CMM-030 Floor Panels REV U

Stefan Kloppenborg Digitally signed by Stefan Kloppenborg
Date: 2020.05.26 12:45:00 -04'00'

COMPONENT MAINTENANCE MANUAL
FLOOR PANEL REPAIRS FOR THE BOMBARDIER DHC-8 SERIES 400 AND
CRJ-700/900/1000
Bombardier Floor Panels CMM List of Revisions Doc. No.: COMCMM-030
Issue Date Page Paragraph Reason for Revision

A 02-05-03 All Original Issue
B 02-05-04 All i) Addition of silicone pad damage type to Table 5 of Section

6.0.
ii) Addition of silicone pad allowable damage to Table 6 of
Section 7.0.
iii) Addition of silicone pad repair/installation instruction in
Section 10, Subsection 10.10.
iv) Clarification of sundry items in Table 3 and Table 4 of
Section 5.0.
v) Miscellaneous formatting updates.
B1 4-Mar-05 All i) Added comments from Bombardier Flammability DAD, and

interim report note into Section 2.0.
ii) Updated material sources in Table 3 & Table 4.
iii) Added Edge Tape Permacel P29-14091 to Repair Materials.
Deleted references to 3M474-3 from Repair Procedures.
iv) Updated Section 10.6 for swaged titanium inserts.
v) Separated Appendix B into Appendices B, C, and D.
vi) P/N correction for Thru Swaged Insert used in Carbon Panels;
Kit No., COMFPRK-508 (Appendix C, page 38). P/N was
SL5170T3-410 and is now SL5107T3-410.
vii) Miscellaneous formatting updates.
C 17-Nov-08 4-8, i) Removed Edge Tape 3M474-3

10, ii) Listed suppliers and removed Comtek Advanced Structures
13, as raw material supplier.
17, iii) Repair to dents and punctures greater than 1” to one skin
21, damage
31, iv) Scrim Ply allowable - damage/repair
33, v) Limitation to the size of panel repair
35, vi) Repopulate part’s list
39-46 vii) Removed repair kit prices and repopulated items in kits to
reflect thickness properties.
D 31-Mar-09 4, i) Added CRJ 1000 parts list.
33, ii) Added Q400 -610 and -611 panels.
44-45 iii) Added PSA-Silicone adhesive specs and supplier.
E 19-Oct-09 40, 41, 43, i) Updated CRJ 700/900/1000 parts list
44-45
F 16-Feb-10 4, i) Added Nitto 223S Flame tape and Bisco HT-805(A) foam tape
42, availability.
44 ii) Updated CRJ 700/900/1000 parts list.
G 30-Mar-10 41,43 i) Added PNs: C B7 31691 1; C B7 31692 1; C B7 31693
1; C S9 33439 31; C S9 33456 17 & C S9 33460 31
H 27-May-10 3, i) Updated specs for EPTFE/PTFE and 223S tapes for CRJ
6, application.
23, ii) Added Nitto 223S callout for Repair/Installation of Edge Tape
26, for Carbon Panels.
30-33, iii) Added punch and anvil tools for swage inserts.
41, iv) Added PNs: C B7 33433 1, C B7 33434 1,
49-50 C B7 33435 1, C B7 33436 1, C B7 33437 1,
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Issue Date Page Paragraph Reason for Revision
C B7 33438 1, C B7 33440 1 & C B7 33441 1
v) Added new repair kits and updated DHC-8 S400 part numbers
affected.
J 2-Apr-13 4, 6, 13,15, i) Updated supplier contacts for Magnobond 6162, sealant and
17-20, Dash-8’s Silicone pads spec and contact
22, 24, ii)Added Magnobond 6162 callout
29-33, iii) Figure callout SB Fig. 10 was Fig. 8
33-34, iv) Added BA PN for DHC-8 S400 part numbers
42-47, v) Added New DHC-8 S400 part numbers
52-65 vi) Added New CRJ part numbers
vii) Updated MSDS 105 and 118
K 9-Mar-15 7 i) Table 4: Added new items
14 ii) Sec 9.7: Revised title of section
14 iii) Sec 9.7: Added Nitto 223S
15 iv) Sec 9.7 Installation of Packers & Shims
23 v) Revised Titanium insert cleaning process
35-48 vi) Appendix C: Added new P/N
L 24-Jun-15 26 i) Sec 10.11: Revised entire replacement steps
33 ii) Appendix B: Revised Repair Kit Number of Selected P/N
34-35 iii) Appendix B: Added new P/N for Cargo Combi Conversion
43 iv) Appendix C: Added new P/N for CRJ
M 11-May-17 4, 6 i) Removed 3K-70-PW carbon fabric from Table 3 & 4, and
removed 7781 Style glass fabric from Table 3.
46 ii) Appendix C: Added new CRJ P/N: C C7 33200 15
36 iii) Appendix B: Added new P/N: CMKD8400FP-734
46 iv) Appendix C: Added new CRJ P/N: C C7 31650 1
14, 15, 27 v) Remove reference to manufacturing drawings
37 vi) Added Appendix B.1: DHC-8 SERIES 400 SEALANT TAPE
& SILICONE PAD REFERENCE
4 vii) Table 3: Split Foam Sheet into separate lines for each thickness
N 06-Nov-17 23 i) Step 2: Changed pH reading from 2.0-2.4 to 2.1-2.6.
P 29-Nov-17 46 i) Appendix C: Added new part numbers for CRJ
R 15-Aug-18 46 i) Appendix C: Added new part numbers for CRJ

15, 17, 18, ii) Updated section callout in sections 9.8, 10.2, 10.3, 10.4, 10.5
19, 20
T 6-Nov-18 4-5 i) Update insert callout in table 3.
17, 18, 19, ii) Update repair verbiage to be clearer in sections 10.2, 10.3,
20 10.4, 10.5, 10.6
17, 18, 19, iii) Update material callouts in Figures 4-8
20
46 iv) Appendix C: Added new part numbers for CRJ
53 v) Update insert callout in Appendix D.
U 22-May-20 10 i) Update wording of Edge filler allowable damage limit
definition.
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TABLE OF CONTENTS
1.0 Purpose .............................................................................................................................................. 1

