Bulk Cargo-Door Linings - Wet Lay-up Repair-Procedure

TASK 52-33-13-340-801-A
Bulk Cargo-Door Linings - Wet Lay-up Repair-Procedure

WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.

ZONE: 827

1. Reason for the Job
Refer to the AMM Task 52-33-13-300-80100.
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	1	ACCESS PLATFORM 4M (13 FT)-ADJUSTABLE
No specific	1	BAG - VACUUM
No specific	1	CLOTH - ABRASIVE (GRADE 120-180)
No specific	1	CLOTH-EMERY (GRADE 240)
No specific	1	CUTTER - THIN BLADE
No specific	1	GUN - FASTENER
No specific	1	PAINTBRUSH

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.04BAM6)	Pore Filler Polyurethane-- - Furnishing
(Material No.04JMD9)	Top Coat Polyurethane-- Decorative Furnishing
(Material No.05RAJ9)	Adhesive Film Tape-- Film PTFE -
(Material No.05WBA1)	Adhesive Primer-Pressure Sensitive Adhesive - -
(Material No.08BBD1)	Non Aqueous Cleaner-- Isopropyl Alcohol -
(Material No.13AEC1)	Dry glass fabric-8H Satin 293 gsm - 181 style SRM Type 2 -
(Material No.13AFB1)	Dry glass fabric-8H Satin 293 gsm - 7781 style SRM Type 1 -
(Material No.13EBK1)	Laminating resin-Epoxy Fire compliant -
(Material No.14SBA1)	Textile-Lint free Cotton -
No specific	ABS1133C
No specific	ABS1133D
No specific	ASNA 0113-32
No specific	NAS 1919 C04

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
827	BULK CARGO COMPARTMENT DOOR

D. Referenced Information

REFERENCE	DESIGNATION
TASK 52-30-00-860-001-A	Open the FWD or Aft Cargo-Compartment Door with the Yellow Electric Pump
TASK 52-30-00-860-002-A	Close the FWD or Aft Cargo-Compartment Door with the Yellow Electric Pump
TASK 52-33-13-000-001-A	Removal of the Lining and Insulation of the Bulk Cargo-Compartment Door
TASK 52-33-13-300-801-A	Bulk Cargo-Door Linings - General Repair Data
TASK 52-33-13-400-001-A	Installation of the Lining and Insulation of the Bulk Cargo-Compartment Door
Bulk Cargo-Door Linings - Repair Area
Bulk Cargo-Door Linings - Wet Lay-up Repair

3. Job Set-up
Subtask 52-33-13-010-053-A

A. Get Access
(1) Put the ACCESS PLATFORM 4M (13 FT)-ADJUSTABLE in position at the aft cargo-compartment door.
(2) Open the aft cargo-compartment door to get access to the inner side of the closed bulk cargo door (Ref. AMM TASK 52-30-00-860-001).
(3) Remove the divider net at FR59 to get access to the bulk cargo compartment.
(4) Remove the door net from the opening of the closed bulk cargo door to get access to the linings.
(5) Remove the applicable bulk cargo-door lining (Ref. AMM TASK 52-33-13-000-001).

4. Procedure
Subtask 52-33-13-210-052-A

A. Identification of the Damage Limits
(1) Make sure that you selected the correct repair procedure (Ref. AMM TASK 52-33-13-300-801).

Subtask 52-33-13-340-051-A

B. Repair of the Bulk Cargo-Door Lining
(1) Remove and discard the applicable insulation mat or a part of the insulation mat from the damaged bulk cargo-door lining:

CAUTION: BE CAREFUL WHEN YOU MAKE A CUTOUT IN THE INSULATION MAT WITH THE CUTTER. IF YOU ARE NOT CAREFUL, YOU CAN CAUSE DAMAGE TO THE CARGO DOOR LINING.

