T.O._42F-1-2.pdf

FURNISHING FABRICATION

TECHNICAL MANUAL

REPAIR AND FABRICATION OF LOCAL

MANUFACTURED ITEMS USED ON C-17 AIRCRAFT

CONTRACT NO.

FA8526-12-D-0001

THIS MANUAL SUPERSEDES TO 42F-1-2 DATED 1 MAY 2014.

TO 42F-1-2

MDC 12K7053

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright 2003 The Boeing Company

Unpublished Work - All Rights Reserved

DISCLOSURE NOTICE - This information is furnished upon the condition that it will not be released to another nation without the specific authority of the department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States.Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT D - Distribution authorized to the Department of Defense and U.S. DoD contractors only for the administrative and operational use, 3 Feb 2011. Other requests shall be referred to AFLCMC/WLMLBC-TOMA, Robins AFB, GA 31098-1607.

WARNING - This document contains technical data whose export is restricted by the DoD Authorization Act of 1984 (Title 10, U.S.C., Sec 140c and Sec. 1217) and the Arm Export Control Act (Title 22, U.S.C., Sec. 2751 et seq.), or Executive Order 12470, or the Export Administration Act of 1979 as ammended (Title 50, U.S.C., App. 2401 et seq.). Violation of these export-control laws is subject to severe criminal penalties. Dissemination of this document is controlled under DoD Directive 5230.25 and AFI 61-204.

HANDLING AND DESTRUCTION - Comply with distribution statement and destroy any method that will prevent disclosure of the contents or reconstruction of the document.

1 NOV 2014

Basic and all changes have been merged to make this a complete publication.

Title A i thru v vi blank vii viii blank ix thru xii 1-1 thru 1-3 1-4 blank 1-5 thru 1-7 1-8 blank 1-9 thru 1-11 1-12 blank 1-13 1-14 blank 1-15 1-16 blank 1-17 1-18 blank 1-19 thru 1-21 1-22 blank 1-23 thru 1-27 1-28 blank 1-29 thru 1-33 1-34 blank 1-35 thru 1-37 1-38 blank 1-39 thru 1-41 1-42 blank 1-43 thru 1-48 2-1 2-2 blank 2-3 thru 2-5 2-6 blank 2-7 thru 2-8 3-1 3-2 blank 3-3 thru 3-5 3-6 blank 3-7 thru 3-11 3-12 blank 4-1 thru 4-3 4-4 blank 4-5 thru 4-11 4-12 blank 5-1 thru 5-17 5-18 blank 5-19 thru 5-24 6-1 thru 6-4

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Dates of issue for original and changed pages are:

Original . . . . . 0 . . . . . 1 Nov 14

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 122 CONSISTING OF THE FOLLOWING:

A USAF

LIST OF EFFECTIVE PAGES

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by miniature pointing hands.

*Zero in this column indicates an original page.

Page No.

* Change No.

Page No.

* Change No.

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* Change No.

TABLE OF CONTENTS

SECTION PAGE

LIST OF ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v LIST OF TIME COMPLIANCE TECHNICAL ORDERS (TCTO’s) . . . . . . . . . . . . . . . . . . . . . . . . . . . vii INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

REPAIR AND FABRICATION OF INSULATION BLANKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2. Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.3. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4. Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

REPAIR AND FABRICATION OF STRAP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2. Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.3. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.4. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.5. Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

REPAIR AND FABRICATION OF PAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2. Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.4. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.5. Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

REPAIR AND FABRICATION OF CURTAIN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2. Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.3. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.4. Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

REPAIR AND FABRICATION OF SEAT PART MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2. Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.3. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.4. Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

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THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE OR FIRST PAGE.

REPAIR AND FABRICATION OF LIFE VEST STOWAGE COMPARTMENT . . . . . . . . . . . . . . . . . . 6-1

6.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2. Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.3. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.4. Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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TABLE OF CONTENTS - Continued

SECTION PAGE

Page ii

LIST OF ILLUSTRATIONS

Figure No. Title Page

1-1 Insulation Blanket Cover Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-2 List of Symbols/Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1-3 Seaming Blanket Perimeter Edges/ Boxing Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1-4 Tube Dimesion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

1-5 Flange Dimesion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

1-6 Stovepipe or Slit Insert Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

1-7 Assembled Stovepipe or Slit Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

1-8 Sealing Stitched Seams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

1-9 Seaming Cut-Outs and Slit-Knife Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

1-10 Seaming External Cut-Outs and Slit-Boxed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30

1-11 Seaming Internal Cut-Outs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31

1-12 Insulation Blanket Assembly Part Number 17P2N4302 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

1-13 Insulation Blanket Assembly Part Number 17P2N1040 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35

1-14 Insulation Blanket Assembly Part Number 17P8N1008 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39

1-15 Duct Insulation Blanket Assembly Part Number 17P7N9027 . . . . . . . . . . . . . . . . . . . . . . . . 1-43

2-1 Strap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2-2 Barrier Door Strap Assembly Part Number 17P9B1761-503 . . . . . . . . . . . . . . . . . . . . . . . . 2-7