2.0 Scope ................................................................................................................................................. 1
3.0 Health and Safety .............................................................................................................................. 1
4.0 Facilities and Equipment ................................................................................................................... 1
5.0 Raw Materials ................................................................................................................................... 3
6.0 Inspection Procedures ....................................................................................................................... 8
7.0 Allowable Damage .......................................................................................................................... 10
8.0 Repairable Damage Limits .............................................................................................................. 10
9.0 General Repair Procedures .............................................................................................................. 11
9.1 Damage Removal ........................................................................................................................ 11
9.1.1 Paint Removal ........................................................................................................................ 11
9.2 Decontamination ......................................................................................................................... 11
9.3 Repair Plug Fabrication .............................................................................................................. 12
9.4 Mixing of Epoxies ...................................................................................................................... 12
9.5 Repair Plug Bonding and Curing ................................................................................................ 13
9.6 Post Cure Inspection ................................................................................................................... 14
9.7 Installation of Edge Seal Tapes, Foam Tapes, Packers, Shims and Pads .................................... 14
9.8 Finishing ..................................................................................................................................... 15
10.0 Specific Repair Procedures ............................................................................................................. 15
10.1 Repair to Dents and Punctures Less Than 1” Diameter .............................................................. 15
10.2 Repair of damage greater than 1” to only one skin – Non-Mat Overlay Glass Panels and Carbon
Panels .......................................................................................................................................... 17
10.3 Repair of Damage Greater than 1” to One Skin and Core – Non Mat Overlay Glass Panels and
Carbon Panels ............................................................................................................................. 18
10.4 Repair of Damage Greater than 1” to Two Skins and Core – Non Mat Overlay Glass Panels and
Carbon Panels ............................................................................................................................. 19
10.5 Repair of Skin and Core Damage to Mat Overlay Panel, Greater than 1” in Diameter .............. 20
10.6 Repair of Scrim ply damage to COMPS-027 carbon HSP panels .............................................. 21
10.7 Replacement of Inserts ................................................................................................................ 22
10.8 Repair of Lifting/Torn Mat Overlay ........................................................................................... 24
10.9 Repair/Installation of Edge Filler for Glass Panels ..................................................................... 25
10.10 Repair/Installation of Edge Tape for Carbon Panels ................................................................... 26
10.11 Repair/Installation of Sealant Tape ............................................................................................. 26
10.12 Repair/Installation of Pads .......................................................................................................... 27
10.13 Repair of Skin Delamination ...................................................................................................... 27
10.14 Temporary Repair of Skin .......................................................................................................... 27
APPENDIX A – Tap TEST PROCEDURE .................................................................................................. 29
APPENDIX B – DHC-8 SERIES 400 PART NUMBER & REPAIR KIT CROSS REFERENCE .............. 30
APPENDIX B.1 – DHC-8 SERIES 400 SEALANT TAPE & SILICONE PAD INSTALLATION ............ 37
APPENDIX C – CRJ-700/900/1000 PART NUMBER & REPAIR KIT CROSS REFERENCE ................ 38
APPENDIX D – CRJ-700/900/1000 AND DHC-8 SERIES 400 REPAIR KIT CONTENTS ..................... 52
APPENDIX E – MATERIAL SAFETY DATA SHEETS (MSDS’s) .......................................................... 56
LIST OF FIGURES
Figure 1 – Allowable Temperature and Humidity Conditions ........................................................................ 2
Figure 2 – Evaluation of Damage Size ............................................................................................................ 9
Figure 3 – Core Ribbon Direction ................................................................................................................. 12
Figure 4 – Repair of Punctures and Dents less than 1” Diameter .................................................................. 16
Figure 5 – Repair of Damage to only one-skin.............................................................................................. 17
Figure 6 – Repair of Damage to One Skin and Core – non mat overlay ....................................................... 18
Figure 7 – Repair of Damage to Two Skins and Core – non mat overlay ..................................................... 19
Figure 8 – Repair of Damage to Mat Overlay Panel ..................................................................................... 20
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Figure 9 – Scrim ply layer repair – one for one ............................................................................................. 21
Figure 10 – Potted Insert Installation ............................................................................................................ 22
Figure 11 – Swaged Insert Installation for CRJ-700/900/1000 Panels .......................................................... 23
Figure 12 – Repair of Lifting/Torn Mat Overlay ........................................................................................... 24
Figure 13 – Repair / Installation of Edge Filler ............................................................................................. 25
Figure 14 – Temporary Repair of Skin Dents & Punctures – less than 4 Sq. inches ..................................... 28
Figure 15 – Tap Test Scan Pattern................................................................................................................. 29
Figure 16 – Typical Placement of Silicone Pad #50416 and Foam Tape HT-805(A) GRAY .188 ............... 37
Figure 17 – Typical Placement of Silicone Pad #50313 and Foam Tape HT-805(A) GRAY .063 ............... 37
Figure 18 – Typical Silicone Pad Placement Relative to Insert Location...................................................... 37
LIST OF TABLES
Table 1 – Shop Equipment .............................................................................................................................. 2
Table 2 – Consumable Materials ..................................................................................................................... 3
Table 3 – Repair Materials for DHC-8 Series 400 Passenger and Cargo Floor Panels ................................... 4
Table 4 – Repair Materials for CRJ-700/900/1000 Passenger and Cargo Floor Panels .................................. 6
Table 5 – Damage Types and Inspection Methods .......................................................................................... 8
Table 6 – Allowable Damage ........................................................................................................................ 10
Table 7 – Epoxy Data .................................................................................................................................... 13
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1.0 Purpose
The intent of this manual is to supply technical data for the maintenance and repair of Comtek
manufactured floor panels for the production Bombardier DHC-8 Series 400 and CRJ-700/900/1000
aircraft.
2.0 Scope
This manual will establish allowable damage limits, repairable damage limits and repair procedures,
including the materials and equipment required to carry out repairs.
The repairs incorporated in this CMM show compliance with the applicable Flammability requirements of
FAR 25.853 and 25.855, by similarity to Flammability Test Specimen configurations previously tested in
prior approved and accepted Flammability Test Programmes with Transport Canada Civil Aviation.
3.0 Health and Safety

Composite materials can be hazardous to one’s health if not handled properly. The manufacturers’
Material Safety Data Sheet (MSDS) should be carefully reviewed before using any of the repair materials
listed in this manual. The MSDS will provide specific details on protective equipment, first aid and
characteristics of the material.
The following are only general guidelines for working with composite materials.
Epoxies
• Use in well ventilated areas.
• Do not contact skin or eyes. Use protective gloves; barrier creams will not provide sufficient
protection and will contaminate the repair bond-line.
• Thoroughly wash hands with soap before eating, smoking, going to the washroom or going home
Composite Panels
• Protect skin, eyes and respiratory system from dust when drilling, sanding or cutting.
• Use a vacuum cleaner to capture dust generated by tools at the source.
• Carbon fibre panels should only be machined using air driven tools. Carbon dust is conductive and
will short-circuit electric motors.
• Thoroughly wash hands with soap before eating, smoking, going to the washroom or going home.
4.0 Facilities and Equipment

The repair lay-up area must be controlled. As a minimum, the area must be free from airborne dust,
moisture, oil-mist and exhaust fumes. The repair area temperature and humidity must be in the range given
in Figure 1, as seen on the following page. All tools used in the repair process must be clean and free of
dirt, grease and oils to ensure the bond-line is not contaminated.
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Figure 1 – Allowable Temperature and Humidity Conditions
Table 1 – Shop Equipment

DESCRIPTION SOURCE NOTES
die grinder Commercial
2” sanding mandrel commercial
2” sanding discs 60-80 grit Commercial
fibreglass routing bit 23125000D Norvic tooling 514 745 7144 ¼” dia., flat bottom bit
weigh scale Commercial 0.1gram accuracy, minimum
capacity 200 grams
measuring scale Commercial 24”
isband caliper or Commercial 0.001” accuracy
micrometer
air drill Commercial
3/16” drill bit Commercial high speed steel
hole saw US Industrial 800 521 4800 0.562” dia. Hole saw (diamond or
carbide grit) with 3/16” pilot
vacuum cleaner Commercial
c-clamps and rigid plates or 50 lb Commercial
shot bag
sharpie marker © Commercial
Spatula Commercial
vacuum pump or isband Airtech 310 603 9040
(if vacuum bag is used)
vacuum gauge Airtech 310 603 9040 0”-30” Hg
vacuum port Airtech 310 603 9040
SL5107-3P Shur-Lok Punch – tooling for swage
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titanium insert SL5107T3-
410SP8
SLT5107-3ASP5 Shur-Lok Anvil – tooling for swage
titanium insert SL5107T3-
410SP8
The sources provided are only examples. There are many suppliers with equivalent materials that can be
acceptably used.
5.0 Raw Materials

Table 2 – Consumable Materials
mixing cups Commercial Mixing cups must not have a wax
or silicon coating on the inner
surface. Cups must be resistant
to the base and hardener resin
components.
Stir sticks Commercial Popsicle sticks or tongue
depressors
10 cc syringe Pharmacy
release film A4000R Airtech 310 603 9040
vacuum bagging materials Airtech 310 603 9040
(optional)
latex gloves Commercial
dust mask or respirator with dust Commercial
cartridge
flash breaker tape Airtech 310 603 9040
MEK or Acetone Commercial
Cotton wipes Commercial Must be clean and lint free
The sources provided are only examples. There are many suppliers with equivalent materials that can be
used.
The repair materials listed in Table 3 and Table 4, on the following pages, must be used to accomplish the
repairs described in this manual – no substitutions are permitted. The materials have been rigorously tested
to ensure the repairs will meet all of the structural and flammability requirements. Failure to comply will
result in a sub-standard, unapproved repair. The materials must be stored in accordance with the
manufacturers’ instructions.
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Table 3 – Repair Materials for DHC-8 Series 400 Passenger and Cargo Floor Panels
MATERIAL SOURCE NOTES
EA 9309.3 paste adhesive Dexter HYSOL (415) 687-4201 BMS 5-109, Type 1,
E.B. Peerless LTD (905) 362-1151 Class 1
Wolcott Park (585) 342-3120
Graco Supply (817) 534-1127
120 style glass Northern Fiberglass Sales, Inc. BMS 9-3, Type D, Class 4
(603) 926-1910 or AMS-C-9084, Class 2,
Type 3 or equivalent.
Epocast 50A1/9816 E.B. Peerless LTD BMS 8-201, Type 3
(905) 362-1151
Magnobond 92-1 edge filler Glotrax (905) 377-1441 BMS 5-28, Type 18,
Magnolia US (800) 831-8031 Class 1
Aluminum Tape 3M425 E.B. Peerless Ltd. Used as outer layer for the
(905) 362-1151 temporary repair of floor
panel skin as outlined in
Subsection 10.14.
Edge Tape Permacel P29-14091 JOLI Distribution -14901 indicates internal
(514) 335-3172 colour code for Permacel
P29 Grey
Edge Tape Nitto 223S JOLI Distribution
(514) 335-3172
Foam Sheet MF Siltec 63, Magnifoam Technology INC
Part No. . . .060-8-12 SH (905) 564-9700
Foam Tape MF Siltec 63, Magnifoam Technology INC

Part No. . . .060-8-12 RL (905) 564-9700
Foam Tape MF Siltec 200, Magnifoam Technology INC
Part No. . . .190-8-12 RL (905) 564-9700
Foam Sheet/Tape Bisco HT-805(A) Rogers Corporation

