipper (1, Figure 4-5).

1. If zipper stop (3) was determined unserviceable and discarded, measure approximately 1/4 inch from thread wrap installed in step step 4.3.B.1.g and repeat step 4.3.B.1.g, other-wise proceed to next step.

h. Clean curtain fabric (2) in the zipper (1) repair area using wiper (No. 16, Table A-1).

j. Apply adhesive (No. 25, Table A-1) to the area of curtain fabric (2, Figure 4-5) that was cut and peeled to gain access to zipper stop (3). Allow cement to cure a minimum of 2 hours.

4.4. Fabrication.

A. Fabricate curtain assembly as follows:

(1) Cut cloth in accordance with dimension specified in the drawing.

(2) Serge edges of cloth to prevent raveling.

(3) Determine type of seam to be used for fabrication of the curtain assembly. Refer to engineering drawing.

(4) Machine stitch using 6 to 8 stitches per inch, stitching type 301.

NOTE:

The stitch type 301 is formed with two threads: one needle thread, (A) and one bobbin thread (B).

a. Use one needle thread and one bobbin thread.

b. A loop of needle thread shall be passed through cloth and interlacing with bobbin thread.

c. Pull needle thread back between surfaces of cloth being sewn.

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NOTE:

● Interlace is midway between faying surfaces of cloth.

● 8 stitches per inch and an edge margin of 0.12 inch is used.

(5) If grommet is to be installed, install per NASM16491; superseding MIL-G-16491.

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Figure 4-1. Standard Stitching and Seam Method

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Figure 4-2. Crew Berth Curtain Assembly Part Number 17P1B2141 (Sheet 1 of 2)

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Description, Gauge and Size Material or Make From

Reference

17P1B2141-1 Curtain Assembly, Crew Berth (Left Side) 17P1B2141-2 Curtain Assembly, Crew Berth (Right Side)

1 17P1B2141-3 Drape, 48 in. wide by 51 in. long [1] [2] 1 17P1B2141-4 Drape, 48 in. wide by 51 in. long [1] [2] 2 17P1B2141-7 Strip 0.750 in. wide by 43 in. long [1] [3] 3 17P1B2141-9 Strip 1.00 in. wide by 50.00 in. long [1] [4] 4 17P1B2141-5 Thread 20 Yd. [1] [5] 5 MS27981-4N Stud 6 MS27981-5N Eyelet 7 92121 Carrier, Snap, Tab [6] [7]

[1] Number of pieces and length to be determined on assembly.

[2] Cloth, Polyester, Herring Bone Weave. Material per DMS 1959, Class 2, Color to be Gray 36231 per FED-STD-595.

[3] Tape, Closure Element, Loop, Material per DMS 1982, Type 2.

[4] Material per A-A-55126B, Type I, Class I, Black, Flame Retardant; Superseding MIL-F-21840.

[5] Thread, Nylon (8.5 lb.). Material per V-T-295, Type I, Class A, Size E with color to match assembly.

[6] Install as required on curtain assembly. Reference drawing 17P1B2148.

[7] Material per Acetal, ASTM D4181.

Figure 4-2. Crew Berth Curtain Assembly Part Number 17P1B2141 (Sheet 2)

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Figure 4-3. Window Curtain Part Number 17P1B2153 (Sheet 1 of 2)

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Description, Gauge and Size Material or Make From

Reference

17P1B2153-1 Curtain, Window 1 17P1B2153-3 Panel, 30.00 in. wide by 30.00 in. long [2] 2 17P1B2153-7 Stripe, 30 in. wide by 11 in. long [2] 3 17P1B2153-9 Tape 1.0 in. wide by 7.0 in. long [1] [3] 4 17P1B2153-11 Thread [1] [4] [5] 5 MS27977-1B Socket 6 MS27977-3B Plate 7 M16491/1-0170N Grommet, Metallic [6]

[1] Number of pieces and length to be determined on assembly.

