Preliminary Requirements

Procedure

1. SUBTASK 72-32-85-350-064 Prepare the Bonding Surfaces

   1. Refer to Figure.

   2. Prepare the bonding surface, refer to Figure.

      1. 
         CAUTION
         DO NOT USE POWERED TOOLS WITH STEEL CHISEL OR SIMILAR BITS.
         
         CAUTION
         THE FAN CASE IS MADE FROM TITANIUM ALLOY AND IS THIN IN SOME AREAS. IF YOU HIT THE FAN CASE WITH A CHISEL OR SCRAPER YOU CAN MAKE IT UNSERVICEABLE.
         
         CAUTION
         YOU MUST USE THE CHISEL, SHARP BLADE OR SCRAPER IN A CIRCUMFERENTIAL DIRECTION TO PREVENT THE EDGES OF THE BLADE SCORING THE FAN CASE.
         
         CAUTION
         YOU MUST ALWAYS TRY TO POINT THE CHISEL OR SHARP BLADE PARALLEL WITH THE SURFACE OF THE FAN CASE.
         
         CAUTION
         DO NOT OPERATE WITHOUT SAFETY GOGGLES AND OTHER GUARD EQUIPMENT. FLYING PARTICLES CAN CAUSE INJURY.
         
         CAUTION
         PARTIAL REPLACEMENT AT MIDDLE AND REAR ANTI ICE IMPACT PANEL AREA CAN BE DONE AS FOLLOWS:
         
         CAUTION
         REPLACE THE DAMAGED SHORT PANEL (01-910 AND/OR 01-920) ONLY.
         
         CAUTION
         REPLACE THE DAMAGED LONG PANEL(S) (01-905 AND/OR 01-915) THRU TO THE SHORT PANEL (01-910 AND/OR 01-920).

         Remove most of the damaged panels.

         1. Use air hammer or flux chipper with aluminum chisel.

            1. Refer to Figure.

      2. 
         CAUTION
         PREVENT TOO MUCH SURFACE ABRASION OF THE FAN CASE MATERIAL. SURFACE FINISH USING ABRASIVE BLASTING IS NECESSARY. THIS WILL GIVE THE BEST BONDING RESULTS.
         
         CAUTION
         HAND DRESSING TOOLS ARE NOT TO BE USED AT THE SAME LOCATION, DO NOT DWELL IN ONE AREA OR ANY AREA.

         Remove the remaining unwanted material and adhesive on the case.

         1. Use CoMat 05-185 POLISHING DISCS or CoMat 05-186 CONDITIONING DISCS with air grinder to the case.

            1. Make sure new replacement panels can be placed in the position shown in Figure.

      3. 

         WARNING

         AIR BLASTS CREATES FLYING PARTICLES. YOU MUST USE SAFETY SHIELD AND OTHER PROTECTIVE EQUIPMENT. FLYING PARTICLES CAN CAUSE EYE INJURY.

         Remove the remaining debris with dry air blast and/or vacuum cleaner.

      4. Degrease the repair area.

         1. Refer to the SPM TASK 70-11-26-300-503.

      5. 
         WARNING
         ALWAYS MAKE SURE THERE IS SUFFICIENT VENTILATION IN THE WORK AREA. EYE PROTECTION MUST ALWAYS BE USED. DO NOT LET THE SOLVENT CLEANER OR ITS VAPOR TOUCH THE EYES OR SKIN. PROTECTIVE CLOTHING AND FACE MASK MUST ALWAYS BE USED. ALWAYS KEEP OPEN FLAMES AWAY FROM THE WORK AREA. IT IS THE RESPONSILIBILTY OF THE OPERATOR TO OBTAIN AND OBSERVE THE MANUFACTURERS MATERIAL SAFETY SHEETS FROM THE CONSUMABLE MATERIALS INFORMATION SUCH AS HAZARDOUS INGREDIENTS, PHYSICAL/CHEMICAL CHARACTERISTICS, FIRE, EXPLOSION, REACTIVITY, HEALTH HAZARD DATA, PRECAUTIONS FOR SAFE HANDLING, USE AND CONTROL MEASURES AND ALSO TO TAKE LOCAL REGULATIONS INTO CONSIDERATION.