Part No. . . . HT-805(A) GRAY .063
Foam Sheet/Tape Bisco HT-805(A) Rogers Corporation

Part No. . . .HT-805(A) GRAY .188
Silicone Pad Freudenberg-Nok INC .202 Thick – can be used to

Part No. 50416 (519) 842-6451 create a 3.0 x 3.0x .202 or
3.0 x 1.5 x .202 pads
Silicone Pad Freudenberg-Nok INC .063 Thick – can be used to
Part No. 50313 (519) 842-6451 create a 3.0 x 3.0 x .063 or
3.0 x 1.5 x .063 pads
PSA-529/SRC-18 SILCHEM INC. DHMS A6.13
Adhesive, Contact, Silicone (905)709 5867
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Composite panel repair plug of Comtek Advanced Structures. Pertinent types are:
pertinent type. Only available for COMPS-027 Type 3,
sizes listed on repair kit. Refer to COMPS-027 Type 4,
Appendix D for repair kit listings COMPS-028 Type 1,
COMPS-028 Type 2,
COMPS-028 Type 3,
COMPS-028 Type 4,
COMPS-028 Type 5, and
COMPS-028 Type 6
INSERTS M&M Aerospace Hardware
(305) 592-5155
NAS1833C3-295 thru threaded
NAS1833C3-400 thru threaded Shur-Lok Corporation
NAS1834C3-295 thru (949) 474 6000
NAS1834C3-400 thru
NAS1834C3-540 thru The Young Engineers
NAS1834C3-585 thru (949) 581-9411
NAS1834C3K-295 csk thru
NAS1834C5-535 thru
NAS1835C3 blind floating threaded
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Table 4 – Repair Materials for CRJ-700/900/1000 Passenger and Cargo Floor Panels
EA 9309.3 paste adhesive Dexter HYSOL (415) 687-4201
E.B. Peerless LTD (905) 362-1151
Wolcott Park (585) 342-3120
Graco Supply (817) 534-1127
Magnobond 6162 A/B paste adhesive Magnolia (800) 831-8031 QPL CMNP008 Type I,
Nancy Foltz (770) 451-2777 Class A.
Clay Plavcan (770) 451-2777
EA 956 adhesive resin Dexter HYSOL (415) 687-4201 Used as adhesive resin, in
E.B. Peerless LTD (905) 362-1151 small quantities, in the
Wolcott Park (585) 342-3120 repair of minor
Graco Supply (817) 534-1127 delaminated skin as
outlined in Subsection
10.11.
Epibond 420 insert adhesive Ciba 1-800-367-8793 For Ti inserts (SL5107T3-
Dexter HYSOL/E.B. Peerless 410)
Wolcott Park/Graco Supply
Magnobond 74-3 insert adhesive Glotrax (905) 377-1441

Magnolia US (800) 831-8031
Magnobond 92-1 edge filler Glotrax (905) 377-1441
Magnolia US (800) 831-8031
120 style glass Northern Fiberglass Sales, Inc. BMS 9-3, Type D, Class 4
(603) 926-1910 or AMS-C-9084, Class 2,
Type 3 or equivalent.
Epocast 50A1/9816 E.B. Peerless LTD BMS 8-201, Type 3
(905) 362-1151
Aluminum Tape 3M425 E.B. Peerless Ltd. Used as outer layer for the
(905) 362-1151 temporary repair of floor
panel skin as outlined in
Subsection 10.12.
ScotchWeld DP100FR 3M Used as core filler, in small
1-800-364-3577 quantities, in the repair
outlined in Subsection
10.1.
Solvent ALUMIPREP 33 Henkel Canada Corp. For Ti inserts (SL5107T3-
(416) 743-8811 410)
Edge Tape Permacel P29-14091 JOLI Distribution -14901 indicates internal
(514) 335-3172 colour code for Permacel
P29 Grey
Edge Tape Nitto 223S JOLI Distribution
(514) 335-3172
EPTFE Sealant Tape (PG06510100) Inertech Inc. AMS 3255, 06510100
626-282-2000 indicates .065” thick x
1.00” wide x 100’ long.
PTFE Tape (GUA 1301-1) Gore AMS 3255, alternative to
EPTFE Sealant Tape
(PG06510100)
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Composite panel repair plug of Comtek Advanced Structures. Pertinent types are:
pertinent type. Only available for COMPS-022 Type 1,
sizes listed on repair kit. Refer to COMPS-022 Type 2,
Appendix D for repair kit listings. COMPS-027 Type 3,
COMPS-027 Type 4,
COMPS-028 Type 1, and
COMPS-028 Type 6
INSERTS M&M Aerospace Hardware
(305) 592-5155
NAS1833C3-400 thru threaded
NAS1834C08-400 Shur-Lok Corporation
NAS1834C3-400P (949) 474 6000
SL5107T3-410 spacer The Young Engineers
SL618-3CM (949) 581-9411
Kydex Shim Comtek Advanced Structures Various sizes

Packers Comtek Advanced Structures Various sizes
Pressure Sensitive Adhesive (PSA) Flexcon Adhesive used to bond
(2178SL DLC-503-78MO) (508) 885-8200 Kydex Shim or Packer to
floor panel
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6.0 Inspection Procedures

There are three primary categories of typical structural damage to the honeycomb sandwich – broken skin,
delaminated skin and soft core. Often a damage site will contain all three of the damage types.
To give a panel a thorough inspection, the inspector will require the panel to be clean and in a well-lit area.
The following table gives a description of these damage types and how to detect them.
Table 5 – Damage Types and Inspection Methods

Damage Type Description Inspection Method
Broken skin May include punctures, cuts and cracks. Visual
(upper or lower)
Skin -skin may be blistered, but not always. Visual + tap testing *
delamination -delamination often occurs in dented areas.
(upper or lower) -on glass skinned panels the skin looks white in delaminated
area.
Scrim ply -delamination Visual

damage (Carbon -tear
panels only)
Soft core -present wherever core is dented. Visual + tap testing *
-skin may or may not be bonded. + squeezing and
-panel will feel ‘squishy’; squeezing or flexing the panel will flexing
result in a crunching sound.
Disbonded mat -the mat overlay is the abrasion resistant layer on top of high Visual
overlay impact panels.
-mat isbanding will typically occur at an edge of a panel.
Disbonded areas of mat will quickly be broken off in service.
Looking at the edge of the panel will reveal a gap between the
mat and top skin if the mat is delaminated.
Edge filler Edge filler can become cracked and loose or be missing Visual
locally.
Edge Tape May include tears, peels or punctures. Visual
Inserts -inserts can become loose and/or pulled out. Visual + check threads
-threaded inserts may have damaged threads, screws may with appropriate sized
have seized into the insert. screw
Pad Silicone pad may have holes. Visual
* see Appendix A for tap test procedure.
Determining the damage size and proximity to panel features and repairs is critical in deciding on the
applicable repair. Damage sizing and location are illustrated in Figure 2, on the following page.
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Figure 2 – Evaluation of Damage Size
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7.0 Allowable Damage

Table 6 – Allowable Damage
Damage Type Allowable Damage Limit
Dents Damage to the floor panel is expected over its service life. Dent damage that does not
puncture or break fibres in the skin and does not result in a delamination will not impact
the functionality of the floor panel. For a dent to be classified as allowable it must be
less than 1” diameter and no greater than 0.100” deep. Each panel is allowed to contain
a maximum of 8 dents, where the distance between any two dents is not less than 3”.
Punctures & No broken skin is allowed. Broken areas of 1” diameter or less can be repaired by
broken or Section 10.1. The 10.1 repair can be used once per square foot; 10.1 repairs must be
dented skin separated by a minimum of 4 inches edge to edge.
(upper or lower)
A temporary repair of damage (punctures/dents) less than 4 square inches is permissible
using Section 10.14 provided that no dimension of the damage is greater than 4”. The
temporary repair must be removed and replaced with a permanent repair within 250
flight hours.
Two temporary repairs are permitted on a panel at the same time. The repairs must be
separated by at least 10”.
Skin Skin delaminations less than 1” in diameter are allowed. A panel may have up to 3
delamination delaminations per square foot but all delaminations must be separated by 6 inches and
(upper or lower) must be at least 1.5 inches from any edge, insert, or repair.
Scrim Ply For COMPS-027 carbon HSP panels, damage is limited to the glass scrim ply only and
Damage not to exceed 10% of the panel area.
Soft core Same as skin delamination.
Disbonded mat Disbonding of the mat overlay is not desirable since it serves to protect the panel from
overlay impact damage. It may be temporarily repaired with high-speed tape (see Figure 14)
and should be permanently repaired within 250 flight hours.
Edge filler A maximum of 10% of the edge filler is permitted to be cracked or missing.
Edge tape Tears, peels or punctures are not allowed in edge tape.
Inserts Unserviceable inserts are not allowed.

