Piper PA-28-161, Maintenance Manual

Page: 698 / 1104

PAGE 2
Nov 30/06
4C20
51-70-00
PIPER AIRCRAFT, INC.
PA-28-161, WARRIOR III
MAINTENANCE MANUAL
(8) Pour out a small amount of resin, add catalyst and mix thoroughly, using a cutting motion
rather than stirring. Use no fibers.
(9) Using the tip of a putty knife or fingertips, fill the hole to about .062 of an inch above the
surrounding surface with the gel coat mixture.
(10) Lay a piece of cellophane over the patch to start the curing process. Repeat step (6), trimming
patch when partially cured.
(11) After trimming the patch, immediately place another small amount of gel coat on one edge of
the patch and cover with cellophane. Then, using a squeegee or the back of a razor blade,
level with area surrounding the patch; leave the cellophane on patch for one to two hours or
overnight, for complete cure.
(12) After repair has cured for 24 hours, sand patched area, using a sanding block with fine wet
sandpaper. Finish by priming, again sanding and applying color coat.
B. Fracture and Patch Repairs
(1) Remove wax, oil and dirt from around the damaged area with acetone, methylethylketone or
equivalent.
(2) Using a key hole saw, electric saber saw, or sharp knife cut away ragged edges. Cut back to
sound material.
(3) Remove paint three inches back from around damaged area.
(4) Working inside the structure, bevel the edges to approximately a 30 degree angle and rough-
sand the hole and the area around it, using 80 grit dry paper. Feather back for about two
inches all around the hole. This roughens the surface for strong bond with patch.
(5) Cover a piece of cardboard or metal with cellophane. Tape it to the outside of the structure,
covering the hole completely. The cellophane should face toward the inside of the structure. If
the repair is on a sharp contour or shaped area, a sheet of aluminum formed to a similar
contour may be placed over the area. The aluminum should also be covered with cellophane.
(6) Prepare a patch of fiberglass mat and cloth to cover an area two inches larger than the hole.
(7) Mix a small amount of resin and catalyst; enough to be used for one step at a time, according
to kit instructions.
(8) Thoroughly wet mat and cloth with catalyzed resin. Daub resin on mat first, and then on cloth.
Mat should be applied against structures surface with cloth on top. Both pieces may be wet out
on cellophane and applied as a sandwich. Enough fiberglass cloth and mat reinforcements
should be used to at least replace the amount of reinforcements removed in order to maintain
the original strength. If damage occurred as a stress crack, an extra layer or two of cloth may
be used to strengthen area.
(9) Lay patch over hole on inside of structure, cover with cellophane, and squeegee from center to
edges to remove all air bubbles and assure adhesion around edge of hole. Air bubbles will
show white in the patch and they should all be worked out to the edge. Remove excess resin
before it gels on the part. Allow patch to cure completely.
(10) Remove cardboard or aluminum sheet from outside of hole and rough-sand the patch and
edge of hole. Feather edge of hole about two inches into undamaged area.
(11) Mask area around hole with tape and paper to protect surface. Cut a piece of fiberglass mat
about one inch larger than the hole and one or more pieces of fiberglass cloth two inches
larger than the hole. Brush catalyzed resin over hole, lay mat over hole and wet out with
catalyzed resin. Use a daubing action with brush. Then apply additional layer or layers of
fiberglass cloth to build up patch to the surface of structure. Wet out each layer thoroughly with
resin.
(12) With a squeegee or broad knife, work out all air bubbles in the patch. Work from center to edge
pressing patch firmly against the structure. Allow patch to cure for 15 to 20 minutes.