[2] Cloth, Polyester, Herring Bone Weave. Material per DMS 1959, Class 2, Color to be Gray 36231 per FED-STD-595.

[3] Tape, Closure Element, Hook, Material per DMS 1982, Type 1.

[4] Thread, Nylon. Material per V-T-295, Type 2, Class A, Size E with color to match assembly.

[5] Color as required to match assembly.

[6] Material per Acetal, ASTM D4181.

Figure 4-3. Window Curtain Part Number 17P1B2153 (Sheet 2)

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Figure 4-4. Flight Deck Curtain Assembly Part Number 17P1B1085 (Sheet 1 of 3)

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Figure 4-4. Flight Deck Curtain Assembly Part Number 17P1B1085 (Sheet 2)

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Index Drawing/Part Number Description, Gauge and Size Material or Make From

Reference

17P1B1085-503 Curtain Assembly, Flight Deck [A] 17P1B1085-505 Curtain Assembly, Flight Deck [B] 17P1B1085-509 Curtain Assembly, Flight Deck [C]

1 17P1B1085-3 Fabric [1] [2] 2 17P1B1085-5 Liner [1] [3] 3 17P1B1085-7 Thread [1] [4] 4 17P1B1085-9 and -11 Tape 0.625 in. long by [1] [5] 5 17P1B1085-13 and -15 Tape 0.625 in. long by [1] [6] 6 17P1B1085-17 Strap 1.25 in. wide by 12.00 in long [7] 7 MS27980-1C Button 8 MS27980-6C Socket 9 M16491/1-0170N Grommet, Metallic [8]

10 9D0183-1 Carrier

[1] Number of pieces and length to be determined on assembly.

[2] Cloth, Polyester, Herring Bone Weave. Material per DMS 1959, Class 2, Color to be Gray 36231 per FED-STD-595.

[3] Cloth, Glass Coated. Material per DMS 1992, Type 2.

[4] Thread, Nylon (8.5 lb.). Material per V-T-295, Type I, Class A, Size E with color to match assembly.

[5] Made from Tape Closure Element, Loop. Material per DMS 1982, Type 2.

[6] Made from Tape Closure Element, Hook. Material per DMS 1982, Type 1.

[7] Made from Webbing Nylon Uncoated. Material per MIL-W-4088, Type 3.

[8] Procure part per NASM16491, Superseding MIL-G-16491.

Figure 4-4. Flight Deck Curtain Assembly Part Number 17P1B1085 (Sheet 3)

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Figure 4-5. Main Avionics Rack Curtain Assembly (Sheet 1 of 2)

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Index Drawing/Part Number Description, Gauge and Size Material or Make From

Reference

4MA1445-1 Curtain Assembly, Main Avionics Rack 1 430X Zipper [1] 2 4MA1445-5 Fabric [1] [2] 3 - Zipper Stop (Part of 430X Zipper) 4 - Barb (Feature on Zipper Stop)

[1] Number of pieces and length to be determined on assembly.

[2] Single Ply Neoprene Coated Fiberglass

Figure 4-5. Main Avionics Rack Curtain Assembly (Sheet 2)

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REPAIR AND FABRICATION OF SEAT PART MATERIALS

5.1. General.

A. This section contains the following procedures for repair and fabrication of seat materials for the fol-lowing Part Numbers:

Part Number Cage Code Noun, Description

0A326-0201 K9075 Headrest Assembly

0A326-0203 K9075 Cushion Assembly, Back

0A326-0207 K9075 Cushion Assembly, Pan

0A326-0209F K9075 Cover Assembly, Pan

1A326-0205F K9075 Cover Assembly, Back Cushion

1A326-0213F K9075 Upholstery Assembly, Armrest

1A326-0321F K9075 Upholstery Assembly, Rotational Pad

1A326-0459F K9075 Upholstery Assembly, Headrest

104044-1 54786 Seat Pan Assembly

103231-2 00679 Cushion Assembly, Seat Back

103234-2 00679 Cushion Assembly, Seat Pan

104052-1, -2 54786 Cushion Foam, Back and Head Rest

B. Identify new seat materials with the same part number and appropriate material specification.

C. Maintenance personnel should familiarize themselves with referenced drawings and specifications be-fore starting the fabrication process.