3-1 Mattress-Crew Bunk Pad Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3-2 Standard Stitching and Seam Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-3 Mattress-Crew Bunk Pad Assembly Part Number 17P1B2144-1 . . . . . . . . . . . . . . . . . . . . . 3-10

4-1 Standard Stitching and Seam Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4-2 Crew Berth Curtain Assembly Part Number 17P1B2141 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4-3 Window Curtain Part Number 17P1B2153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4-4 Flight Deck Curtain Assembly Part Number 17P1B1085 . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

5-1 Seat Pan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5-2 Seat Back Cushion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-3 Seat Pan Cushion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5-4 Back and Head Rest Cushion Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5-5 Headrest Upholstery and Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

5-6 Back Cushion Cover and Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

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5-7 Pan Cushion Cover Assembly and Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

5-8 Crew Seat Arm Assembly Cover and Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

6-1 Life Vest Stowage Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

LIST OF ILLUSTRATIONS - Continued

Figure No. Title Page

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LIST OF TABLES

Table No. Title Page

A-1 List of Supplies and Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x

A-2 List of Equipment/Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii

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LIST OF TIME COMPLIANCE TECHNICAL ORDERS (TCTO’s)

The lists of TCTO’s contains all current TCTO’s that affect the technical content on text or illustrations found in this manual

TCTO

NUMBER

TITLE

TCTO

DATE

APPLICABILITY

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INTRODUCTION

A. Purpose of Manual.

This stand alone manual provides the fabrication and intermediate repair procedures for the pur-pose of refurbishing the local intem parts and/or materials.

The data included in this manual has been compiled and presented to enable the restoration of the local manufactured items equivalent to the original parts specification.

Repair information beyond the scope of this manual which requires specific engineering is not pre-sented. The issuance of Time Compliance Technical Order (TCTO) and special repair drawings may be required.

This manual is issued by Boeing Company, Long Beach, California.

B. Content of this Manual.

This manual contains the following sections as applicable:

(1) Section 1, Repair and Fabrication of Insulation Blanket Assembly

(2) Section 2, Repair and Fabrication of Strap Assembly

(3) Section 3, Repair and Fabrication of Pad Assembly

(4) Section 4, Repair and Fabrication of Curtain Assembly

(5) Section 5, Repair and Fabrication of Seat Part Materials

(6) Section 6, Repair and Fabrication of Life Vest Stowage Compartment

C. Use of this Manual.

In order to assist in locating the information, Table of Contents lists topics by section, paragraph, title, and page number. A list of illustrations and tables, which is used to supplement the text mate-rial, indicates the figure or table number, title, and page number.

D. Change Recommendations.

Recommendations concerning changes to this manual shall be submitted in accordance with T.O.

00-5-1.

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Page ix

E. Supplies and Consumables.

NOTE:

Only non-standard supplies and consumables are included in the Supplies and Consum-ables table. Standard items such as cleaning materials, wipes, tape, etc., are not in-cluded.

Table A-1. List of Supplies and Consumables

Index Num-ber Nomenclature CAGE Part Number Specification

1 Webbing, Nylon 81348 MIL-W-4088, Type 15

2 Tape, Closure Hook 81348

Adhesive, Elasto-meric Contact 25670 Stabond C-148B

Thread, Beta Glass, Coated 1DRW1 Glasmo-Tee A (B-4) DPM 2907-2

5 Cleaner, Solvent 0M3C8 SW250041 DPM 6380-3

Adhesive, Silicone

Sealant

38735 DPM 5110

7 Thread, Fiberglass 12% to 16% by wt. PTFE

Coating

8 Tape, Adhesive 1ECV7 2915-10 DMS 1983, Type 2

9 Foam, Airflex 48818 ILD = 30 to 40; Nominal Density = 2.6 to 3.2 PCF,

0.75 THK (or 1.5 THK)∗

10 Adhesive 04963 1300L

11 Sealant, Clear 25670 U-148 DPM 5626

Adhesive, Elasto meric Contact

25670 C-148B DPM 6307

13 Sealant, Adhesive 71984 3140 RTV Coating DPM 6368

Cord, Teflon-

Coated, Glass Fiber

09079 DPM 5921

Tape, Paper, Pressure Sensitive DPM 1861, Type 2

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Table A-1. List of Supplies and Consumables - Continued

Index Num-ber Nomenclature CAGE Part Number Specification

Wiper, General Pur-pose, Cleaning

1820-1A4 DMS 1820 T1A4

Adhesive, Silicone, Sealant

01139 RTV-106 DPM 6380-3

18 Foam KC174 Part Identification

NG32/3

19 Foam KC174 Part Identification MP55

20 Cushion K9075 0A326-0517

21 Cushion K9075 1A326-0519

22 Plastazote KC174 Part Identification

LD45FR

23 Adhesive 81348 MMM-A-121

NOTE: ∗ Applicable when fabricating the item using the optional method.

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F. Equipment/Tools.