(a) If the damaged area of the insulation mat is small, use the CUTTER - THIN BLADE to make a sufficient cutout.
(b) If you repair more than one damaged area, remove the full insulation mat from the damaged bulk cargo-door lining.
(2) Prepare the damaged area:
(a) On the front side of the bulk cargo-door lining, use the CLOTH-EMERY (GRADE 240) to remove the paint.
(b) Make sure that:
1 Diameter P of the area from which you remove the paint is approximately 150 mm (5.91 in.).
2 You only remove the paint but not the material from the glass fabric layer of the bulk cargo-door lining.
(c) On the rear side of the bulk cargo-door lining, use the CLOTH-EMERY (GRADE 240) to carefully remove the ply:
1 In each direction, the area from which you remove the ply must be a minimum of 15 mm (0.59 in.) larger than the damaged area (dimension B).
(d) For a crack repair, make sure that you remove all the loose glass fibers from the crack.
(e) Clean the repair area with Non Aqueous Cleaner-- Isopropyl Alcohol - (Material No.08BBD1) and the Textile-Lint free Cotton - (Material No.14SBA1) .
(f) Let the area dry for a minimum of 15 minutes.
(3) Prepare the two repair patches for the rear side of the bulk cargo-door lining:
(a) Cut the small repair patch from Dry glass fabric-8H Satin 293 gsm - 7781 style SRM Type 1 - (Material No.13AFB1) or Dry glass fabric-8H Satin 293 gsm - 181 style SRM Type 2 - (Material No.13AEC1) to the applicable dimensions:
1 In each direction, the small repair patch must be 35 mm (1.38 in.) larger than the damaged area (dimension E = B + C + C). Dimension C is 10 mm (0.39 in.).
2 If the damaged area is near a fixation hole (less than 60 mm (2.36 in.)), you must apply the small repair patch on the fixation hole with an overlap of 25 mm (0.98 in.) minimum (dimension G).

NOTE: If the distance between the two damaged areas is less than 100 mm (3.94 in.), the repair patch must include the two damaged areas.

3 Make each corner of the small repair patch circular with a radius of approximately 10 mm (0.39 in.).

NOTE: This is not necessary for the corner of the repair patch at the edge of the bulk cargo-door lining.

(b) Cut the large repair patch from Dry glass fabric-8H Satin 293 gsm - 7781 style SRM Type 1 - (Material No.13AFB1) or Dry glass fabric-8H Satin 293 gsm - 181 style SRM Type 2 - (Material No.13AEC1) to the applicable dimensions:
1 In each direction, the large repair patch must be 15 mm (0.59 in.) larger than the small patch (dimension D).
2 Make each corner of the large repair patch circular with a radius of approximately 10 mm (0.39 in.).

NOTE: This is not necessary for the corner of the repair patch at the edge of the bulk cargo-door lining.

(4) Prepare the two repair patches for the front side of the bulk cargo-door lining:
(a) Cut the small repair patch from Dry glass fabric-8H Satin 293 gsm - 7781 style SRM Type 1 - (Material No.13AFB1) or Dry glass fabric-8H Satin 293 gsm - 181 style SRM Type 2 - (Material No.13AEC1) to the applicable dimensions:
1 In each direction, the small repair patch must be 42.5 mm (1.67 in.) larger than the damaged area (dimension E + 1/2*D).
2 Make each corner of the small repair patch circular with a radius of approximately 10 mm (0.39 in.).

NOTE: This is not necessary for the corner of the repair patch at the edge of the bulk cargo-door lining.

(b) Cut the large repair patch from Dry glass fabric-8H Satin 293 gsm - 7781 style SRM Type 1 - (Material No.13AFB1) or Dry glass fabric-8H Satin 293 gsm - 181 style SRM Type 2 - (Material No.13AEC1) to the applicable dimensions:
1 In each direction, the large repair patch must be 15 mm (0.59 in.) larger than the small repair patch (dimension D).
2 Make each corner of the large repair patch circular with a radius of approximately 10 mm (0.39 in.).

NOTE: This is not necessary for the corner of the repair patch at the edge of the bulk cargo-door lining.

(5) Fill the cracks/holes with Laminating resin-Epoxy Fire compliant - (Material No.13EBK1) .
(6) Make sure that the epoxy resin is flush with the prepared area.

NOTE: The resin will become hard after approximately 25 minutes at 23 deg.C (73.40 deg.F).