Pad Redundant holes are allowed in silicone pads.
8.0 Repairable Damage Limits

The maximum skin/core repair area per panel is 144in². There are no limits to other permanent repairs
given in this manual. Multiple repairs to a panel are permitted but must not overlap.
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9.0 General Repair Procedures

Many of the various repair procedures described here used common processes i.e. drying, damage removal
etc. The processes are described below in detail and referenced in the specific repair description. Using
the methods described in Section 6.0 ‘Inspection Procedures’, mark out the full extent of the damage. If the
damage removal will encompass any inserts or changes in panel profile, make a template of the affected
details before beginning the damage removal.
9.1 Damage Removal

Remove the damaged skin(s) and underlying core in the area previously marked out, being careful not to
gouge or score any undamaged material. Figure 6 through Figure 9 show the appropriate skin and core
removal for various damage and panel types.
To simplify the repair it is best to make the cut-outs a regular shape such as a circle or square with ½”
radius corners. Use the routing bit to cut the skin and remove the core. The core should be removed to the
opposite skin and sanded down far enough to remove the gloss from the film adhesive; the pattern of the
honeycomb will still be visible. When removing damage from a mat overlay panel where a repair plug will
be used, ensure that the top skin and mat overlay are left intact, with the exception of top skin/mat damage.
Remove only the bottom skin and core to create the interior bond surface. The skin surrounding the cut-out
should be lightly scuffed with 120 grit sand paper, if the panel is painted the paint must be completely
removed in the bonding area.
9.1.1 Paint Removal

It is important to remove paint in the bond areas to ensure the strength and longevity of the repair. DO
NOT USE CHEMICAL PAINT STRIPPERS. Paint strippers, solvent, thinners, etc. will react with the resin
of the skin face resulting in damage to the panel. Only remove paint via mechanical means. Use an orbital
sander or die grinder, with 120 grit sand paper, to remove any paint, avoiding damage to the skin fibres.
9.2 Decontamination
The key to a successful bonded repair is the cleanliness of the bonding surfaces. Panels will become dirty
after being in service and any breaks in the skin or edge filler will allow moisture and dirt ingress for the
panel.
If the panel is wet after the damage removal, dry the panel using a heat gun, halogen lamp or oven. The
temperature must not exceed 150F. If the equipment is available, vacuum bagging during the dry cycle is
the preferred method.
Once the panel is completely dry, wipe the bonding areas with a clean white rag wetted with MEK or
acetone. MEK and acetone are extremely dangerous, review and follow the MSDS sheets for MEK and
acetone. Wipe the panels until no trace of contamination remains. Do not allow solvent to stand on panel.
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9.3 Repair Plug Fabrication

Determine the ribbon direction of the damaged panel as shown in Figure 3. The repair plug must be cut out
with the ribbon in the same direction. Use Figure through Figure to determine the details of the repair
plug. The plug should fit the panel cut-out snugly so that there is no play between the plug and the panel.
In the area where the core is removed from the original panel and the plug, the inner surface of the skin
must be scuffed until the film adhesive is no longer glossy, the pattern of the honeycomb will still be
visible. The bottom surface of the plug must be lightly abraded to ensure bond adhesion. The fibres of the
skin must not be damaged. Test fit the plug into the panel to be repaired to ensure a snug fit on all edges.
Mask around repair patch with flash breaker tape on exterior faces, leaving 1/16 of an inch between edge of
repair plug and the tape. Further mask the repair plug to its edges with flash breaker tape on exterior faces.
Figure 3 – Core Ribbon Direction
9.4 Mixing of Epoxies

Contact with epoxies will cause dermatitis. A basic understanding of handling techniques is important for
their safe use. The major consideration in the control and prevention of this problem is to use the materials
with care. Generally speaking, PROPER VENTILATION AND GOOD HOUSEKEEPING ARE
ESSENTIAL. Prevention rather than cure is the successful approach when handling any chemical product.
Technicians must follow the specific MSDS for the materials being used.
Structural fillers and paste adhesives for structural bonding must be mixed in a clean environment as
described in Section 4.0 ‘Facilities and Equipment’.
Verify that material is not time expired. Visually inspect material for irregularities i.e. lumps,
crystallization, cloudiness, if any are found contact manufacturer for disposition.
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Two part epoxies will always be measured by mass as opposed to volume. Measuring by volume will
require temperature corrections of the mix ratio.
Determine the quantity of material required for the task; never mix batches larger than 200g. Large batches
will experience an exothermic reaction that can result in fire. Calculate the quantity of base and hardener to
give the proper mix ratio for the desired batch size.
Before dispensing base or hardener it is important to stir the entire can of material. This is especially
important when dealing with paste adhesives and potting compounds, in these materials the densest
components will settle to the bottom. Put the base component of the epoxy into the mixing cup first. Then
put in the correct amount of hardener. The base and hardener must be measured to within +/- 0.2g.
Stir the base/hardener mixture with a new, clean stir stick. Stir the mixture for approximately 1 minute. Be
sure to use the stir stick to scrape the cup’s bottom and edges. Mixed epoxy should be a uniform colour
and texture.
The pot life or work life for an epoxy is the amount of time after mixing to use the epoxy. It is critical that
the epoxy is applied within the pot life and not disturbed again until cured. The table below gives
information on the epoxies used in these repairs.
Table 7 – Epoxy Data

MATERIAL USE MIX RATIO POT CURE TO CURE TIME
LIFE HANDLE
A B @ 70F
EA9309.3 A/B Adhesive 100 22 35 min. 12 hr @ 77F 3 days @ 77F
OR 2 hr @ 150F
EA 956 Adhesive 100 58 N/A 24 hr @ 77F 5-7 d @ 77F
OR 1 hr @ 200F
Magnobond 6162 A/B Paste Adhesive 100 40 30 min 6-8 hr @ 75F 7 days @ RT or can
be heat cured
Magnobond 74-3 Insert 100 25 20 min. 12 hr @ 77F 7 days @ 77F
Adhesive
Epibond 420 Insert 100 40 80 min. 20 min. @ 7 days @ 77F
Adhesive 77F OR 4 hr @ 125F
Magnobond 92-1 A/B Edge 100 20 12 min. 4 hr @ 77F 24 hr @ 77F OR
Potting/Filler 3 hr @100F
ScotchWeld Surface 100 98 5 min. 20 min. @ 24-48 hr @ 77F
DP100FR Potting 77F
Epocast 50-A1/9816 Laminating 100 14 65 min. 16-24 hr @ 5 days @ 77F
Resin OR 2 hr @ 170-
77F
200F
9.5 Repair Plug Bonding and Curing

Wipe the plug and panel with MEK or acetone before bonding. The plug and panel must be handled with
clean gloves for the rest of the bonding process.
Figure 4 through Figure 8 show where the EA9309.3 A/B (Magnobond 6162 as an alternative) adhesive
and the Magnobond 92-1 is to be applied. Coat the edge of the core in the panel and on the plug with
Magnobond 92-1. Brush on a thin layer of adhesive on the bonding faces of the panel and the plug. Press
the plug into the panel while Magnobond is still wet. Ensure the plug ribbon direction still matches the
panel ribbon direction. Wipe away any excess adhesive using a rag wetted with MEK or Acetone.
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Pressure must be applied to the bond area during the entire cure cycle. There are three methods to apply
the pressure; distributed weight, mechanical force and vacuum bagging. Whichever method is used, a layer
of plastic film must be placed between the repair and the pressure source to prevent the repair from bonding
to the pressure source.
• Distributed weight may consist of lead shot bags, stacks of books, etc. The distributed weight on
the plug must be at least 150 pounds per square foot. The panel must be fully supported on the
bottom and the weight applied to the repair area only on the top surface. To ensure a uniform
pressure distribution a rigid plate should be placed over the repair area.
• Mechanical force may be applied with clamps. Rigid plates must be used to distribute the
clamping force. Clamping with too much force will damage the panel. It is recommended that the
clamping method used be tried on a scrap piece of panel first to determine the amount of pressure
that will damage the panel.
• Vacuum bagging is the preferred method of pressure application. Vacuum pressure should not
exceed 15” Hg and be no less than 2.5”Hg. If the materials and equipment are available use this
method.
9.6 Post Cure Inspection

Tap test (see Appendix A) the repair area for voids and delaminations; neither are acceptable. If any are
found remove and rework the repair. The repair skin overlaps should be smooth and free of irregularities.
9.7 Installation of Edge Seal Tapes, Foam Tapes, Packers, Shims and
Pads
Preparation of Sandwich Panels