         Inspect the repair area.

         1. Examine the surface.

         2. Repair any nicks, dents, scratches and gouges.

         3. If necessary, do Repair, VRS1405, TASK 72-32-85-300-005 (REPAIR-005).

      6. Mask the non-bonding area.

         1. Mask off all areas except bonding area using CoMat 02-224 SILICONE ADHESIVE POLYESTERTAPE and/or other applicable procedures.

      7. 
         WARNING
         A PRESSURIZED AIR STREAM CAN CAUSE INJURY. WEAR SAFETY GOGGLES AND PROTECTIVE CLOTHING.

         Make the repair area rough.

         1. Use CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADE with the blasting equipment.

         2. Remove the glossy surface from the repair area of the fan case.

         3. Ensure that a constant matt surface is maintained.

         4. Operate vacuum sand blaster at approximately 70 to 100 psi (480 to 690 Kpa).

         5. If you use the pressure blaster to remove the glossy surface from the repair area.

         6. Optimum distance between the nozzle and the repair surface is 5 to 15 in. (127 to 381 mm).

         7. Do the procedure given in the SPM TASK 70-36-02-360-501.

         8. Do not use abrasive paper.

      8. Remove any remaining debris.

         1. Use vacuum cleaner.

      9. Immediately blow out the area.

         1. Use oil free dry air.

   3. 
      CAUTION
      DO NOT USE TAP WATER OR MINERAL WATER. YOU MUST USE DISTILLED OR DEIONIZED WATER DURING THE WATER-BREAK INSPECTION.

      Water-break inspection of the repair area.

      1. Refer to the SPM TASK 70-36-02-360-501.

   4. Prepare the repair part, refer to Figure.

      1. NOTE

         The replacement panel, item number 3 and 5, is made longer than necessary to make easier the necessary adjustment.

         Cut the replacement panel, item number 3 and/or 5, to the correct length to give the necessary gap.

         1. Use hand tools. Refer to Figure.

      2. Remove all remaining unwanted material.

         1. Use the vacuum cleaner.

      3. NOTE

         If the measured clearances in a pre-bonding condition are not satisfactory in front anti ice impact panel area (01-900), the following conditions are permitted. Total clearance is less than 2.181 in. (55.4 mm) measured in the circumferential width. Maximum clearance is not greater than 0.508 in. (12.9 mm).

         Make sure that the replacement panels can be placed in position and adjustment is in the gaps given in Figure.

2. SUBTASK 72-32-85-360-055-001 Bond the Replacement Panels (Vacuum Bag Method)

   1. Refer to Figure.

   2. Degrease the replacement panels, refer to Figure.

   3. 
      WARNING
      DO NOT GET CLEANING FLUID ON YOUR SKIN OR IN YOUR EYES. PUT ON PROTECTIVE CLOTHING, GOGGLES AND A FACE MASK. USE THE FLUID IN A WELL VENTILATED AREA. DO NOT BREATHE THE VAPOR. IF YOU GET THE CLEANING FLUID ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.

      NOTE

      Always pour cleaning fluid on the cloth to avoid contaminating the cleaning fluid supply. Wash one small area at a time.

      It is important that the surface is dried with a second clean cloth prior to the cleaning fluid evaporating to prevent the redeposition of contaminants on the fan case surface.

      Remove all grease from the linings and casing.

      1. Refer to the SPM TASK 70-11-26-300-503.

   4. Apply adhesion promoter, refer to Figure.

      1. 
         WARNING
         YOU MUST FIND AND OBEY THE MANUFACTURER'S HEALTH AND SAFETY DATA FOR THE MATERIAL (MSDS). YOU MUST ALSO REFER TO LOCAL REGULATIONS TO MAKE SURE THAT THE PROCEDURES ARE DONE SAFELY. IF YOU DO NOT DO THIS, AN INJURY OR ENVIRONMENTAL DAMAGE CAN OCCUR.