Only non-standard tools and equipment are included in the Equipment/Tools table. Stan-dard shop tools and equipment such as utility knife, scissors, sewing machines, etc., are not included.

Table A-2. List of Equipment/Tools

Index Num-ber Nomenclature CAGE Part Number Specification

1 Knife, Heated Ungar No. 776

2 Ink, Rubber Stamp 12744

DPM 1445

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REPAIR AND FABRICATION OF INSULATION BLANKET

1.1. General.

A. This section contains the following procedures for repair and fabrication of the insulation blanket for the following Part Number(s):

Part Number Cage Code Noun, Description

17P2N4302 Blanket Assembly, Water Separator

17P2N1040 Insulation Blanket, Thermal, Duct

17P7N9027 Blanket Assembly, Insulation, Duct

17P8N1008 Insulation Assembly, Muffler Cowl Ice Protection

B. Identify new insulation blanket 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 (DPS, DPMS, etc.)

are applicable. Standard Method drawings define the materials and process specification necessary to fabricate the desired insulation blanket.

E. Figure 1-12 thru 1-15 contain the illustration of insulation blanket assembly configuration, 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 insulation blanket assembly configuration or part detail of the insulation blanket configuration.

(3) Description, Gage and Size column describe each insulation blanket 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 insulation blanket assembly configuration on text, to cross reference to illustration.

1.2. Check.

A. Inspect insulation blanket assembly:

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(1) If insulation blankets are contaminated with Corrosion-Inhibiting Compound (CIC), which are oily or waxy substances that typically change the color and appearance of the insulation blanket cover, replace blanket.

(2) If the cover material of a blanket has been cut, and the solvent or CIC’s have been absorbed by the batting, replace blanket.

1.3. Repair.

A. General.

(1) Repair hole, cut, or tear in insulation blanket cover only if tear is less than 4 in.; otherwise, remove and replace cover.

B. Repair of insulation blanket covers.

(1) Repair hole, cut, or tear in insulation blanket as follows:

a. Identify perimeter around the damaged area. If tear or cut is under 0.5 in., repair as follows:

1. Clean surfaces to be sealed with cleaning wiper (No. 5, Table A-1). Wipe the solvent off the surface as soon as the solvent is applied.

2. Apply a uniform coat of adhesive/sealant (No. 6, Table A-1) over cuts overlapping approxi-mately quater of an inch onto surrounding area.

b. If tear in cover is 0.5 in. to 4 in. long, repair as follows:

1. Sew the tear with thread (No. 4, Table A-1) using 6 to 8 stitches per inch.

2. Prepare a patch of silicone rubber coated glass cloth one inch larger in each dimension than the tear.

3. Wipe area to be repaired and patch.

(a) Seal vinyl to vinyl sewed seams with adhesive (No. 3, Table A-1).

(b) Seal silicone to silicone sewed seams with adhesive (No. 6, Table A-1).

(c) For silicone to vinyl sewed seams, apply coat of adhesive (No. 3, Table A-1) approxi-mately 18 in. to the vinyl surface, and allow to dry tack free. Seal seam with adhesive/sealant (No. 6, Table A-1).

4. Allow patch to cure.

NOTE:

Maximum adhesion is obtained after 3 days.

(2) Repair insulation blanket cover material (optional method):

a. Inspect damaged insulation blanket; identify perimeter around damaged area.

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SECTION 1

b. Cut patch from the same material being repaired. Extend patch 0.15 in. (13 mm) minimum be-yond the damaged area.

c. Clean faying surfaces with white cotton cleaning wipers dampened with diluted liquid deter-gent, 0.5 fl-oz (15 ml) per 1 gal (3.8 l) of water. Wipe with clean, dry white cotton cleaning wip-ers until there is no sign of contamination on the faying surface.

d. Apply a uniform coat, approximately 5 mils (0.13 mm) to 10 mils (0.25 mm) thick, of adhesive (No. 3, Table A-1) to both faying surfaces. Allow the neoprene contact adhesive to air dry until tacky, approximately 5 minutes.

e. Join the faying surfaces using firm hand pressure or with a hard rubber roller. Allow to dry a minimum of eight hours before handling.

(3) Repair moisture damaged insulation blankets.

a. For blanket with observed internal moisture content, dry out blankets and seal with insulation cover splicing adhesive tape (No. 8, Table A-1) on any observed tears or other gaps that per-mit moisture to enter blankets.

b. Make sure the overlaps on all insulation blankets, cap strips, and tabs are correctly positioned to prevent any condensation that can flow between the insulation blankets into the inboard side of the insulation blanket.

1.4. Fabrication.

A. General.

(1) Cover templates are fabricated using paper or mylar (ref. Figure 1-1).

NOTE:

● Existing blanket may be used as a pattern when cutting and making the location of the fold lines.

● When using reinforced plastic films, the plastic side of the material should always be fac-ing up as the outside of the blanket.

● Coated side or heaviest coated side of the material should always be facing up as the outside of the blanket.