D. Review applicable drawings to identify which Standard Method drawings defined (ASTM, FED-STD, etc.) are applicable. Standard Method drawings define the materials and process specification neces-sary to fabricate the desired seat parts or materials.

E. Figures 5-1 thru 5-8 contain the illustration of seat parts configurations, providing the parts material descriptions and illustration references.

(1) Number on the index column assigned to the part in order to determine an exact location and allow cross referencing between illustration and text.

(2) Drawing/part number listed under this column is either seat part assembly or part detail of the seat part assembly configuration.

(3) Description, Gauge and Size column describe each seat part material or item. It also contains the assigned nomenclature that appears in the title block of the engineering drawing, along with the modifiers and descriptive information to completely identify the item.

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(4) Material or Make From column contains the description of the material, specification, and information used to fabricate the part.

(5) Reference column contains boxed letter assigned to seat part assembly configuration on text, to cross reference to illustration.

5.2. Check.

A. Inspect fabric for damage, wear and tear.

5.3. Repair.

A. General

(1) Repair is not applicable. Fabricate and replace assembly when damaged.

5.4. Fabrication.

A. General.

(1) Use drawing as reference when creating template for the part.

NOTE:

Existing fabric may be used as a pattern when cutting and marking location of the fold lines.

(2) Cut cloth and fastener tapes In Accordance With (IAW) dimension specified in the drawing.

(3) Determine type of seam to be used on location specified on the drawing; melt-seal web ends.

NOTE:

● Stitches, seams and stitching are per FED-STD-751.

● Type 301, 7 to 11 stitches per inch using thread is used.

● Stitch lines must be visible as two separate lines on double row stitches.

(4) Install fastener tapes on location specified on fabrics per drawing; stitch tapes per A-A-55126B.

B. Fabricate back and head rest cushion foam Part Number 104052 (ref. Figure 5-4) follows:.

NOTE:

● The headrest rest cushion foams (PN 104052-2) consist of a simple cut out piece of AIR- FLEX foam.

● The backrest cushion foam consists of the AIRFLEX foam. Optional method of fabricating

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1077512256C Highlight the foam core is to cut the AIRFLEX foam into one piece per measurement indicated on the drawing in lieu of cutting one large and two small pieces.

(1) When fabricating headrest foam (3, Figure 5-4) and backrest foam (1), using the optional method, cut AIRFLEX foam (No. 9, Table A-1) in accordance with the dimension per drawing (ref. Figure 5-4).

(2) Fabricate backrest foam (1) as follows:

a. Cut one large piece and two small pieces of AIRFLEX foams (No. 9, Table A-1) in accordance with the dimension per drawing.

b. Using a spatula, apply thin layer of adhesive (No. 10, Table A-1) between the mating surfaces of the foams to be bonded.

c. Place, one at a time, small Airflex foams (No. 9, Table A-1) to bond on the location on large piece of Airflex foams. Allow adhesive on bonded foams to cure at room temperature.

C. IPECO Seat Covers and Cushion Foams.

(1) The following are IPECO Reference Documents for seat cover parts and foam fabrication:

Document Number CAGE Title

ES 056 K9075 Hook & Loop Colour Requirements (Engineering Specification)

1A001-1769 K9075 Upholstery Material Code

D. Fabricate upholstery assembly (seat cover) and/or foam as follows (see Figures 5-5 thru 5-8):

(1) Fabricate seat upholstery or cover assembly as follows:

a. Use drawing or existing upholstery assembly as reference when creating template for the part.

NOTE:

● Existing fabric may be used as a pattern when cutting and marking location of the fold lines when fabricating seat covers.

● Hook and loop fasteners requirements are IAW ES 056 (CAGE K9075).