         NOTE

         If primed surface contaminated or bonding is not accomplished within eight hours after application of the adhesion promoter, repeat priming procedure.

         Apply the primer.

         1. Apply a thin coat of CoMat 08-155 ADHESION PROMOTER to the cleaned surface by brush or clean gauze and allow to dry for approximately 30 minutes at room temperature.

   5. Apply the sealant, refer to Figure.

      1. 
         WARNING
         YOU MUST FIND AND OBEY THE MANUFACTURER'S HEALTH AND SAFETY DATA FOR THE MATERIAL (MSDS). YOU MUST ALSO REFER TO LOCAL REGULATIONS TO MAKE SURE THAT THE PROCEDURES ARE DONE SAFELY. IF YOU DO NOT DO THIS, AN INJURY OR ENVIRONMENTAL DAMAGE CAN OCCUR.
         
         WARNING
         YOU MUST USE THE PLASTIC GLOVES, DURING THE PREPARATION AND USE OF THE SEALANT, TO PREVENT CONTAMINATION OF THE SKIN.
         
         CAUTION
         DO NOT USE CoMat 08-154 SEALANT, TWO PART, EPOXY-CURED POLYTHIOETHER. THIS MATERIAL IS 30 MINUTES APPLICATION LIFE TYPE SEALANT. THIS BONDING STEP IS ESTIMATED TO TAKE MORE THAN 1 HOUR WHEN DONE BY SKILLED MECHANICS FAMILIARIZED WITH THIS APPLICATION PROCEDURE.

         NOTE

         Application life is dependent upon ambient environmental conditions. Increases in temperature and low humidity will shorten application time. Conversely, lower temperatures and high humidity will increase application life. For the examples, the life of the mixed sealant is approximately two hours, at 77 deg F (25 deg C) and 50 percent relative humidity.

         Prepare the sealant.

         1. Use CoMat 08-154 SEALANT, TWO PART, EPOXY-CURED POLYTHIOETHER. Weigh out 100 parts of base compound (white compound) and 18.5 parts of curing compound (black compound). When using SEMKIT form sealant, prepare either by hand, or using a mixing machine as described in the manufacturer's leaflet. Mix the two parts by kneading until the color of compound is constant quality. No streaks permitted.

      2. NOTE

         In order to ensure that anti ice impact area of the panel has contact with the surface of the sealant it is necessary to apply the sealant to the maximum specified thickness 0.024 in. (0.61 mm). The sealant layer thickness must not fall below the specified minimum 0.015 in. (0.38 mm).

         For the best results apply a thin layer of the sealant for anti ice impact area but satisfactory results can be achieved with layer as much as 0.02 in. (0.5 mm) thick.

         Wear lint free gloves (CoMat 02-097 LINT-FREE GLOVES) or white nylon gloves (CoMat 02-100 GLOVES, LINT-FREE) when you touch the parts.

         Apply the sealant to the bonding surfaces.

         1. Use a putty knife or airpowered sealant gun to apply the sealant to mating surfaces of both components to a thickness of between 0.015 and 0.024 in. (0.38 and 0.61 mm).

   6. NOTE

      If all the anti-ice impact panels for the complete location group are to be replaced (Refer to Figure), circumferential position is free from the initial location. Option 2, Figure is recommended.

      Install the replacement panels, refer to Figure.

      1. Put the replacement panels in position and hold with tape.

         1. Use CoMat 02-224 SILICONE ADHESIVE POLYESTERTAPE.

   7. Secure the replacement panels, refer to Figure.

   8. Make-up an annular vacuum bag.

      1. Cover the replacement panels with a sheet of CoMat 02-334 POROUS RELEASE FILM which is 3.00in. (76.2 mm) longer than each end of the panels, 3 plies of CoMat 02-166 BREATHER CLOTH and one ply of CoMat 02-223 RELEASE FILM.