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Figure 1-1. Insulation Blanket Cover Template

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B. Fabricate insulation blanket as follows:

(1) Fabricate insulation blanket from template as follows:

NOTE:

The new insulation blanket can either be cut from the assembly of various component materi-als or from a semi-finished insulation blanket strip that is pre-assembled and built from equivalent component materials that are comparable in type/class/grade as those which are pre-assembled.

a. Position cover template over cover material.

b. Mark location of breather, if applicable, cut-out, tuft, and other details to be placed, using large fine point marking pen (permanent), DPM 5274 (ref. Figure 1-2).

c. Position template on cover material over the marked location.

d. Using utility knife, or scissors, cut around template leaving 1 in. (25 mm) to 2 in. (51 mm) to overlap material around the edge.

e. Identify blankets with part number and material on the cover.

f. Seal (or stitch) three sides of the cover (ref. Figure 1-3).

g. Cut the batting into layers to fit cover envelope. Assemble sufficient layers of 1 in. (25 mm) or

0.5 (13 mm) thick insulation to match the correct thickness required.

h. Insert batting. Make sure that scrim side of batting is turned toward outer side of the blanket construction.

j. Seal or stitch, as applicable the remaining edge and any large cutouts.

k. Make sure that all seams are watertight, and that no batting is exposed.

l. Sew or tape all holes made for wire bundles, support struts, or other items.

m. Put nylon fasteners through blanket at 18 in. (457 mm) intervals to reduce movement of bat-ting inside cover.

NOTE:

In very thick blankets, a stovepipe may be necessary to protect a controlled opening.

A stovepipe is a piece of cover material that is sealed to form a tube as long as the thickness of the blanket. A flange is added to both ends of the tube. The flange gives a bonding surface on two sides of the blankets.

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Figure 1-2. List of Symbols/Nomenclature

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Figure 1-3. Seaming Blanket Perimeter Edges/ Boxing Edges (Sheet 1 of 2)

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Figure 1-3. Seaming Blanket Perimeter Edges/ Boxing Edges (Sheet 2)

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(2) Install slits and cut-outs on blanket assembly, if applicable as follows:

a. Fabrication:

1. Determine length and diameter (or perimeter) of tube or slit from the pattern and cut cover material to these dimensions plus enough for seam allowances (ref. Figure 1-4).

2. Cut out flanges from the same material as the top and bottom cover materials (ref. Figure 1-5). For film covers, use insulation cover splicing adhesive tape to fabricate flanges with the release liner in place.

3. Machine stitch one of the flanges to one end of the tube (ref. Figure 1-6).

4. Stitch or seal the remaining flange to the opposite end of the tube (ref. Figure 1-8), if simple stovepipe or slit insert is being fabricated.

5. Separate the two flanges by the distance equal to the thickness of the blanket, and then stitch or seal the flange to the tube if a simple stovepipe or a slit insert with a sleeve is being fabricated. The sleeve may be fabricated using two pieces of covering material at-tached with insulation cover splicing adhesive tape.

6. Fold the tube along its length, align seam edges, and stitch or seal seam closed as shown in Figure 1-4.

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Figure 1-4. Tube Dimesion

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Figure 1-5. Flange Dimesion

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Figure 1-6. Stovepipe or Slit Insert Fabrication

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Figure 1-7. Assembled Stovepipe or Slit Insert

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b. Installation of Tube:

1. Cut a slit or hole (depending on type and size of stovepipe or slit) through the entire blan-ket, the size of the tube.

2. Insert the tube through the slot or hole and position the flanges on the outsides of the blanket.

3. Cement flanges to blanket surfaces as follows:

(a) Apply a uniform coat, approximately 5 mil (0.13 mm) to 10 mil (0.25 mm) thick, of adhesive to both faying surfaces. Allow the adhesive to air dry until tacky, approxi-mately 5 minutes.

(b) Join the faying surface using firm hand pressure.

(c) Allow to dry a minimum of eight hour before handling.

4. For flanges fabricated from insulation cover splicing adhesive tape, remove release liner from tape and press flanges onto blanket surface with firm hand.

(3) Install hook and loop tape (ref. DPS 1.07-8, type 1) to cover.

NOTE:

● Sewing with 0.5 in. (12.7 mm) seam allowance is acceptable as an option to cementing.

● Masking off with masking tape the outer boundaries of the cementing area is necessary to prevent contact of adhesive residues and to prevent marring of the surfaces adjacent.

a. Method A - Cementing:

1. Apply epoxy adhesive to insulation cover per DPS 1.07-8, type 1.

2. Position closure tape on cover and press the parts together with sufficient pressure ensur-ing without causing excessive adhesive squeeze-out.

3. Use masking tape to hold parts together.

4. Cure the assembly at 60ÍF to 80ÍF for 24 hours.

b. Method B - Stitching:

1. Machine stitch the hook or loop tape as specified to cover material using six to eight stitches of fiber glass thread (No. 7, Table A-1) per 1 in. (25 mm).

