scope:

This handbook contains a description of standard methods for the repair of bonded-sandwich-and metal-laminate-type aircraft construction. The items covered include prerepair damage evaluation, preparation of the part for repair, a description of the materials, and repair procedures. The repair methods designated in section 6.0 will cover the majority of small damage repair cases. These methods have been selected from those used in the current aircraft repair technical orders (T.O.'s). Large area repairs are covered in section 7.0. Postrepair inspection instruction is also included.

A direct substitution can usually be made between the methods and materials presented here and those in the T.O. In general, an equivalency or improvement in repair quality can be expected. The handbook is, however, intended to supplement but not to supersede the specific aircraft's repair T.O.

NOTE: The aircraft's T.O. must be consulted regarding such information as repair size and weight limitations and operating environment. The repair limitations have been established by the manufacturer based on criticality of the specific aircraft. Violation of these may cause problems such as operational difficulties with control surface dynamics or structural deficiencies in critical components or structural failure. Deviations from these limitations, extension of the methods, or substitution of materials shall be defined or authorized by the responsibile engineering authority.

While certain bonding materials are identified in this report as preferred, this does not signify that these are the only materials which are capable of being used in the repair of adhesive bonded structure. Other bonding materials, particularly those developed since the conclusion of the study, may have equal or superior qualities when tested to individual requirements.

Lists of ancillary materials have been included in this document for information purposes. These materials have been found satisfactory for the intended purposes. Other materials from other sources may be equal or better.