(7) Install the two repair patches on the rear side of the bulk cargo-door lining:
(a) Apply a smooth layer of Laminating resin-Epoxy Fire compliant - (Material No.13EBK1) on the prepared area.
(b) Make sure that the area with the epoxy resin has the same size as the small repair patch.
(c) Put the small repair patch in position.
(d) Make sure that:
1 The angle between the fiber direction of the glass fabric layer (of the bulk cargo-door lining) and of the small repair patch is 45 degrees.
2 In each direction, the small repair patch is 35 mm (1.38 in.) larger than the damaged area (dimension E).
(e) Apply a smooth layer of Laminating resin-Epoxy Fire compliant - (Material No.13EBK1) on the small repair patch and the prepared area.
(f) Make sure that the area with the epoxy resin has the same size as the large repair patch.
(g) Put the large repair patch in position.
(h) Make sure that:
1 The angle between the fiber direction of the glass fabric layer (of the bulk cargo-door lining) and of the large repair patch is 0 or 90 degrees.
2 In each direction, the large repair patch is 15 mm (0.59 in.) larger than the small patch (dimension D).
(8) Install the two patches on the front side of the bulk cargo-door lining:
(a) Apply a smooth layer of Laminating resin-Epoxy Fire compliant - (Material No.13EBK1) on the prepared area.
(b) Make sure that the area with the epoxy resin has the same size as the small repair patch.
(c) Put the small repair patch in position.
(d) Make sure that:
1 The angle between the fiber direction of the glass fabric layer (of the bulk cargo-door lining) and of the small repair patch is 45 degrees.
2 In each direction, the small repair patch is 42.5 mm (1.67 in.) larger than the damaged area (dimension E + 1/2*D).
(e) Apply a smooth layer of Laminating resin-Epoxy Fire compliant - (Material No.13EBK1) on the small repair patch and the prepared area.
(f) Make sure that the area with the epoxy resin has the same size as the large repair patch.
(g) Put the large repair patch in position.
(h) Make sure that:
1 The angle between the fiber direction of the glass fabric layer (of the bulk cargo-door lining) and of the large repair patch is 0 or 90 degrees.
2 In each direction, the large repair patch is 15 mm (0.59 in.) larger than the small patch (dimension D).
(9) On the rear and front sides of the bulk cargo-door lining, attach the BAG - VACUUM around the large repair patches.
(10) Let the resin cure for 2.5 hours at 66 deg.C (150.80 deg.F) with a vacuum pressure of delta 0.6 bar (8.70 psi).
(11) Remove the vacuum bag.
(12) Use the CLOTH - ABRASIVE (GRADE 120-180) to carefully make the repaired area smooth.
(13) Make sure that you do not cause damage to the glass ply.
(14) Install the blind rivets on the front side of the bulk cargo-door lining:
(a) Make marks to identify the correct positions of the blind rivets.
(b) Make sure that:
1 You make a minimum of three marks.

NOTE: This is to make sure that you attach each repair patch with a minimum of three blind rivets.

2 The distance between the heads of the blind rivets and the parts of the bulk cargo-door structure is 6.40 mm (0.25 in.) minimum.
3 You do not make marks in the areas with a contour radius of less than 100 mm (3.94 in.).
4 The distance between all the marks is the same and between 20 mm (0.79 in.) and 50 mm (1.97 in.) (dimension A).
(c) At each mark, drill holes through the repair patches and the bulk cargo-door lining.
(d) Make sure that the diameter of the holes is the same as the diameter of the blind rivets that you use ( 3.2 mm (0.13 in.) or 4 mm (0.16 in.)).
(e) Remove all the loose particles and the dust from around the holes.
(f) Clean the area around the holes with Non Aqueous Cleaner-- Isopropyl Alcohol - (Material No.08BBD1) and the Textile-Lint free Cotton - (Material No.14SBA1) .
(g) Let the area dry for a minimum of 15 minutes.
(h) Put a washer (for example, ASNA 0113-32) at each hole, on each side of the bulk cargo-door lining.
(i) Use the GUN - FASTENER to install each blind rivet (for example, NAS 1919 C04) on the front side of the bulk cargo-door lining.
(15) Install the blind rivets on the rear side of the bulk cargo-door lining:
(a) If possible, do not install the blind rivets in the area with VELCRO tape.
(b) Make marks to identify the correct positions of the blind rivets.
(c) Make sure that:
1 You make a minimum of three marks.

NOTE: This is to make sure that you attach each repair patch with a minimum of three blind rivets.