2. Stitch the entire perimeter of tape with nominal seam edge distance of 0.125 in. (3.18 mm).

(4) Sealing stitch seams.

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a. All covers - fold seam edges of the perimeter seam to one side, and cover both seam edge and seam with insulation cover splicing adhesive tape (No. 8, Table A1) (ref. Figure 1-8, views A and B).

b. For interior seams, insulation cover splicing adhesive tape may be folded around seam (ref.

Figure 1-8, view C).

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Figure 1-8. Sealing Stitched Seams

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(5) Splicing coverings, battings and foams - if blanket pattern requires materials larger than the available stock size or as required to meet the dimensions of the approved template, splice materials together as follows (unless otherwise noted):

NOTE:

There shall be no more than two splice per material face used.

a. Splicing plastic films:

1. Overlap material 0.0 in. (0 mm) to 1 in. (25 mm) and tape together using 2 in. (51 mm) or 3 in. (76 mm) wide adhesive tape, with a minimum of 0.7 in. (18 mm) on each piece of film cover.

b. Splicing coated fabrics:

1. Sew the two pieces together with approximately 0.5 in. (13 m) seam using fiberglass Tef-lon coated thread (No. 7, Table A-1).

2. Seal seam.

c. Splicing batting:

1. Method A

(a) Circular stitch batting together using fiberglass Teflon coated thread (No. 7, Table A-1), use approximately one stitch per 1 in. (25 mm).

2. Method B

(a) One inch thick bating may be stapled at approximately one staple per 1 in. (25 mm).

(6) Seaming blanket edges:

NOTE:

Covers are sewn with 6 to 8 stitches per 1 in. (25 mm).

a. Knife edge - place top and bottom covers together, and seam the perimeter edges. At the cor-ners, create the square box corner by pulling cover materials apart (ref. Figure 1-3, view A) and seaming the corner perpendicular to the edge seam. If a flap is required on a blanket edge, seam the perimeter as shown on Figure 1-3, view B.

b. Boxed - place top and bottom covers, together and seam the perimeter edges (ref. Figure 1-3, view C), first seaming on edge, and then bringing up the second to form a boxed corner.

Seam the second edge as shown and finish by seaming the corner perpendicular to the first two. If a flap is required on the blanket edge, seam the edge as shown on Figure 1-3, view D.

c. Tacking cover material - blanket cover material may be tacked using heat, stitch, pin, clip or equivalent to aid in the fabrication of the blanket. Ensure the tack is on the outer side of the final edge seam.

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(7) Seaming external cut-outs and slits:

a. If 1.5 in. (38.1 mm) thick or less, seam top and bottom covers together with a knife-edge seal as shown on Figure 1-9.

b. If thicker than 1.5 in. (38.1 mm), seam boxing into cut-out or slit as shown on Figure 1-10.

(8) Seaming internal cut-outs and slit:

a. If 1.5 in. (38.1 mm) thick or less, seam top and bottom covers together with a knife-edge seal as shown on Figure 1-9. If a sleeve is required, fabricate cut-out or slit.

b. If thicker than 1.5 in. (38.1 mm), seam boxing into internal cut-out as shown on Figure 1-11.

Slits, stovepipes, and cut-outs may be fabricated.

(9) Apply silicone binder, batting, glass fiber insulation on duct or tube (ref. Figure 1-15).

a. Cut insulation (2) to shape of duct or tube.

NOTE:

Least number of joints is required when cutting insulation batting.

b. Wrap specified number of layers of insulation (2) and compress in accordance with specified thickness per engineering drawing.

c. Spiral wrap insulation (2) with cord (No. 14, Table A-1) to hold in place prior to and while cov-ering.

(10) Apply cover on duct or tube (ref. Figure 1-15).

a. Measure length of insulation (2) along duct or tube; add approximately 2 1/2 in. and cut length dimension of cover (1).

b. Cut cover (1) to circumference of insulated duct or tube.

NOTE:

● Seam allowance of approximately 3/4 in. in dimension should be added when cut-ting cover to circumference of insulated duct or tube.

● Seam allowance of 1 1/4 in. at each end and allowance for insulation compression application should be added.

● If more than one section of cover is used for covering, all seams are hand or ma-chine stitch with thread, 4 to 8 stich per in., except area to secure cover to duct.

c. Wrap cover (1) around insulation (2) at each end.

NOTE:

Silicone is side-out when wrapping cover.

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d. Double-fold edges of cover (1) and hand stitch in place with thread (No. 4, Table A-1).

● Masking tape (No. 15, Table A-1) or pins may be used to hold cover in place tem-porarily for sewing.

● Stitching is 4 to 8 stitch per in.

e. Double-fold edges and machine stitch cover (1) with thread (No. 4, Table A-1) into the duct or tube. Slip cover (1) over the insulated cover duct or tube.