      2. Over them spread a CoMat 02-222 BAGGING FILM between the area of the hook of the fan case and/or other anti ice impact panels and the metal surfaces of the fan case.

      3. NOTE

         Find the seal points (Locations 1 to 5) from the illustration. Refer to Figure.

         Seal the edges of the bagging film to the anti ice impact panels and the metal surface of the fan case with CoMat 02-225 TAPE, VACUUM BAG SEALANT.

   9. Evacuate the air from the vacuum bag and check for leaks audibly or with an ultrasonic leak detector.

      1. Use vacuum pump and ultrasonic leak detector.

   10. Apply and maintain a vacuum of 10.2 psi (70 kPa).

       1. This must be maintained during cure time.

   11. NOTE

       Make sure that you monitor the ambient temperature of the sealant and work area with suitable instruments, across all of the lining.

       Make sure the full cure time is used and correct temperature maintained.

       If the curing process is applied for 48 hours at 50 deg F (10 deg C) or more the necessary strength has been secured, regardless of the level of humidity.

       Cure the sealant.

       1. Allow the CoMat 08-154 SEALANT, TWO PART, EPOXY-CURED POLYTHIOETHER to cure for nine hours at ambient temperature 77 deg F to 95 deg F (25 deg C to 35 deg C).

       2. Cure may be hastened by applying heat, CoMat 08-154 SEALANT, TWO PART, EPOXY-CURED POLYTHIOETHER can obtain a serviceable cure hardness after four hours at 113 deg F (45 deg C).

       3. If the remainig sealant material after repair exceeds the limit, dress the sealant material with CoMat 05-020 WATERPROOF SILICON CARBIDE if necessary.

   12. Remove the vacuum bag.

3. SUBTASK 72-32-85-360-055-002 Bond the Replacement Panels (Fixture Retaining Method)

   1. Refer to Figure.

   2. Degrease the replacement panels, refer to Figure.

   3. 
      WARNING
      DO NOT GET CLEANING FLUID ON YOUR SKIN OR IN YOUR EYES. PUT ON PROTECTIVE CLOTHING, GOGGLES AND A FACE MASK. USE THE FLUID IN A WELL VENTILATED AREA. DO NOT BREATHE THE VAPOR. IF YOU GET THE CLEANING FLUID ON YOUR SKIN OR IN YOUR EYES, FLUSH IT AWAY WITH WATER. GET MEDICAL AID IF YOUR SKIN OR EYES BECOME IRRITATED.

      NOTE

      Always pour cleaning fluid on the cloth to avoid contaminating the cleaning fluid supply. Wash one small area at a time.

      It is important that the surface is dried with a second clean cloth prior to the cleaning fluid evaporating to prevent the redeposition of contaminants on the fan case surface.

      Remove all grease from the linings and casing.

      1. Refer to the SPM TASK 70-11-26-300-503.

   4. Apply adhesion promoter, refer to Figure.

      1. 
         WARNING
         YOU MUST FIND AND OBEY THE MANUFACTURER'S HEALTH AND SAFETY DATA FOR THE MATERIAL (MSDS). YOU MUST ALSO REFER TO LOCAL REGULATIONS TO MAKE SURE THAT THE PROCEDURES ARE DONE SAFELY. IF YOU DO NOT DO THIS, AN INJURY OR ENVIRONMENTAL DAMAGE CAN OCCUR.

         NOTE

         If primed surface contaminated or bonding is not accomplished within eight hours after application of the adhesion promoter, repeat priming procedure.

         Apply the primer.

         1. Apply a thin coat of CoMat 08-155 ADHESION PROMOTER to the cleaned surface by brush or clean gauze and allow to dry for approximately 30 minutes at room temperature.

