Tech Order.pdf

8.100.1 Ceiling and Sidewall Panel Vinyl Replacement.

Use extreme care in removing or installing vinyl to prevent damage to panel edges and core.

Overall limitation of combined potting compound repairs or honeycomb core is 10% of panel surface area. Anything over 10% call OC-ALC/MMAR for engineering assistance.

Carpet may be applied to the forward bulkhead per Paragraph 8.100.2.

The procedure is applicable only to nomex honeycomb panels.

a. Remove any seals, hardware, etc., attached to panel to facilitate removal of vinyl.

Save for reinstallation.

b. Prior to removing vinyl, check panel honeycomb for soft spots by lightly tapping using a blunt instrument. Mark damaged areas on underside of panel for later repair

c. Using a sharp knife and a heat gun, strip old vinyl from the panel.

d. Remove any dacron cloth underliner that may remain after vinyl has been removed

e. Examine panel core and edges for dents, depressions, cracks, gouges, etc.

f. Using Adtech 15-3 or EC-3524 AB potting compound, fill all damaged areas. Allow to cure for 12 hours.

g. After curing, sand filler to match the surface of the panel including the thickness of the open weave fiberglass.

h. Using number 400 or finer sandpaper, lightly hand sand rough areas of the open weave fiberglass.

i. Remove any sanding dust from panel interior using a vacuum.

Methyl Propyl Ketone is flammable and hazardous to health. Use in a well ventilated area.

After surfaces have been prepared and cleaned, extreme care must be taken to keep all dust and foreign materials off bonding surfaces during subsequent operations. Wear clean knitted gloves at all times while handling or working with cleaned surfaces.

Methyl Propyl Ketone is flammable and hazardous to health. When using adhesive prevent skin contact, avoid inhalation of vapors, blend and use only in areas with adequate ventilation.

Pot life of activated adhesive is eight hours at 65-80 degrees F. Set blended adhesive aside for two minutes prior to use. For spraying, thin adhesive with equal parts by volume of Methyl Propyl Ketone. For brushing, adhesive requires through stirring only.

j. Using gauze or cheesecloth, clean open weave fiberglass with aliphatic naptha of Methyl Propyl Ketone. Wipe off solvent before it has evaporated and do not use excessive amounts which would run down into the honeycomb.

k. Clean bonding side of vinyl using gauze or cheesecloth and aliphatic naptha.

l. Prepare Bostik 7132R adhesive by blending 1 part by volume of Boscodur #24, with 16 parts by volume of Bostic 7132R.

Bostic is extremely toxic and is a sensitizer. Eye and skin protection is required. Air supplied respirator is required unless waived by bioenvironmental engineering. Ventilation required in accordance with

AFOSH STD 161-2.

Vinyl must be aligned with panel so that perforations are straight with panel edge.

Excessive heat applied to vinyl will cause damage. Use only amount of heat required to allow tight forming of vinyl over edges.

Methyl Propyl Ketone is flammable and hazardous to health. Use in well ventilated area.

m. Apply adhesive to panel by spraying, using two to three consecutive cross coats.

n. Brush apply a coat of thinned adhesive around the topside edges of the panel including cutouts for a width of 1/4 inch to 1/2 inch.

o. Starting at one end, sweep the dacron fabric onto the honeycomb panel. Remove a wrinkles by sweeping the fabric down from the center outward, using moderate han pressure. Trim as required.

p. Repeat Step m. Also spray the non-decorative side of the vinyl with a light coat of adhesive.

q. Apply vinyl to the panel using the same method outlined in Step o, except do not tri at this time.

r. Brush apply a coat of unthinned adhesive to panel side and bottom edges. Bottom edges should be coated for a width of 1/2 inch.

s. Using heat gun, heat vinyl extending over panel edge. Stretch vinyl over panel side and bottom edges to provide a complete edge wrap around. Trim as required.

If heat cure method is used, allow panel to cool below 100 degrees F before removal of vacuum and vacuum bag.

t. Dampen a gauze pad or cheesecloth with Methyl Propyl Ketone and clean any soiled spots or excessive adhesive from the vinyl decorative surface.

u. Using polyvinyl alcohol make a vacuum bag to fit the particular panel being repaired

v. Apply vacuum to provide a pressure of 10 to 20 psi and cure for 2-4 hours at 120 degrees F or 8-12 hours at room temperature.

w. Remove vacuum and vacuum bag. Check panel for complete bonding of vinyl on panel surface and edges.

x. Reinstall all seals, hardware, etc., removed in Step a.

y. Install new decals as required.