CAUTION:

STAPLE SHOULD NOT BE USED ON GLASS SILICONE COATED CLOTH MA-

TERIAL TO HOLD MATERIAL IN PLACE FOR SEWING.

f. Seal ends of completed insulation blanket with tape (No. 8, Table A-1) and press tape in place with heavy hand pressure.

NOTE:

Overlap tape is approximately about 1/2 in. onto the duct or tube.

g. Stamp cover (1) with ″THIN WALL″ in 1/2 in. in height, all capital letters using rubber stamp ink (No. 2, Table A-2).

NOTE:

Marking is in the length direction and with one foot spacing in the length and 5 in.

spacing around the circumference.

h. Compress insulation (2) to the required thickness using two layers of tape (No. 8, Table A-1).

j. Seal sewed seams. Procedures are as follow:

1. Clean surfaces of area to be sealed with cleaning wipers (No. 16, Table A-1) dampened with solvent cleaner (No. 5, Table A-1).

2. Wipe solvent cleaner (No. 5, Table A-1) off surface as soon as the solvent is applied.

NOTE:

Solvent or cleaner are to be wiped off and not to be left evaporated dry on the surface area.

3. Seal sewed seams with adhesive (No. 17, Table A-1).

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k. Seal duct or tube.

1. Apply adhesive (No. 6, Table A-1) to tape (No. 8, Table A-1) and secure cover (1, Figure 1-15) around fitting, bosses, brackets, etc. with tape (No. 8, Table A-1).

NOTE:

Exposed adhesive bead between tape and cover should not exceed 1/2 in. in width and 1/4 in. in height.

l. If rework of cover (1) is required, repair damage area(s) in place in accordance with paragraph 1.3.

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Figure 1-9. Seaming Cut-Outs and Slit-Knife Edge

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Figure 1-10. Seaming External Cut-Outs and Slit-Boxed

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Figure 1-11. Seaming Internal Cut-Outs

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Figure 1-12. Insulation Blanket Assembly Part Number 17P2N4302 (Sheet 1 of 2)

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Index Drawing/Part Number

Description, Gage and Size Material or Make From

Reference

17P2N4302-503 Blanket Assy, Water Separator Insulation 17P2N4302-21 Blanket Assy, Water Separator Insulation [A] 17P2N4302-23 Blanket Assy, Water Separator Insulation [B]

1 17P2N4302-3 Cover [1] [2] 2 17P2N4302-5 Insulation, 1.00 Thk. by [1] [3] 3 17P2N4302-7 Tape, 1.00 Thk. wide by [1] [4] 4 17P2N4302-9 Tape, 2.00 Thk. wide by [1] [4] 5 17P2N4302-11 Tape, 2.00 Thk. wide by [1] [5] 6 17P2N4302-13 Tape, 1.00 Thk. wide by [1] [5] 7 17P2N4302-15 Thread [6]

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

[2] Film, Plastic Reinforced Heat Sealable Insulation Covering, Material per DMS 2450, Type 1.

[3] Batting, Glass Fiber, Silicone Binder, Material per DMS 1966, Class AA, 0.6 PCF.

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

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

[6] Thread, Glass Fiber 12 to 16% by Wt. PTFE Coating.

Figure 1-12. Insulation Blanket Assembly Part Number 17P2N4302 (Sheet 2)

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Figure 1-13. Insulation Blanket Assembly Part Number 17P2N1040 (Sheet 1 of 3)

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Figure 1-13. Insulation Blanket Assembly Part Number 17P2N1040 (Sheet 2)

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Description, Gage and Size Material or Make From

Reference

17P2N1040-525 Blanket Assy, Thermal - Duct Insulation [A] 17P2N1040-527 Blanket Assy, Thermal - Duct Insulation [B] 17P2N1040-535 Blanket Assy, Thermal - Duct Insulation

8.50 L X 31.20 W X 0.50 Thk

[C]

17P2N1040-537 Blanket Assy, Thermal - Duct Insulation

7.00 L X 31.20 W X 0.50 Thk

[C]

17P2N1040-539 Blanket Assy, Thermal - Duct Insulation

8.50 L X 35.90 W X 0.50 Thk

[C]

17P2N1040-551 Blanket Assy, Thermal - Duct Insulation

6.50 L X 14.14 W X 0.50 Thk

[C]

17P2N1040-559 Blanket Assy, Thermal - Duct Insulation

6.50 L X 18.85 W X 0.50 Thk

[C]

17P2N1040-563 Blanket Assy, Thermal - Duct Insulation

5.00 L X 14.14 W X 0.50 Thk

[C]

1 17P2N1040-3 Cover, 2.00 Sq Ft. [1] [2] 2 17P2N1040-11, -17 Cover, 1.00 Sq Ft. [1] [2]

3 17P2N1040-7 Cover, 2.00 Sq Ft. [1] [7] 4 17P2N1040-5 Insulation, 1.00 Thk. wide by [1] [3] 5 17P2N1040-9 Thread [1] [4] 6 17P2N1040-13 Tape, 2.00 Thk. wide by [1] [5] 7 17P2N1040-15 Tape, Loop, 1.50 Thk. wide by [1] [6] 8 17P2N1040-21 Tape, Hook, 1.00 Thk. wide by [1] [5] 8 17P2N4302-23 Tape, Loop, 1.00 Thk. wide by [1] [6]

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

[2] Cloth, Glass Silicone Coated, Material per DMS 1953, Type 3.