● Cover assembly and foam templates can be made as per sample.

b. Cut fabric and loop and/or hook fastener tapes IAW dimension specified in the drawing or tem-plate.

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c. Determine type of seam to be used on location specified per existing fabric template; melt-seal web ends.

NOTE:

● Installation of loop and/or hook fastener tapes can be sewn or glued to the uphol-stery.

● When stitching method is to be used, seams and stitchings are per FED-STD-751.

● Type 301, 7 to 11 stitches per inch using thread is used.

● Stitch lines must be visible as two separate lines on double row stitches.

● All loop fasteners are to be sewn or glued on inside of cover assembly when in-stalling.

d. Install hook and loop fasteners on locations specified on fabrics per template. For hook and loop material with a pressure sensitive adhesive pre-applied, peel the liner and install. For hook and loop material with no pre-applied adhesive, cement per general instructions of TO 1C-17A-3-1 using Epibond 1544-1 A82/D (No. 28, Table A-1). If to be sewn, stitch fasteners per A-A-55126.

(2) Fabricate foam as follows:

NOTE:

Foam part number 3A520-XXXX series is an upholstery item. Complete specification of item is per Benson Lund Quality Dept. CAGE KC174.

a. Cut foams (4, Figure 5-5, 7, Figure 5-6, and 3, Figure 5-8), cushions (8, 9, Figure 5-7) or plastazote (4, Figure 5-8) IAW the dimensions per template.

b. Clean foam or cushion surfaces by blowing with clean, dry compressed air (30 psi).

c. Using a brush, apply adhesive (No. 14, Table A-1) to foam or cushion faying surfaces.

d. Allow adhesive to dry until tacky.

NOTE:

Time allowance is 5 to 10 minutes minimum to dry before joining.

e. Join foams or cushions with firm hand or roller pressure.

NOTE:

● No air should be trapped when joining two surfaces together.

● Clamping can be used while curing when bonding foams or cushions.

f. Allow 24 hours to cure.

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Figure 5-1. Seat Pan Assembly (Sheet 1 of 2)

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Description, Gauge and Size Material or Make From

Reference

104044-1 Seat Pan Assembly [8] [9] [1] 1 103633-1 Fabric [2] [3] 2 103282-1 Fabric, Aramid [2] [4] 3 V-T-295 Thread [2] [5] 4 Fastener, Tape, Hook, 2.0 in. wide [2] [6] 5 Fastener, Tape, Pile, 2.0 in. wide [2] [6] 6 Webbing, 1.0 in., 0.025-0.040 in. Thk. [2] [7]

[1] Parts Manufactured by BAE System Aero, CAGE 54786.

[2] As required; number of pieces and length to be determined on assembly.

[3] Aramid Fabric, Water/Stain Resistant, 9-11 oz/sq yard material; Vertical Burn Test per FAR 25.853(b), 1988 Rev compliant.

[4] Flame Resistant Fabric, Color Black material; Vertical Burn Test per FAR 25.853(b), 1988, Rev compliant.

[5] Black Nylon; Material per V-T-295, Type II, Class A, Size E.

[6] Material per A-A-55126B, Type II, Class I, Black; Superseding MIL-F-21840.

[7] Material per MIL-W-4088 or MIL-W-27265, Class R or Class L, Color Red.

[8] All stitches, seams and stitchings are per FED-STD-751; for double-row stitches, stitch lines must be visible as two separate lines.

[9] Melt seal web ends; no bare fabric edges to be visible on outside finish product.

Figure 5-1. Seat Pan Assembly (Sheet 2)

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1077512256C Highlight

Figure 5-2. Seat Back Cushion Assembly (Sheet 1 of 2)

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1077512256C Highlight

1077512256C Sticky Note Seat back

Description, Gauge and Size Material or Make From

Reference

103231-2 Seat Back Cushion Assembly [3] [7] [1] 1 103232-1 Core Assembly, Seat Back [3] 1 103817-1 Core Assembly, Seat Back [3] [10] 2 103287-1 Fabric, Upholstery [2] [3] [8] [11] 3 Tape, Pile Fastener, 3/4 in. wide [2] [3] [9] [4] 4 Thread [2] [3] [5] 5 103282-1 Fabric, Aramid [2] [3] [6]

[1] Parts Manufactured by Castle Industries of California, CAGE 00679.