Clean off all dirt and dust that may exist on the sandwich panel surfaces and solvent wipe using methyl
ethyl ketone (M.E.K.). Ensure that all excessive adhesives and potting compounds that may have been
dropped on the bonding surfaces during edge and insert potting are removed prior to solvent wiping the
sandwich panel. In cases where edges are not potted, such as when applying edge seal tapes, ensure that all
dust and rough edges from routing process are removed and cleaned. The temperature range for the
installation of all tapes is 60F – 80F.
Installation of Edge Seal Tapes

After surface is free of any contaminants, mark off the desired location of tape edge on the panel surface
using a lead pencil or non-permanent marker with a straight edge. Install either 3M474-3, Permacel
P29-14091 or Nitto 223S edge tape from one end on one side of panel and tack down in a few spots while
locating its position. Smooth out tape along its length once it is in place, to ensure it adheres flat at all
locations, and that all bubbles are removed. Once the one side of the tape is in place, fold over the panel
edge and smooth down along its length to adhere to the sandwich panel honeycomb core. Repeat the
folding process, and smooth the remaining tape width along the opposite face of the panel. Corners are
overlapped and cut at a 90 angle. They are not mitred. Repair edge tape must overlap original tape by a
minimum of 1.0”.
Installation of Foam Tapes

Ensure bonding surface is clean, dust free and solvent wiped with MEK. Mark off the required location of
the foam tape using a lead pencil or non-permanent marker. If unsure of the location of the foam tape,
please contact Comtek for further assistance. Peel off the tape backing at one end. Locate and adhere at the
peeled end. Slowly pull off the remainder of the tape backing while at the same time locating and adhering
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the tape. Ensure that all air bubbles are squeezed out while working along the length of the tape. Repair
foam tape may be butt joined with any original tape.
Installation of Packers or Shims

Ensure bonding surfaces are clean, oil, grease and dust free, and solvent wipe with MEK. Cut and apply
double-sided adhesive tape or Pressure Sensitive Adhesive (PSA) to the bonding surface of the shim or
packer. This is not necessary for self-adhering shims or packers. Locate and apply the shim or packer with
clamping pressure until fully adhered.
Installation of Pads
Measure existing pads prior to removal and cut new pads to size. Ensure the bonding surface is clean, dust
free and solvent wiped with MEK prior application of pad bonding adhesive. Mark off the desired bonding
location for the pad using masking tape, lead pencil or marker. Apply an equal amount of specified 2 part
adhesive to the bonding surface on panel and the bonding side of the pad. Locate and install pad with
enough pressure to squeeze out any excessive adhesive. Allow the bonding adhesive to cure under pressure
clamps or weight (follow manufacturer’s curing specifications). Pads may also be self-adhering.
When stacking multiple pads on top of each other apply the above installation process and repeat for each
successive pad.
Inspection Requirements
Visually inspect the adhesion of tapes, packer and pads. Ensure tapes, packers and pads are clean, free of
dust, dirt, damage or adhesive flashing. Also inspect the edge quality and overlap details, i.e. clean, square,
and sharp cuts.
9.8 Finishing
The edges of the repair plug should be filleted with EA9309.3/Magnobond 6162 to prevent the edges of the
repair from protruding.
Any inserts, packers, or pads removed must be reinstalled per Sections:
Component Section
Inserts 10.7
Packers, Pads 9.7
10.12
If the repair plug replaced part of a potted panel edge it must be repotted per Section 10.9
Repair/Installation of Edge Filler for Glass Panels or Section 10.10 Repair/Installation of Edge Tape for
Carbon Panels.
It is not necessary to repaint the panels after the repair; this is left to the discretion of the operator.
10.0 Specific Repair Procedures
10.1 Repair to Dents and Punctures Less Than 1” Diameter

This repair is detailed in Figure 4.
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1) Remove damaged skin and core in accordance with 9.1.

2) Decontaminate damaged area per 9.2.
3) Verify damage size is less than 1.0” diameter.
4) Mix Magnobond 92-1 or ScotchWeld DP100FR per 9.4. Pack epoxy into damaged area ensuring
it penetrates any open cells in the core. Over fill the damaged area so that the repair sits proud
from the damaged skin and allow to cure per 9.4.
5) Sand the cured Magnobond 92-1 or ScotchWeld DP100FR flush with the surrounding skins.
6) For edge damage, replace edge tape and sealant tape per 9.7, where required.
Figure 4 - Repair of Punctures and Dents less than 1” Diameter
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10.2 Repair of damage greater than 1” to only one skin – Non-Mat Overlay
Glass Panels and Carbon Panels
1) Remove skin in damaged area in accordance with 9.1.
3) Fabricate repair plug per 9.3.
4) Mix Magnobond per 9.4.
5) Pot core edges with Magnobond 92-1
6) Mix EA 9309.3/Magnobond 6162 epoxy adhesive per 9.4.
7) Install repair plug and apply pressure per 9.5.
8) Allow adhesive to cure as per 9.4 Table 7.
9) Inspect per 9.6.
10) Finish repair area per 9.8.
11) Install edge tape and sealant tape per 9.7 if required.
Figure 5 - Repair of Damage to only one-skin
1.00”
MIN
ONE SKIN ONLY
Non Mat Overlay Glass Panels and Carbon Panels
1.00”
REPAIR PLUG 2.00” MIN 2.00”
EA 9309.3 OR MAGNOBOND 6162

CORE = SKIN THK
MAGNOBOND 92-1 MAGNOBOND 92-1
EXPLODED VIEW

FILLET OF EA
9309.3B OR
MAGNOBOND 6162
AROUND EDGE OF
PATCH
FINISHED
REPAIR
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10.3 Repair of Damage Greater than 1” to One Skin and Core - Non Mat
Overlay Glass Panels and Carbon Panels
1) Remove skin and core in damaged area in accordance with 9.1.

3) Fabricate core plug per 9.3.
6) Mix EA 9309.3/Magnobond 6162 epoxy adhesive per 9.4.
8) Allow adhesive to cure as per 9.4.
9) Inspect per 9.6.
Figure 6 - Repair of Damage to One Skin and Core - non mat overlay
1.00”
MIN
ONE SKIN ONLY
1.00”
EA9309.3 OR MAGNOBOND 6162 EA 9309.3 OR MAGNOBOND 6162
MAGNOBOND 92-1
EA9309.3 OR MAGNOBOND 6162 MAGNOBOND 92-1
MAGNOBOND 92-1 EA 9309.3 OR MAGNOBOND 6162
EXPLODED VIEW
FILLET OF EA
9309.3B OR
MAGNOBOND 6162
AROUND EDGE OF
PATCH
FINISHED
REPAIR
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10.4 Repair of Damage Greater than 1” to Two Skins and Core - Non Mat
Overlay Glass Panels and Carbon Panels
1) Remove skin and core in damaged area in accordance with 9.1.

3) Fabricate core plug per 9.3.
4) Mix Magnobond per 9.4
6) Mix EA9309.3/Magnobond 6162 epoxy adhesive per 9.4.
9) Inspect per 9.6.
Figure 7 - Repair of Damage to Two Skins and Core - non mat overlay
1.00”
MIN
ONE SKIN ONLY
1.00”
EA9309.3 OR MAGNOBOND 6162 EA 9309.3 OR MAGNOBOND 6162
MAGNOBOND 92-1
EA9309.3 OR MAGNOBOND 6162 MAGNOBOND 92-1

MAGNOBOND 92-1
1.00 1.00
EXPLODED VIEW
Non Mat Overlay Panels
FILLET OF EA
9309.3B OR
MAGNOBOND 6162
AROUND EDGE OF
PATCH
FINISHED
REPAIR
Non Mat Overlay Panels
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10.5 Repair of Skin and Core Damage to Mat Overlay Panel, Greater than 1”
in Diameter
1) Remove damaged skin and core in damaged area in accordance with 9.1.
3) Fabricate core plug per 9.3
5) Pot core edges with Magnobond 92-1.
9) Inspect per 9.6.
Figure 8 - Repair of Damage to Mat Overlay Panel
MAGNOBOND 6162 OR
MAGNOBOND 6162 OR MAGNOBOND 6162 OR
OR MAGNOBOND 6162 OR MAGNOBOND 6162
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10.6 Repair of Scrim ply damage to COMPS-027 carbon HSP panels
1) Decontaminate per Section 9.2