[3] Batting, Glass Fiber, Silicone Binder, Material per DMS 1966, Class AA, 0.6 PCF.

[4] Thread, Glass Fiber 12 to 16% by Wt. PTFE Coating: Commercial item.

[5] Tape, Closure Element, Hook, Material per DMS 2138, Type 1, Grade B, Class I, Color Black.

[6] Tape, Closure Element Loop, Material per DMS 2138, Type 2, Class I, Color Black.

[7] Cloth, Glass, Fiber Finish, Epoxy Resin Compatible, Material per MIL-C-9084, Type 8B, Class 2.

Figure 1-13. Insulation Blanket Assembly Part Number 17P2N1040 (Sheet 3)

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Figure 1-14. Insulation Blanket Assembly Part Number 17P8N1008

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Figure 1-14. Insulation Blanket Assembly Part Number 17P8N1008 (Sheet 2)

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Description, Gage and Size Material or Make From

Reference

17P8N1008-503 Insulation Assy, Muffler Cowl Ice Protection [A] 17P8N1008-521 Insulation Assy, Muffler Cowl Ice Protection [B] 17P8N1008-523 Insulation Assy, Muffler Cowl Ice Protection [A] 17P8N1008-535 Insulation Assy, Muffler Cowl Ice Protection [C] 17P8N1008-541 Insulation Assy, Muffler Cowl Ice Protection [D] 17P8N1008-543 Insulation Assy, Muffler Cowl Ice Protection [E]

1 17P8N1008-3, -9, -41, -45, -53

Cover [1] [2]

2 17P8N1008-5 Batting, 0.5 in. Thk. [1] [3] 3 17P8N1008-7 Cover [1] [4] 4 17P8N1008-11 Tape, Hook, 2.00 Thk. wide by [1] [6] 5 17P8N1008-13 Tape, Loop, 1.00 Thk. wide by [1] [7] 6 17P8N1008-15 Thread, 1.00 Thk. wide by [1] [5] 7 17P8N1008-17 Cover [1] [4] 8 17P8N1008-25, -27, -31, -43 Cover [1] [8]

9 17P8N1008-33 Insulation, 0.50 in. Thk. wide by [1] [9] 10 17P8N1008-35 Cover [1] [10] 11 17P8N1008-37 Tape, Hook, 2.00 Thk. wide by [1] [11] 12 17P8N1008-39 Tape, Loop, 2.00 Thk. wide by [1] [12] 13 17P8N1008-51 Tape, Loop, 1.00 Thk. wide by [1] [12]

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

[2] Cloth, Glass Silicone Coated, Material per DMS 1953, Type 3.

[3] Batting, Glass Fiber, Silicone Binder, Material per DMS 1966, Class AA, 0.6 PCF.

[4] Cloth, Glass Finish Epoxy Resin Compatible, Material per MIL-C-9084, Type 8B, Class 2.

[5] Thread, Glass Fiber 12 to 16% by Wt., PTFE Coating; Commercial Item.

[6] Tape, Closure Element, Hook, Material per DMS 2138, Type 1, Grade B, Class 1, Color Black.

[7] Tape, Closure Element, Loop, Material per DMS 2138, Type 2, Class 1, Color Black.

[8] Cloth, Glass Silicone Coated, Material per DMS 1953, Type 1.

[9] Insulation Felt, Ceramic, 6 PCF, Material per DMS 2484, Type 1, Class 2, Grade B.

[10] Cloth, Glass, Satin Weave, Heave weight, Material per MIL-C-20079, Type 1, Class 2.

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

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

Figure 1-14. Insulation Blanket Assembly Part Number 17P8N1008 (Sheet 3)

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Figure 1-15. Duct Insulation Blanket Assembly Part Number 17P7N9027 (Sheet 1 of 6)

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(Sheet 3)

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(Sheet 4)

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(Sheet 5)

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Description, Gage and Size Material or Make From

Reference

17P7N9027-1 Blanket Assy, Insulation, Duct [A] 17P7N9027-501 Blanket Assy, Insulation, Duct [B] 17P7N9027-503 Blanket Assy, Insulation, Duct [A] 17P7N9027-505 Blanket Assy, Insulation, Duct [C] 17P7N9027-507 Blanket Assy, Insulation, Duct [D] 17P7N9027-509 Blanket Assy, Insulation, Duct [E] 17P7N9027-511 Blanket Assy, Insulation, Duct [F] 17P7N9027-513 Blanket Assy, Insulation, Duct [G] 17P7N9027-515 Blanket Assy, Insulation, Duct [H] 17P7N9027-517 Blanket Assy, Insulation, Duct [J] 17P7N9027-519 Blanket Assy, Insulation, Duct [K]