[2] As required; number of pieces and length to be determined on assembly.

[3] Must meet Flammability Requirements per FAR 25.853(b) or (c) Rev 1988.

[4] Material per A-A-55126, Type II, Class I, Color Black; superseding MIL-F_21840.

[5] Manufactured from Polyester, Blue Color to match # 15180 per FED-STD-595. Material per MIL-DTL-32072, Type II, Class I, Size E; superseding V-T-285.

[6] Part is alternate to PN 103633-1, CAGE 00679.

[7] All seams to be type SSa-1 and stitching type 301 per FED-STD-751; 6 to 8 stitches per inch.

[8] All perimeter edges of fabric to be finished per FED-STD-751, Seam type EFd-1 and Stitching type 505.

[9] Edge distance for stitching fastener tape will be 1/16 to 1/8 inch.

[10] PN 103817-3, Back Cushion Assembly is an alternate part.

[11] Use approved material when fabricating part(s); Refer to drawing for approved material list.

Figure 5-2. Seat Back Cushion Assembly (Sheet 2)

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Figure 5-3. Seat Pan Cushion Assembly (Sheet 1 of 2)

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1077512256C Highlight

Description, Gauge and Size Material or Make From

Reference

103234-2 Seat Back Cushion Assembly [3] [7] [11] [1] 1 103816-1 Core Assembly, Seat Pan Cushion [4] 2 103287-1 Fabric, Upholstery [2] [3] [9] [10] 3 Tape, Pile Fastener, 0.75 in. wide [2] [3] [5] [8] 4 Thread, Blue Polyester [2] [6] 5 Tape, Pile Fastener, 1.5 in. wide [2] [3] [5]

[1] Parts Manufactured by Castle Industries of California, CAGE 00679.

[2] As Required; Number of pieces and length to be determined on assembly.

[3] Must Meet Flammability Requirements per FAR 25.853(b) or (c) Rev 1988.

[4] Use approved material when fabricating part(s); refer to drawing for approved material list.

[5] Material per A-A-55126, Type II, Class I, Color Black; Superseding MIL-F-21840.

[6] Color Blue to match #15180 per FED-STD-595; material per specification MIL-DTL-32072, Type II, Class I, Size E; Superseding V-T-285.

[7] All seams to be type SSa-1 and stitching type 301 per FED-STD-751; 6 to 8 stitches per inch.

[8] All perimeter edges of fabric to be finished per FED-STD-751, Seam type EFa-1 and Stitching type 505.

[9] Edge distance for stitching fastener tape will be 1/16 to 1/8 inch.

[10] Approved material to use is Discovery #21 blue dot, Anton Maix Fabric Inc., Ft Lauderdale, Fl.

[11] All finished cover should fit all parts of cushion when installed on the seat frame.

Figure 5-3. Seat Pan Cushion Assembly (Sheet 2)

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1077512256C Highlight

Figure 5-4. Back and Head Rest Cushion Foam (Sheet 1 of 2)

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1077512256C Highlight

Description, Gauge and Size Material or Make From

Reference

104052 Cushion Foam, Back and Head Rest [1] [4] 1 104052-1 Foam, Backrest [1] [2] [3] [5] [6] [7] [A] 2 Adhesive [2] [3] [8] 3 104052-2 Foam, Headrest [1] [2] [3] [5] [7] [B]

[1] Parts Manufactured by Simula, Government Products Inc of Phoenix, Arizona, CAGE 54786.

[2] As Required; Amount to be used to be determined on assembly.

[3] Must Meet Flammability Requirements per FAR 25.853(a), 12 Second Burn.