2) Remove any lose areas of scrim ply, being careful not to damage any underlying carbon ply.
3) Cut 120 style glass with 0.25” overlaps
4) Mix Epocast 50-A1/9816 per 9.4
5) Laminate with Epocast 50-A1/9816
6) Apply repair ply per Figure 9.
7) Allow resin to cure under a minimum pressure of 21” Hg as per 9.4 .
8) Post-cure inspect per Section 9.6
Figure 9 – Scrim ply layer repair – one for one
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10.7 Replacement of Inserts
No more than two adjacent inserts and 20 percent of all inserts on a panel may be replaced.
Damaged blind potted inserts may be removed by using a heat gun to relax the adhesive and then gently
pulling the insert out of the panel. A fastener may be screwed into the insert for pulling.
Damaged thru potted inserts may be removed by drilling through the insert flange(s) with a 3/8” drill. The
drilling process should generate enough heat to relax the adhesive, allowing any remaining insert material
to be pushed out of the hole.
Damaged swaged titanium inserts may be removed by drilling through the countersunk end with a 3/8”
drill. It is recommended to use low speed and low feed when drilling and to firmly clamp the panel and
insert flange to a hard surface to prevent the remaining portion of the insert from “spinning” in the hole,
which will result in further damage to the face skins.
Remove any remaining insert adhesive and decontaminate the area per Section 9.2.
The installation hole size for the through type inserts is 0.562” in diameter. For swaged titanium inserts the
installation hole size is 0.437” in diameter.
Potted inserts are installed using Magnobond 74-3, and the installation procedure detailed in Figure 10.
Carefully clean and degrease the insert before installation.
Figure 10 - Potted Insert Installation
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For swaged titanium inserts:

1) Prepare Alumiprep 33 solution using: 1 part Alumiprep 33 to 3 parts room temperature fresh water
2) Mix together and verify the pH level is between 2.1 to 2.6 (adjust solution amount to achieve pH
level if required).
3) Immerse the inserts in the mixed solution of Alumiprep 33 for 4 minutes (+30 sec). Ensure all
inserts are fully submerged in the solution.
4) Rinse with cold running water for 1 minute (+30 sec).
5) Air dry inserts – do not solvent wipe. Inserts must be dried before moving to the next step.
6) Store inserts in a closed container to maintain cleanliness. Do not handle without gloves after
treating.
7) The inserts must be applied to the panel within 20 days of treatment. If time limit has elapsed,
repeat steps 1-6.
8) Apply Epibond 420 adhesive directly to the insert washer region (insert flange).
9) Install the insert and press-fit using appropriate tools (SL5107-3P & SLT5107-3ASP5 punch and
anvil or equivalent)
10) Ensure proper contact between the panel surface and the insert flanges. Gaps are unacceptable.
11) Replace foam tape, packers, and pads per 9.7 as required.
Figure 11 - Swaged Insert Installation for CRJ-700/900/1000 Panels
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10.8 Repair of Lifting/Torn Mat Overlay

Mat overlay repairs are detailed in Figure 12.
1) If the mat overlay is lifting but not broken or torn;

Remove entire mat by lifting edge and softening adhesive with solvent (MEK, Acetone). Wash all
adhesive residue from the panel and mat overlay.
3) Apply adhesive to panel and mat overlay.
4) Bond mat onto panel and apply pressure per 9.5.
5) Allow adhesive to cure per 9.4.
6) Remove adhesive flash.
Local areas of damaged mat can be cut out and a new piece spliced in. Use butt joint with splices - do not
overlap mat overlay.
Figure 12 - Repair of Lifting/Torn Mat Overlay
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10.9 Repair/Installation of Edge Filler for Glass Panels

Repair/Installation of Edge Filler is shown in Figure 13.
1) Using a die grinder and routing bit remove damaged filler and core at edge of panel.
2) Decontaminate panel edge per 9.2.
3) Mix Magnobond 92-1 epoxy filler per 9.4.
4) Spatula filler into panel edge using a stir stick.
5) Allow adhesive to cure.
6) Sand filler to match profile of panel.
Figure 13 - Repair / Installation of Edge Filler
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10.10 Repair/Installation of Edge Tape for Carbon Panels
1) Before removing damaged edge tape, mark off the location for the new tape edge. Use a lead
pencil or non-permanent marker.
2) Remove edge tape and ensure surface is free of any contaminants.
3) Install either Permacel P29-14091 or Nitto 223S edge tape from one end on one side of panel and
tack down in a few spots while locating its position.
4) Smooth out tape along its length, once it is in place, to ensure it adheres at all locations and that all
trapped air bubbles are removed.
5) A rubber roller or a nylon spatula can be used for applying pressure. Care must be taken not to
puncture or tear the tape, as galvanic protection will be compromised.
6) Once the one side of the tape is in place, fold over the panel edge and smooth down along its
length to adhere to the sandwich panel honeycomb core.
7) Repeat the folding process, and smooth the remaining tape width along the opposite face of the
panel.
8) Corners are overlapped at a minimum of .250” and cut at a 90 angle, ensuring that no gaps exist.
Corners are not to be mitered. Edges must have straight clean cuts.
10.11 Repair/Installation of Sealant Tape
1) Using a lead pencil or a non-permanent marker, mark the existing location of the sealant tape on
the panel prior to removing.
2) Remove the damaged sealant tape from the panel.
3) Clean panel surface and ensure surface is free of contaminants.
4) If thru holes are present where the sealant tape is to be installed, place the tape (with backing still
installed) onto the panel and mark the center point of the hole into the sealant tape. Remove the
tape and punch or cut out a .50” diameter hole concentric to the center mark.
5) Remove the backing off the sealant tape and start aligning the sealant tape onto the panel at one
edge. Ensure the holes are aligned with the panel.
6) Once the sealant tape is aligned with the panel, carefully press the tape onto the panel (moving
from one side to the next). Smooth out the tape as it is being applied to remove any wrinkles or
trapped air bubbles.
7) Trim off excess sealant tape by using a sharp blade (edges to have straight clean cuts). To prevent
damage to the panel, elevate the sealant tape away from the panel and trim. Secure sealant tape
onto the panel.
8) A rubber roller or a nylon spatula can be used for applying pressure. Care must be taken not to
puncture or tear the tape.
9) Butt joints are permitted, at corners, provided that no gaps exist between the joints. Overlap of
sealant tape at a corner is not permitted.
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10.12 Repair/Installation of Pads
1) Remove damaged pad(s) and ensure surface is free of any contaminants and solvent wipe with
MEK.
2) Cut replacement pad(s) to size.
3) Mark off the location for the replacement pad(s). Use a lead pencil or non-permanent marker.
4) Apply an equal amount of specified 2 part adhesive to the bonding surface on panel and the
bonding side of the pad(s).
5) Locate and install pad(s) with enough pressure to squeeze out any excessive adhesive.
6) Allow the bonding adhesive to cure under pressure clamps or weight (follow manufacturer’s
curing specifications). Pads may also be self-adhering.
When stacking multiple pads on top of another, apply the above steps and repeat for each successive pad.
10.13 Repair of Skin Delamination
Refer to Table 5 for specific damage type’s description and Table 6 for allowable damage limits.
1) Vacuum and decontaminate damaged area per 9.2. Ensure MEK does not penetrate under
delaminated skin as this may cause further delamination.
2) Mix EA 956 resin adhesive per 9.4.
3) Using a syringe, inject the adhesive resin into the delaminated area, ensuring that it fills
completely.
4) Clamp the delaminated area, to ensure proper contact, using a backing plate on either face.
5) Allow adhesive to cure.
6) Inspect per 9.6.
7) Reinstall edge tape, sealant tape, packers, and pads per 9.7, if required.
10.14 Temporary Repair of Skin

This section is only applicable to a damage area of less than 4 sq. inches with no dimension greater than 4
inches and the allowable damage limits of Section 7.
Temporary repairs are shown in Figure 14.
1) Cut out damage.

2) Wash damaged panel area with solvent (MEK, acetone).
3) Fill any voids with Magnobond 92-1. Mix Magnobond 92-1 epoxy filler per 9.4.
4) Allow Magnobond 92-1 to cure 1.0 hour.
5) Apply four layers of 3M425 Aluminum tape.
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Figure 14 - Temporary Repair of Skin Dents & Punctures - less than 4 Sq. inches
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APPENDIX A – Tap TEST PROCEDURE

1.0 Inspection of Sandwich Panel Structures Using The Tap Test Method
1.1 Sandwich panels that are suspected to have damage or need to have damage quantified are
subjected to a tap test. This test will reveal skin to core disbonds, crushed core, and skin
delaminations.
Note: tap testing will only provide any information regarding current structural integrity, not
durability.
1.2 Tap testing uses mechanical resonance to produce a sound that gives an indication of the integrity
of the panel structure. The test is conducted using a hand held metallic disc or sphere shaped
object to repeatedly tap on the surface of the suspect area. A coin, 1” dia steel washer or similar
object may be used.
1.3 Always inspect an area greater than the suspected damage. Use a grid pattern to methodically tap
back and forth across the surface of the component. A narrow scan pattern and increased
frequency of tapping will detect a smaller damage size. Use a marker to outline the extent of the
damage as the inspection progresses. After the initial scan is complete, repeat the pattern scanning
perpendicular to the original pattern.
1.4 The tap test will give a relative indication by means of a sound change from an acceptable area to
an unacceptable area; therefore an area known to be good needs to be tapped for a baseline
reference.
Note: it is normal for sounds to change as ply thickness and core depth vary - near component
edges, attachment points or previous repairs etc. This inspection method decreases in
effectiveness in the noisy area as the thickness of the laminate over a defect increases.
1.5 A clear, crisp sound is produced when the structure has good integrity. A dull sound indicates a
disbond, delamination, or crushed core. Inspections that give unclear results should be further
tested using LF bond test or HF pulse-echo methods of NDI.
Note: further inspection may be required to determine which side of a sandwich panel has the
defect, i.e. tapping will determine that a panel has an area of disbonded core, but may not reveal
which face is disbonded.
Figure 15 - Tap Test Scan Pattern
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PART NUMBER & REPAIR KIT CROSS REFERENCE FOR DHC-8 SERIES 400
APPENDIX B – DHC-8 SERIES 400 PART NUMBER & REPAIR KIT