1 17P7N9027-3, -9, -23

Cover [1] [2]

2 17P7N9027-5 Insulation, 1.00 in. Thk. by [1] [3] 3 17P7N9027-7 Cover, 1.00 sq ft. [1] [4] 4 17P7N9027-11 Tape, Hook, 2.00 in. Thk. wide by [1] [6] 5 17P7N9027-13 Tape, 1.00 in. Thk. wide by [1] [7] 6 17P7N9027-15 Thread [1] [5] 7 17P7N9027-17 Cover [1] [8] 8 17P7N9027-19 Tape, 0.75 in. Thk. wide by [1] [6] 9 17P7N9027-21 Tape, 0.625 in. Thk. wide by [1] [7]

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

[2] Cloth, Glass Silicone Coated, Material per DMS 1953, Type 3.

[3] Batting, Glass Fiber, Silicone Binder, Material per DMS 1966, Class AA, 0.6 PCF.

[4] Cloth, Glass Finish Epoxy Resin Compatible, Material per MIL-C-9084, Type 8B, Class 2.

[5] Thread, Glass Fiber, Beta Type B4 with 12 to 16% by Wt., PTFE Coating; Commercial Item.

[6] Tape, Closure Element, Hook, Material per DMS 2138, Type 1, Grade B, Class 1, Color Black.

[7] Tape, Closure Element, Loop, Material per DMS 2138, Type 2, Class 1, Color Black.

[8] Cloth, Glass Fiber, Finish Epoxy Resin Compatible, Material per MIL-C-9084, Class 2. Plain weave, bonded edges,

1.5 in. width fiberglass binding tape is an acceptable substitute; commercially available.

Figure 1-15. Duct Insulation Blanket Assembly Part Number 17P7N9027 (Sheet 6)

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REPAIR AND FABRICATION OF STRAP ASSEMBLY

2.1. General.

A. This section contains the following procedures for repair and fabrication of strap assembly, Part Num-ber 17P9B1761-503 (ref. Figure 2-1).

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

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 (DPS, DMS, etc.) are applicable for fabrication. Standard Method drawings define the materials and process specification necessary to fabricate the desired strap assembly.

E. Figure 2-2 contains the illustration of the strap assembly configuration, providing the parts material de-scription 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 strap assembly configuration or part detail of the assembly configuration.

(3) Description, Gage and Size column describe each strap 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 strap assembly configuration on text, to cross reference to illustration.

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Figure 2-1. Strap Assembly

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2.2. Check.

A. Inspect strap assembly:

(1) If webbing of the strap assembly has been cut, and solvents or flammable agents have been absorbed, fabricate and replace assembly.

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

(3) Check all stitching for broken thread.

(4) Examine webbing for damaged spot.

NOTE:

In order to be repairable, there must be at least 2.5 in. of sound material between the defect and the nearest joint or adjustment slide area.

2.3. Cleaning.

A. Wash entire assembly in solution of mild detergent. Use bristle brush to remove stubborn deposits.

Rinse and dry in warm air.

2.4. Repair.

A. General

(1) Replace worn or damaged metal parts.

(2) Replace damaged webbing.

(3) Repair damaged stitching.

B. Repair

(1) Stitching:

a. Type of stitch:

1. Use one needle thread and one bobbin thread.

2. A loop of needle thread shall be passed through webbing and interlacing with thread.

3. Thread shall be pulled back so that interlacing will be at faying surfaces of webbing.

NOTE:

Use 8 stitches per in. and an edge margin of 0.12 in.

(2) Repair of strap assembly by replacing hook(s):

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

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b. Remove hook from webbing.

c. Install new hook and re-stitch in accordance with paragraph 2.4.B.(1).

(3) Repair damaged stitching:

a. Using suitable cutter, remove old thread and using nylon thread, re-stitch in accordance with paragraph 2.4.B.(1).

2.5. Fabrication

A. General

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

(2) Visually inspect each roll of webbing for cuts, frayed edges, and defective or deteriorated fabric;

reject webbing that fails to meet requirements.

B. Fabricate strap assembly, Part Number 17P9B1761-503:

(1) Cut out webbing in accordance to the dimension specified in the drawing.

(2) Sear cut the end of the webbing using electrically heated knife.

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Figure 2-2. Barrier Door Strap Assembly Part Number 17P9B1761-503

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Description, Gage and Size Material or Make From

Reference

17P9B1761-503 Strap Assy, Barrier Door [A] 1 17P9B1761-3 Thread, 30 in. [1] [2] 2 17P9B1761-5 Webbing, .190 in. Thk. x 1.0 in. wide by 54 in. long [3] 3 NAS128A20 Hook [4]

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

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

[3] Webbing, Nylon. Material per MIL-W-4088, Type 20, color red per DN1251.

[4] Alternate part to NAS128A16.

Figure 2-2. Barrier Door Strap Assembly Part Number 17P9B1761-503 (Sheet 2)

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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, Gage 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…