[4] Use Approved material when fabricating part(s); refer to drawing for approved material list.

[5] Material: Open Cell Polychloroprene Foam Compound; Stiffness Indentation Load Deflection (ILD) = 30 to 40;

Nominal Density = 2.6 to 3.2 PCF; 0.75 Thk.

[6] Material (Applicable for Alternate Method of Fabrication): Open Cell Polychloroprene Foam Compound; Stiffness Indentation Load Deflection (ILD) = 30 to 40; Nominal Density = 2.6 to 3.2 PCF; 1.5 Thk. (Only applicable when using alternate method of fabrication).

[7] Approved Material: AIRFLEX Foam, Manufactured by Chestnut Ridge Foam, Latrobe, PA, CAGE Code 48818.

[8] Approved Material: 1300L Adhesive, Manufactured by 3M Co., St. Paul MN, CAGE Code 04963.

Figure 5-4. Back and Head Rest Cushion Foam (Sheet 2)

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1077512256C Highlight

Figure 5-5. Headrest Upholstery and Foam (Sheet 1 of 2)

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1077512256C Highlight

1077512256C Sticky Note Headrest

Description, Gauge and Size Material or Make From

Reference

1A326-0459F Upholstery Assembly, Headrest [3] [1] [A] 0A326-0201 Headrest Assembly [3] [1] [B]

1 1A326-0459AY Material, Cover [2] [3] [4] [A] 2 3A505-0001 Fastener, Hook, 15 mm. [2] [3] [5] [A] 3 3A505-0002 Fastener, Loop 15, mm. [2] [3] [5] [A] 4 3A520-0005 Foam [2] [3] [6] [B] 5 3A520-0011 Plastazote, Foam [2] [3] [7] [A]

[1] Parts Manufactured by IPECO, CAGE K9075.

[2] As Required; Number of pieces and length to be determined on assembly.

[3] Must Meet Flammability Requirements per FAR 25.853(b) or (c) Rev 1988.

[4] Made from leather, Color Pacific Blue per material code 1A001-1769AY. Part manufactured by Bridge of Weir, CAGE U2472.

[5] Color Grey per IPECO requirements specification ES056. Material to be sewn or glued.

[6] Part identification is NG32/3, Special Application Foam (Brown). Specification information per Benson Lund, CAGE KC174.

[7] Part identification is LD45FR. Specification information per Benson Lund Quality Dept. CAGE KC174.

Figure 5-5. Headrest Upholstery and Foam (Sheet 2)

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1077512256C Highlight

Figure 5-6. Back Cushion Cover and Foam (Sheet 1 of 3)

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Figure 5-6. Back Cushion Cover and Foam (Sheet 2)

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Description, Gauge and Size Material or Make From

Reference

1A326-0205F Cover Assembly, Back Cushion [3] [1] [A] 0A326-0203 Cushion Assembly, Back [3] [1] [B]

1 1A326-0205NY Material, Cover [2] [3] [4] [A] 2 3A505-0004 Fastener, Loop 20 mm. [2] [3] [5] [A] 3 3A505-0003 Fastener, Hook 20 mm. [2] [3] [5] [B] 4 3A505-0008 Fastener, Loop 50 mm. [2] [3] [5] [B] 5 3A520-0007 Nylon [2] [3] [6] [B] 6 3A520-0023 Scrim [2] [3] [7] [B] 7 3A520-0031 Foam [2] [3] [8] [B]

[1] Parts Manufactured by IPECO, CAGE K9075.

[2] As Required; Number of pieces and length to be determined on assembly.

[3] Must Meet Flammability Requirements per FAR 25.853(b) or (c) Rev 1988.

[4] Part is made from Sheepskin and Trevira Cloth; Sheepskin in body contact area, Color: Pacific Blue. Manufactured by Sleepmaster; made from Trevira Cloth on remaining area, Color: Blue, Manufactured by Concept Fabrics, Inc.

[5] Color Black and to be sewn or glued on material cover.

