Service manual

6-33
T-294-01
h. The surface must be cleanand dry. Roughen the sur-
face with sandpaper to ensure a good bond.
i. Cut the fiberglass cloth to allow a 25m m (1 --inch)
overlap around the area t o be repaired.
j. Stretch and position the cloth over the area to be re-
paired and secure it with masking tape.
k. Make up sufficient epoxy glue to cover the cloth by
mixingequalpartsofresinandhardener. Saturatethe
cloth with the epoxy glue, spreading evenly.
l. Remove the tape and overlap the edge of the cloth
approximately 6 to 12 m m (1/4” to 1/2”) with glue.
m.Epoxy will dryi n 45--60 minutes. Whencompletely
cured (12 hours), use sandpaper to smooth edges of
the patch.
6.29.3 Chips And Holes
Chips and holes in the control box arerepaired using a
piece of aluminum or stainless steel to cover the
damagedarea.Thematerialcanbecuttosuitandriveted
in place. An adhesive sealant must be used to makethe
repairwatertight.Theadhesivesealant(Sikaflex221)is
included in Crack Repair Kit CTD part number
76-00724-00SV(seeTable 6-1).Donotuseanacetone
based silicone sealant (Which can be identified by a
vinegar--like odor).
a. To make up the patch, cut a piece of aluminum or
stainlesssteelsothatitwilloverlapthe damagedarea
by at least 40 mm (1 1/2”) on all sides.
b. Choose rivet locationsand drill the rivet holes in the
correspondinglocationsonthecontrolboxandpatch
piece.
c. Apply the adhesivesealant around the damagedarea
to form a seal between the control box and t he patch
piece.
d. Rivet the patch piece in place.
e. File smooth any rough edges (including rivets) that
may come into contact with wires.
6.29.4 Inserts
The threaded brass inserts that are molded into the
control box will need to be replaced if the threads
become stripped, or if the insert becomes loose. The
inserts and epoxy are contained in repair kit, CTD part
number 76-50084-00 (see Table 6-2). There are 6
different inserts used in the control box. Refer to
Figure 6-36 for the locations of the various inserts.
NOTE
Anepoxyapplicationgunisalsoneeded,CTD
part number 07 -- 00391 -- 00.
The damaged insert must be removed from the control
box. Table 6-3identifiesthedrill sizeand drill depthto
beusedforeachinsert.Astopringshouldbeusedonthe
drill bit to limit the depth.
a. Center the drill bit on the insert and drill to the pre-
scribed depth.
b. Remove the chips from the drilled hole.
c. Mix the two component epoxy and fill the hole 1/2
way to the top with epoxy.
d. Press the insert in until it is flush with the surface.
e. Wipe away any excess epoxy. The part is ready for
service after the bond material has hardened and is
tack free (approximately 20 minutes)
6.29.5 Door Hinge Inserts
Ifthedoorhingeshavebeenpulledfromthecontrolbox
drillandreinstallthehingeasshowninFigure 6-35and
described in the following steps.
Figure 6-35 Door Hinge Repair
Materials needed:
7. Cut two square pieces of 3 mm thick (1/8 inch) alu-
minum or stainless steel approximately 40 mm (1
5/8”) square. These squares will serve as backing
plates.
8. Two nuts, bolts (10 -- 24 x 1”) and washers for each
insert that needs repair.
a. Drill a 1/4” holeinthe center of each squarebacking
plate.
b. Pass the bolts through the bolts holes in the door
hinge, then through the control box at the location
where the hinge insert pulled out.
c. From insidethe controlbox, slide the backing plates
over the bolts and secure in place with the washers
and nuts.