   5. Apply the sealant, refer to Figure.

      1. 
         WARNING
         YOU MUST FIND AND OBEY THE MANUFACTURER'S HEALTH AND SAFETY DATA FOR THE MATERIAL (MSDS). YOU MUST ALSO REFER TO LOCAL REGULATIONS TO MAKE SURE THAT THE PROCEDURES ARE DONE SAFELY. IF YOU DO NOT DO THIS, AN INJURY OR ENVIRONMENTAL DAMAGE CAN OCCUR.
         
         CAUTION
         DO NOT USE CoMat 08-154 SEALANT, TWO PART, EPOXY-CURED POLYTHIOETHER. THIS MATERIAL IS 30 MINUTES APPLICATION LIFE TYPE SEALANT. THIS BONDING STEP IS ESTIMATED TO TAKE MORE THAN 1 HOUR WHEN DONE BY SKILLED MECHANICS FAMILIARIZED WITH THIS APPLICATION PROCEDURE.

         NOTE

         You must use the plastic gloves, during preparation and use of the sealant, to prevent contamination of the skin.

         Application life is dependent upon ambient environmental conditions. Increases in temperature and low humidity will shorten application time. Conversely, lower temperatures and high humidity will increase application life. For the examples, the life of the mixed sealant is approximately two hours, at 77 deg F (25 deg C) and 50 percent relative humidity.

         Prepare the sealant.

         1. Use CoMat 08-154 SEALANT, TWO PART, EPOXY-CURED POLYTHIOETHER. Weigh out 100 parts of base compound (white compound) and 18.5 parts of curing compound (black compound). When using SEMKIT form sealant, prepare either by hand, or using a mixing machine as described in the manufacturer's leaflet. Mix the two parts by kneading until the color of compound is constant quality. No streaks permitted.

      2. NOTE

         In order to ensure that acoustic area of the panel honeycomb has contact with the surface of the sealant it is necessary to apply the sealant to the maximum specified thickness 0.024 in. (0.61 mm). The sealant layer thickness must not fall below the specified minimum 0.015 in. (0.38 mm).

         Wear lint free gloves (CoMat 02-097 LINT-FREE GLOVES) or white nylon gloves (CoMat 02-100 GLOVES, LINT-FREE) when you touch the parts.

         Apply the sealant to the bonding surfaces.

         1. Use a putty knife or airpowered sealant gun to apply the sealant to mating surfaces of both components to a thickness of between 0.015 and 0.024 in. (0.38 and 0.61 mm).

   6. NOTE

      If all the anti-ice impact panels for the complete location group are to be replaced (Refer to Figure), circumferential position is free from the initial location.

      Install the replacement panels.

      1. Put the replacement panels in position and hold with tape.

         1. Use CoMat 02-224 SILICONE ADHESIVE POLYESTERTAPE.

   7. NOTE

      Make sure that the sealant material juts out into the slots and front side (front panel only) surface.

      Secure the replacement panels.

      1. Use IAE 3J13052 Fixture, bonding 1 off.

   8. Cure the sealant.

      1. Allow the CoMat 08-154 SEALANT, TWO PART, EPOXY-CURED POLYTHIOETHER to cure for nine hours at ambient temperature 77 deg F to 95 deg F (25 deg C to 35 deg C).

         1. Cure may be hastened by applying heat. CoMat 08-154 SEALANT, TWO PART, EPOXY-CURED POLYTHIOETHER can obtain a serviceable cure hardness after four hours at 113 deg F (45 deg C).

         2. If the remaining sealant material around the repair exceeds the dimensional limits, dress the sealant material with CoMat 05-020 WATERPROOF SILICON CARBIDE, if necessary.

   9. Remove bonding fixture.

4. SUBTASK 72-32-85-360-086-002 Fill the Gap around the Replacement Panels by Sealant

   1. Refer to Figure.

   2. 
      WARNING
      YOU MUST FIND AND OBEY THE MANUFACTURER'S HEALTH AND SAFETY DATA FOR THE MATERIAL (MSDS). YOU MUST ALSO REFER TO LOCAL REGULATIONS TO MAKE SURE THAT THE PROCEDURES ARE DONE SAFELY. IF YOU DO NOT DO THIS, AN INJURY OR ENVIRONMENTAL DAMAGE CAN OCCUR.
      