[6] Upholstery item. Material is made from Nylon (White), part identity is 4 oz AHV 504 per IPECO, CAGE K9075.

[7] Upholstery item. Material is made from Polyester Scrim (White), part identity is PK186 per IPECO, CAGE K9075.

[8] Upholstery item. Material is made from foam, part identity is MP55 per IPECO, CAGE K9075.

Figure 5-6. Back Cushion Cover and Foam (Sheet 3)

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1077512256C Highlight

1077512256C Highlight

Figure 5-7. Pan Cushion Cover Assembly and Foam (Sheet 1 of 4)

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Figure 5-7. Pan Cushion Cover Assembly and Foam (Sheet 2)

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Figure 5-7. Pan Cushion Cover Assembly and Foam (Sheet 3)

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Description, Gauge and Size Material or Make From

Reference

0A326-0209F Cover Assembly, Pan Cushion [3] [1] [A] 0A326-0207 Cushion Assembly, Pan [3] [1] [B]

1 0A326-0209NY Material, Cover [2] [3] [4] [A] 2 3A521-0001 Button, Push Fastener [5] [A] 3 3A521-0009 Socket, Push Fastener [5] [A] 4 3A521-0013 Stud, Push Fastener [5] [A] 5 3A521-0015 Eyelet, Push Fastener [5] [A] 6 3A505-0002 Fastener, Loop 15 mm. [2] [3] [6] [A] 7 3A505-0005 Fastener, Loop 30 mm. [2] [3] [6] [A] 8 0A326-0517 Cushion, Seat Pan [2] [3] [7] [B] 9 1A326-0519 Cushion, Thigh Pad [2] [3] [8] [B]

9A 1A326-0520 Cushion, Thigh Pad [2] [3] [8] [B] 10 3A505-0001 Fastener, Hook 15 mm. [2] [3] [6] [B] 11 3A505-0003 Fastener, Hook, 20 mm. [2] [3] [6] [B] 12 3A505-0005 Fastener, Hook 30 mm. [2] [3] [6] [B] 13 3A505-0008 Fastener, Loop 50 mm. [2] [3] [6] [B] 14 3A505-0006 Fastener, Look 30 mm. [2] [3] [6] [B] 15 3A520-0007 Nylon [2] [3] [9] [B] 16 3A520-0033 Thread [2] [3] [10] [B] 17 3A520-0012 Fabric, Fire Blocking [2] [3] [11] [B]

[1] Parts Manufactured by IPECO, CAGE K9075.

[2] As Required; Number of pieces and length to be determined on assembly.

[3] Must Meet Flammability Requirements per FAR 25.853(b) or (c) Rev 1988.

[4] Part is made from Sheepskin and Trevira Cloth; Sheepskin in body contact area, Color: Pacific Blue. Manufactured by Sleepmaster; made from Trevira Cloth on remaining area, Color: Blue, Manufactured by Concept Fabrics, Inc.

[5] Made from Nickel Plate Finish. Manufactured by Benson Lund, CAGE KC174.

[6] Color: Black; to be sewn or glued on material cover.

[7] Made from material Vastipur W5450; Cushion Hardness to be 350 to 420 Newton at 50% Relative Humidity.

[8] Made from material Vastipur W5450; Cushion Hardness to be 200 Newton +- 10% at 50% Relative Humidity.

[9] Upholstery item. Material is made from Nylon (White), part identity is 4 oz AHV 504 per IPECO, CAGE K9075.

[10] Upholstery item. Material is made from Kevlar ECRU thread, part identity is TEX-50-2 per IPECO, CAGE K9075.

[11] Upholstery item. Material is made from Panotex Fire Blocking Fabric, part identity is P505 per IPECO, CAGE K9075.

Figure 5-7. Pan Cushion Cover Assembly and Foam (Sheet 4)

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1077512256C Highlight

1077512256C Highlight

Figure 5-8. Crew Seat Arm Assembly Cover and Foam (Sheet 1 of 2)

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