CROSS REFERENCE
Bombardier Part Number Comtek Part Number Repair Kit Part Number
8SC8001-077 CMKD8400FP-077 COMFPRK-507
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APPENDIX B.1 – DHC-8 SERIES 400 SEALANT TAPE &

SILICONE PAD INSTALLATION
The Dash 8 Q400 program uses Sealant Tape and Silicone Pads on most floor panels. The location of the
Sealant Tape and Silicone Pads vary from panel to panel. Additionally, not all floor panels require both
Silicone Pads and Sealant Tape. If the floor panel to be repaired has the original finishing items, standard
repair procedures can be followed. If the Sealant Tape or Silicone Pads are missing or their location is
uncertain, please contact Comtek for further assistance.
There are some general rules that apply to the placement of these items. Figure 16 shows the placement of
Silicone Pad #50416 and Sealant Tape HT-805(A) GRAY .188. For placement of Silicone Pad #50313 and
Sealant Tape HT-805(A) GRAY .063, see Figure 17. Typically, Foam Tape is applied along the edges of
the floor panel. In most applications, the Silicone Pads are installed on the bottom surface of the floor panel
and are centered over insert locations, see Figure 18.
Figure 16 – Typical Placement of Silicone Pad #50416 and Foam Tape HT-805(A) GRAY .188
Figure 17 – Typical Placement of Silicone Pad #50313 and Foam Tape HT-805(A) GRAY .063
Figure 18 – Typical Silicone Pad Placement Relative to Insert Location.
Note: Figure 16-18 are typical representations but are not applicable to every application. If the Sealant
Tape or Silicone Pads are missing or their location is uncertain, please contact Comtek for further
assistance.
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PART NUMBER & REPAIR KIT CROSS REFERENCE FOR CRJ-700/900/1000
APPENDIX C – CRJ-700/900/1000 PART NUMBER & REPAIR KIT

CROSS REFERENCE
Bombardier Part
Number Comtek Part
Panel Location Repair Kit
Number
Basic Part # Dash #
601R31670 -5 CMKRJ700FP-139 STAIRWAY BOTTOM COMFPRK-507
-9 CMKRJ700FP-180 STAIRWAY TOP COMFPRK-507
-11 CMKRJ700FP-182 STAIRWAY KICK COMFPRK-507
-13 CMKRJ700FP-184 STAIRWAY BOTTOM COMFPRK-507
-17 CMKRJ700FP-117 STAIRWAY TOP COMFPRK-507
-19 CMKRJ700FP-119 STAIRWAY KICK COMFPRK-507
BA670-31669 -1 CMKRJ700FP-159 AFT BAGGAGE BAY COMFPRK-500
BA670-31670 -1 CMKRJ700FP-155 MID BAGGAGE BAY COMFPRK-500
BA670-31671 -1 CMKRJ700FP-151 FWD BAGGAGE BAY COMFPRK-500
BA670-31674 -1 CMKRJ700FP-153 BAGGAGE BAY DOOR COMFPRK-500
-11 CMKRJ700FP-303 AFT BAGGAGE BAY COMFPRK-500
-11 CMKRJ700FP-301 FWD BAGGAGE BAY COMFPRK-503
-11 CMKRJ700FP-305 FWD BAGGAGE BAY COMFPRK-503
BA670-32565 CMKRJ700FP-095N SPECIAL A/C 10003 COMFPRK-509
25-May-2020
Bombardier Part
Number Comtek Part
Number
Basic Part # Dash #
BA690-31028 -1 CMKRJ700FP-553 BAGGAGE BAY COMFPRK-503
BA690-33455 -1 CMKRJ700FP-599N ApFT SERVICE DOOR COMFPRK-509
-15 CMKRJ700FP-601N AFT SERVICE DOOR COMFPRK-509
-19 CMKRJ700FP-699N AFT SERVICE DOOR COMFPRK-509
BA690-33457 -1 CMKRJ700FP-687N DECOMPRESSION BOX COMFPRK-509
-2 CMKRJ700FP-688N DECOMPRESSION BOX COMFPRK-509
CC670-33200 -7 CMKRJ700FP-001N COCKPIT COMFPRK-509
-11 CMKRJ700FP-121N COCKPIT COMFPRK-509
CC670-33300 -1 CMKRJ700FP-185N CRAWLWAY COCKPIT COMFPRK-503
SH670-30316 -1 CMKRJ700FP-103 CABIN SIDE COMFPRK-509
SH670-32321 -9 CMKRJ700FP-187N CRAWLWAY FWD COMFPRK-509
SH670-32322 -5 CMKRJ700FP-189N CRAWLWAY AFT COMFPRK-509
SH670-32562 -29 CMKRJ700FP-003 CABIN ENTRYWAY COMFPRK-504
-33 CMKRJ700FP-075 CABIN ENTRYWAY COMFPRK-504
SH670-32563 -11 CMKRJ700FP-015N CABIN SIDE COMFPRK-509
-17 CMKRJ700FP-079N CABIN SIDE COMFPRK-509
25-May-2020
Bombardier Part
Number Comtek Part
Number
Basic Part # Dash #
SH670-32569 -15 CMKRJ700FP-027M CABIN AISLE COMFPRK-508
-951 CMKRJ700FP-951M CABIN AISLE COMFPRK-508
SH670-32570 -19 CMKRJ700FP-039 CABIN SERVICE DOOR COMFPRK-504
-35 CMKRJ700FP-061 CABIN SERVICE DOOR COMFPRK-504
25-May-2020
Bombardier Part
Number Comtek Part
Number
Basic Part # Dash #
SH670-32591 -5 CMKRJ700FP-047 AFT CABIN COMFPRK-503
-15 CMKRJ700FP-123 AFT CABIN COMFPRK-503
SH670-32593 -7 CMKRJ700FP-017N AFT CABIN COMFPRK-509
-11 CMKRJ700FP-627N AFT CABIN COMFPRK-509
25-May-2020
Bombardier Part
Number Comtek Part
Number
Basic Part # Dash #
-9 CMKRJ700FP-131 CABIN SIDE COMFPRK-503
25-May-2020
Bombardier Part
Number Comtek Part
Number
Basic Part # Dash #
25-May-2020
Bombardier Part
Number Comtek Part
Number
Basic Part # Dash #
-13 C S9 33456 13 CABIN SIDE COMFPRK-503
H690-33459 -1 CMKRJ700FP-541 CABIN SIDE COMFPRK-503
25-May-2020
Bombardier Part
Number Comtek Part
Number
Basic Part # Dash #
601R31670 -21 C 6R 31670 21 STAIRWAY TOP COMFPRK-507
-23 C 6R 31670 23 STAIRWAY KICK COMFPRK-507
-25 C 6R 31670 25 STAIRWAY BOTTOM COMFPRK-507
BA670-31669 -7 C B7 31669 7 AFT BAGGAGE BAY COMFPRK-500
-11 C B7 31669 11 AFT BAGGAGE BAY COMFPRK-500
BA670-31670 -5 C B7 31670 5 MID BAGGAGE BAY COMFPRK-500
-9 C B7 31670 9 MID BAGGAGE BAY COMFPRK-500
BA670-31671 -5 C B7 31671 5 FWD BAGGAGE BAY COMFPRK-500
-9 C B7 31671 9 FWD BAGGAGE BAY COMFPRK-500
BA670-31674 -11 C B7 31674 11 BAGGAGE BAY DOOR COMFPRK-500
-15 C B7 31674 15 BAGGAGE BAY DOOR COMFPRK-500
-19 C B7 31675 19 AFT BAGGAGE BAY COMFPRK-500
BA670-31691 -1 C B7 31691 1 CABIN SIDE COMFPRK-508
25-May-2020
Bombardier Part
Number Comtek Part
Number
Basic Part # Dash #
-13 C B7 31693 13 CABIN SIDE COMFPRK-509
BA670-32579 -1 C B7 32579 1 CABIN ENTRY WAY COMFPRK-504
BA670-33472 -1 C B7 33472 1 CABIN PANEL COMFPRK-508
BA690-31028 -9 C B9 31028 9 BAGGAGE BAY COMFPRK-503
-41 C B9 32581 41 CABIN ENTRY WAY COMFPRK-504
BA690-32583 -1 C B9 32583 1 CABIN AISLE COMFPRK-508
-11 C B9 32583 11 CABIN AISLE COMFPRK-508
BA690-33455 -25 C B9 33455 25 AFT SERVICE DOOR COMFPRK-509
25-May-2020
Bombardier Part
Number Comtek Part
Number
Basic Part # Dash #
BA690-33457 -11 C B9 33457 11 DECOMPRESSION BOX COMFPRK-509
BA690-33457 -12 C B9 33457 12 DECOMPRESSION BOX COMFPRK-509
CC670-31650 -1 C C7 31650 1 STAIR PANEL COMFPRK-504
CC670-33200 -13 C C7 33200 13 COCKPIT COMFPRK-509
-15 C C7 33200 15 COCKPIT COMFPRK-508
CC670-33300 -3 C C7 33300 3 CRAWLWAY COCKPIT COMFPRK-503
SH670-32321 -11 C S7 32321 11 CRAWLWAY FWD COMFPRK-509
SH670-32322 -7 C S7 32322 7 CRAWLWAY AFT COMFPRK-509
SH670-32562 -53 C S7 32562 53 CABIN ENTRYWAY COMFPRK-504
-57 C S7 32562 57 CABIN ENTRYWAY COMFPRK-504
SH670-32563 -33 C S7 32563 33 CABIN SIDE COMFPRK-509
SH670-32569 -33 C S7 32569 33 CABIN AISLE COMFPRK-508
SH670-32570 -51 C S7 32570 51 CABIN SERVICE DOOR COMFPRK-504
-55 C S7 32570 55 CABIN SERVICE DOOR COMFPRK-504
SH670-32570 -67 C S7 32570 67 CABIN SERVICE DOOR COMFPRK-504
SH670-32592 -17 C S7 32592 17 AFT CABIN COMFPRK-503
25-May-2020
Bombardier Part
Number Comtek Part
Number
Basic Part # Dash #
25-May-2020
Bombardier Part
Number Comtek Part
Number
Basic Part # Dash #
BA698-33428 -1 C S1 33428 1 CABIN SIDE COMFPRK-508
BA698-33451 -19 C S1 33451 19 CABIN AISLE COMFPRK-508
25-May-2020
Bombardier Part
Number Comtek Part
Number
Basic Part # Dash #
25-May-2020
Bombardier Part
Number Comtek Part
Number
Basic Part # Dash #
BA698-33489 -1 C B1 33489 1 CARGO COMFPRK-503
-7 C B1 33492 7 BAGGAGE BAY COMFPRK-500
25-May-2020
COMPONENT MAINTENCE MANUAL
REPAIR KIT CONTENTS DHC-8 SERIES 400 AND FOR CRJ-700/900/1000
APPENDIX D – CRJ-700/900/1000 AND DHC-8 SERIES 400