      CAUTION
      DO NOT USE CoMat 08-154 SEALANT, TWO PART, EPOXY-CURED POLYTHIOETHER. THIS MATERIAL IS 30 MINUTES APPLICATION LIFE TYPE SEALANT. THIS BONDING STEP IS ESTIMATED TO TAKE MORE THAN 1 HOUR WHEN DONE BY SKILLED MECHANICS FAMILIARIZED WITH THIS APPLICATION PROCEDURE.

      NOTE

      Make sure that you monitor the ambient temperature of the sealant and work area with suitable instruments, across all of the lining.

      Make sure the full cure time is used and correct temperature maintained.

      If the curing process is applied for 48 hours at 50 deg F (10 deg C) or more the necessary strength has been secured, regardless of the level of humidity.

      NOTE

      You must use the plastic gloves, during preparation and use of the sealant, to prevent contamination of the skin.

      Application life is dependent upon ambient environmental conditions. Increases in temperature and low humidity will shorten application time. Conversely, lower temperatures and high humidity will increase application life. For the examples, the life of the mixed sealant is approximately two hours, at 77 deg F (25 deg C) and 50 percent relative humidity.

      Prepare the sealant material.

      1. Prepare the sealant.

         1. Use CoMat 08-154 SEALANT, TWO PART, EPOXY-CURED POLYTHIOETHER. Weigh out 100 parts of base compound (white compound) and 18.5 parts of curing compound (black compound). When using SEMKIT form sealant, prepare either by hand, or using a mixing machine as described in the manufacturer's leaflet. Mix the two parts by kneading until the color of compound is constant quality. No streaks permitted.

   3. Apply sealant material, refer to Figure.

      1. Fill the sealant in the gaps with the putty knife.

   4. Remove unwanted sealant, refer to Figure.

      1. Remove all unwanted sealant, when it starts to feel hard.

   5. Cure the sealant.

      1. Allow the CoMat 08-154 SEALANT, TWO PART, EPOXY-CURED POLYTHIOETHER to cure for nine hours at ambient temperature 77 deg F to 95 deg F (25 deg C to 35 deg C).

      2. Cure may be hastened by applying heat. CoMat 08-154 SEALANT, TWO PART, EPOXY-CURED POLYTHIOETHER can obtain a serviceable cure hardness after four hours at 113 deg F (45 deg C).

      3. If the remaining sealant material around the repair exceeds the dimensional limits, dress the sealant material with CoMat 05-020 WATERPROOF SILICON CARBIDE.

5. SUBTASK 72-32-85-220-066 Examine the Repaired Area

   1. Refer to Figure.

   2. Visually and dimensionally examine the repaired area.

      1. Make sure that the surface of the filler is flat and smooth.

      2. Accept a step if it is less than 0.02 in. (0.5 mm).

      3. If necessary do Step again.

   3. Examine the replacement panels and check for indications of lack of bond by pressing or tapping.

      1. If lack of bond is apparent, do this TASK again.

6. SUBTASK 72-32-85-350-157 Identify the Repair

   1. Mark VRS1959 adjacent to the part number.

      1. Use the vibration peen method.

      2. Make a permanent mark by the procedures in the SPM TASK 70-09-00-400-501.

Figure: Repair Details and Dimensions

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Repair Details and Dimensions

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Figure: Repair Details and Dimensions

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Figure: Repair Details and Dimensions

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Figure: Repair Details and Dimensions

Sheet 4



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Figure: Repair Details and Dimensions

Sheet 5



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Figure: Repair Details and Dimensions

Sheet 6



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Repair Details and Dimensions

Sheet 6

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Figure: Repair Details and Dimensions

Repair Details and Dimensions