2 When the bulk cargo door is closed, the distance between the heads of the blind rivets, the door frame lining and the cargo loading system is 25.4 mm (1.00 in.) minimum.
3 When the bulk cargo door is closed, the distance between the heads of the blind rivets and the cargo container is 50.8 mm (2.00 in.) minimum.
4 You do not make marks in the areas with a contour radius of less than 100 mm (3.94 in.).
5 The distance between all the marks is the same and between 20 mm (0.79 in.) and 50 mm (1.97 in.) (dimension A).
(d) At each mark, drill holes through the repair patches and the bulk cargo-door lining.
(e) Make sure that the diameter of the holes is the same as the diameter of the blind rivets that you use ( 3.2 mm (0.13 in.) or 4 mm (0.16 in.)).
(f) Remove all the loose particles and the dust from around the holes.
(g) Clean the area around the holes with Non Aqueous Cleaner-- Isopropyl Alcohol - (Material No.08BBD1) and the Textile-Lint free Cotton - (Material No.14SBA1) .
(h) Let the area dry for a minimum of 15 minutes.
(i) Put a washer (for example, ASNA 0113-32) at each hole, on each side of the bulk cargo-door lining.
(j) Use the GUN - FASTENER to install each blind rivet (for example, NAS 1919 C04) on the rear side of the bulk cargo-door lining.
(16) Install a spacer around each blind rivet on the rear side of the bulk cargo-door lining:
(a) Make a spacer of Adhesive Film Tape-- Film PTFE - (Material No.05RAJ9) with a thickness of 3 mm (0.12 in.) minimum.
(b) Make sure that:
1 Each spacer has a width of 22 mm (0.87 in.) minimum (dimension H).
2 The diameter of the hole of each spacer is between 11 mm (0.43 in.) and 12 mm (0.47 in.) (dimension K).
3 The spacer is 0.5 mm (0.02 in.) longer than the head of the blind rivet (dimension J).
(c) Apply Pore Filler Polyurethane-- - Furnishing (Material No.04BAM6) and Top Coat Polyurethane-- Decorative Furnishing (Material No.04JMD9) on the area around the holes to repair the surface protection.
(d) Clean the area around the holes with Non Aqueous Cleaner-- Isopropyl Alcohol - (Material No.08BBD1) and the Textile-Lint free Cotton - (Material No.14SBA1) .
(e) Let the area dry for a minimum of 15 minutes.
(f) Put a spacer around each blind rivet and bond it to the bulk cargo-door lining.
(g) Make sure that the spacers do not touch the blind rivets.
(17) Complete the repair:
(a) Apply Pore Filler Polyurethane-- - Furnishing (Material No.04BAM6) and Top Coat Polyurethane-- Decorative Furnishing (Material No.04JMD9) on the repaired area, on each side of the bulk cargo-door lining (this includes the heads of the rivets and the washers).

NOTE: This is to repair the surface protection of the bulk cargo-door lining.

NOTE: You can use only Top Coat Polyurethane-- Decorative Furnishing (Material No.04JMD9) , but the surface protection will not be as good as if you use the two materials.

(b) If necessary, repair or replace the VELCRO hook tape ( ABS1133D) or the VELCRO loop tape ( ABS1133C) on the lining or the door structure:
1 Clean the bonding area with Non Aqueous Cleaner-- Isopropyl Alcohol - (Material No.08BBD1) and the Textile-Lint free Cotton - (Material No.14SBA1) .
2 Use the PAINTBRUSH to apply Adhesive Primer-Pressure Sensitive Adhesive - - (Material No.05WBA1) on the bonding area.
3 Apply pressure with your hand to bond the loop tape or the hook tape on the lining or the door structure.
(18) Install the applicable insulation mat:
(a) Clean the repaired area with Non Aqueous Cleaner-- Isopropyl Alcohol - (Material No.08BBD1) and the Textile-Lint free Cotton - (Material No.14SBA1) .
(b) Let the area dry for a minimum of 15 minutes.
(c) Install the applicable insulation mat on the repaired bulk cargo-door lining.
(d) If necessary, make cutouts in the insulation mat for the heads of the rivets
(19) Weigh the insulation mat (for example, with sandbags) for 24 hours at room temperature before you install the bulk cargo-door lining.

NOTE: This is to make sure the insulation mat is tightly attaches to the bulk cargo-door lining.

5. Close-up
Subtask 52-33-13-410-052-A

A. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Install the repaired bulk cargo-door lining (Ref. AMM TASK 52-33-13-400-001).
(3) Install the door net at the opening of the bulk cargo door.
(4) Install the divider net at FR59.
(5) Close the aft cargo-compartment door (Ref. AMM TASK 52-30-00-860-002).
(6) Remove the access platform(s).

[Rev.10 from 2021] 2026.04.02 06:28:06 UTC