REPAIR KIT CONTENTS
Mat Overlay Glass Panel; Kit No., COMFPRK-500

QTY Item Description
20 NAS1834-C3K-400 CSK Thru Insert
10 NAS1834-C3-400 Thru Insert
10 NAS1833-C3-400 Thru Threaded Insert
4 12x24 Panel COMPS-022 Type 1 Panel
2 12 x 24 sheet Mat overlay
1 24-0078 Conformity Certificate


25-May-2020
Non-Mat Overlay Glass Panel; Kit No., COMFPRK-503




25-May-2020

Carbon Panels; Kit No., COMFPRK-508 (CRJ 700/900/1000)

20 SL5107T3-410SP8* Thru Swaged Insert
5 NAS1833C3-400 Thru Threaded Insert
*Repair kit with SL5107T3-410SP8 swage inserts is only for the CRJ program
Carbon Panels; Kit No., COMFPRK-509 (CRJ 700/900/1000)

20 SL5170T3-410SP8* Thru Swaged Insert
*Repair kit with SL5107T3-410SP8 swage inserts is only for the CRJ program
25-May-2020
Carbon Panels; Kit No., COMFPRK-510 (DHC-8 S400)

20 NAS1834-C3K-400 Thru Countersink Insert
5 NAS1833C3-400 Thru Threaded Insert
Carbon Panels; Kit No., COMFPRK-511 (DHC-8 S400)

20 NAS1834-C3K-400 Thru Countersink Insert
25-May-2020
APPENDIX E – MATERIAL SAFETY DATA SHEETS (MSDS’s)
The following is the Material Safety Data Sheet (7 pages) for COMPS-022 Type 1/2/3/4
and COMPS-028 Type 1/2/3/4/5/6.
COMCMM-030 REV. R 56 of 70
29-May-2018
29-May-2018
29-May-2018
29-May-2018
29-May-2018
29-May-2018
29-May-2018
The following is the Material Safety Data Sheet (7 pages) for COMPS-027 Type 3 and 4.
29-May-2018
29-May-2018
29-May-2018
29-May-2018
29-May-2018
29-May-2018
29-May-2018
APPENDIX F – REPAIR KIT ORDER FORM
29-May-2018

CMM-030 Floor Panels REV U

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CMM-030 Floor Panels REV U

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Stefan Kloppenborg Digitally signed by Stefan Kloppenborg

Date: 2020.05.26 12:45:00 -04'00'

Issue Date Page Paragraph Reason for Revision

B 02-05-04 All i) Addition of silicone pad damage type to Table 5 of Section

B1 4-Mar-05 All i) Added comments from Bombardier Flammability DAD, and

C 17-Nov-08 4-8, i) Removed Edge Tape 3M474-3

P 29-Nov-17 46 i) Appendix C: Added new part numbers for CRJ

R 15-Aug-18 46 i) Appendix C: Added new part numbers for CRJ

1.0 Purpose .............................................................................................................................................. 1

COMCMM-030 REV. U iii

3.0 Health and Safety

4.0 Facilities and Equipment

Table 1 – Shop Equipment

5.0 Raw Materials

Foam Tape MF Siltec 63, Magnifoam Technology INC

Foam Sheet/Tape Bisco HT-805(A) Rogers Corporation

Foam Sheet/Tape Bisco HT-805(A) Rogers Corporation

Silicone Pad Freudenberg-Nok INC .202 Thick – can be used to

Magnobond 74-3 insert adhesive Glotrax (905) 377-1441

Kydex Shim Comtek Advanced Structures Various sizes

6.0 Inspection Procedures

Table 5 – Damage Types and Inspection Methods

Scrim ply -delamination Visual

Edge Tape May include tears, peels or punctures. Visual

Pad Silicone pad may have holes. Visual

* see Appendix A for tap test procedure.

Figure 2 – Evaluation of Damage Size

7.0 Allowable Damage

Inserts Unserviceable inserts are not allowed.

8.0 Repairable Damage Limits

9.0 General Repair Procedures

9.1 Damage Removal

9.1.1 Paint Removal

9.3 Repair Plug Fabrication

Figure 3 – Core Ribbon Direction

9.4 Mixing of Epoxies

Table 7 – Epoxy Data

9.5 Repair Plug Bonding and Curing

9.6 Post Cure Inspection

Preparation of Sandwich Panels

Installation of Edge Seal Tapes

Installation of Foam Tapes

Installation of Packers or Shims

Any inserts, packers, or pads removed must be reinstalled per Sections:

10.0 Specific Repair Procedures

10.1 Repair to Dents and Punctures Less Than 1” Diameter

1) Remove damaged skin and core in accordance with 9.1.

Figure 4 - Repair of Punctures and Dents less than 1” Diameter

Figure 5 - Repair of Damage to only one-skin

ONE SKIN ONLY

Non Mat Overlay Glass Panels and Carbon Panels

EA 9309.3 OR MAGNOBOND 6162

MAGNOBOND 92-1 MAGNOBOND 92-1

EA 9309.3 OR MAGNOBOND 6162

Non Mat Overlay Glass Panels and Carbon Panels

1) Remove skin and core in damaged area in accordance with 9.1.

ONE SKIN ONLY

Non Mat Overlay Glass Panels and Carbon Panels

EA9309.3 OR MAGNOBOND 6162 EA 9309.3 OR MAGNOBOND 6162

EA9309.3 OR MAGNOBOND 6162 MAGNOBOND 92-1

MAGNOBOND 92-1 EA 9309.3 OR MAGNOBOND 6162

Non Mat Overlay Glass Panels and Carbon Panels

1) Remove skin and core in damaged area in accordance with 9.1.

ONE SKIN ONLY