Goodrich SRM

850 LAGOON DRIVE
CHULA VISTA CALIFORNIA 91910-2098 TEL: (619) 691-4111•TELEX:69-5038
August 1, 2009
SUBJECT: V2500 Nacelle Structural Repair Manual Publication Reference:

(RDN 600) Revision 1, Dated August 1,2009.
The subject manual revision is being transmitted.
Questions or comments concerning this publication should be

directed to Goodrich Aerospace, Aerostructures, Customer
Support, Attn: Pedro Cano, Mail Zone 107-K, Telephone: (619) 691-4127,
Fax: (619) 498-7025, E-mail address: pedro.cano@goodrich.com.
Printing and distribution and requirement changes should be directed to

Goodrich Aerostructures, Customer Support, Attn: Jan Lewis, Mail Zone
107-K, Telephone: (619) 691-2719, Fax: (619) 498-7025, or E-mail
address: jan.lewis@goodrich.com.
Pedro Cano
V2500 Technical Publications
Customer Support
THIS PAGE INTENTIONALLY LEFT BLANK
GOODRICH AEROSTRUCTURES
STRUCTURAL REPAIR MANUAL
TRANSMITTAL LETTER
TO: V2500 Structural Repair Manual Distribution
CONCERNING: Revision 1, Dated Aug. 1, 2009
MANUAL UPDATE INSTRUCTIONS
New and revised pages were inserted in this manual in accordance with
the current List of Effective Pages. All pages in the old manual that
needs to be replaced with revised pages were removed. Discard the old
manual upon receipt of this revised manual.
An * (asterisk) in front of an entry on the List of Effective Pages show

a revised page.
An (N) in front of an entry on the List of Effective Pages show a new

page to be put into your manual.
An (D) in front of an entry on the List of Effective Pages show a

deleted page to be removed from your manual.
Chapter/Section/Subject Page Number Description of Change
Title -- Revised text.
Record of Revisions 1 - 2 Revised text.
List of Effective Pages 1 - 30 Revised text.
54-30-00
Structure Identification 1-94 Revise Illustration.

Revise to clarify
graphite composite and
aluminum material
information
Allowable Damage 101-154 Correct Figure reference

per TSR8818
V2500 54- TRANSMITTAL LETTER

Page 1
Aug 1/09
Rohr, Inc., a subsidiary of Goodrich Corporation, operating as Goodrich Aerostructures; Goodrich Proprietary
Information subject to the limitation contained in the title page section of the manual.
Chapter/Section/Subject Page Number Description of Change
Repair 31 201-209 Added alternate CoMat,

Revised step in item no.
6
Repair 32 201-228 Revised to correct

illustration references
Added Flag Notes.
Repair 33 201-232 Revised to correct

illustration references
Revised to correct
illustration pages
Added new pages
Repair 48 201-208 Revised to address

missing rivets
Revised illustration
V2500 54- TRANSMITTAL LETTER

Page 2
Aug 1/09
STRUCTURAL
REPAIR MANUAL
V2500-A5 NACELLE IN THE
AIRBUS INDUSTRIE A319
V2500-A1 AND A5 NACELLES IN THE
V2500-A5 NACELLE IN THE
THE CONTENTS OF THIS STRUCTURAL REPAIR

MANUAL ARE APPROVED BY THE DIRECTION
GENERALE DE L’AVIATION CIVILE (D.G.A.C.)
FAA APPROVAL NOTICE

THE INFORMATION CONTAINED WITHIN ATA
CHAPTER/SECTION 54-30-00 AND 54-40-00 HAS BEEN
SHOWN TO COMPLY WITH THE APPLICABLE FEDERAL
AVIATION REGULATIONS AND IS FAA-APPROVED FOR
THE COMPONENTS SPECIFIED
Goodrich Aerostructures Proprietary Information
The information contained in this document is Goodrich proprietary information and is disclosed in confidence. It is the property of Goodrich and shall not be
used, disclosed to others or reproduced without the express written consent of Goodrich, including, but without limitation, it is not to be used in the creation,
manufacture, development, or derivation of any repairs, modifications, spare parts, design, or configuration changes or to obtain FAA or any other government
or regulatory approval to do so. If consent is given for reproduction in whole or in part, this notice and the notice set forth on each page of this document shall
appear in any such reproduction in whole or in part. The information contained in this document may also be controlled by the U.S. export control laws.
Unauthorized export or re-export is prohibited.
Copyright License:
Customer is authorized to copy these materials for its own use only, provided that all copyright notices, proprietary legends, confidential markings, and other
restrictive notices appearing on the original materials are preserved on all such copies.
Caution Regarding Use of Materials:
It is customer’s sole responsibility to ascertain and ensure that all materials are current and appropriate for the use to which they are put and Goodrich assumes
no responsibility whatsoever in that regard. Customer agrees to indemnify and save harmless Goodrich against all claims and liability of whatever nature,
including those of third parties (including contractors and vendors to customer) where and by whomsoever brought, resulting from customer’s use of materials
or other information, consultation, assistance, or training furnished or any other performance in connection with this agreement by Goodrich or from the
manufacture, sale, delivery, resale of any product by customer. In no event shall Goodrich be liable for any special, incidental, indirect or consequential or
punitive damages.
Revision 1: Aug 1/09


RECORD OF REVISIONS
REVISION REVISION REVISION

NUMBER DATE NUMBER DATE NUMBER DATE
Initial Feb 1/09
Rev 1 Aug 1/09
V2500 54- RECORD OF REVISIONS

Page 1
Aug 1/09
V2500 54- RECORD OF REVISIONS

Page 2
Aug 1/09
RECORD OF TEMPORARY REVISIONS
ISSUE DATE ISSUE DATE

REV. DATE INSERTED BY REV. DATE INSERTED BY
RETAIN THIS RECORD IN THE FRONT OF MANUAL. UPON RECEIPT OF REVISION,

INSERT REVISED PAGES IN THE MANUAL, AND ENTER REVISION NUMBER, ISSUE
DATE, DATE INSERTED, AND INITIALS.
V2500 54- TEMPORARY REVISIONS

Page 1
Feb 1/09
V2500 54- TEMPORARY REVISIONS

Page 2
Feb 1/09
SERVICE BULLETIN LIST
SERVICE DATE BULLETIN

BULLETIN SERVICE LETTER REVISION INCORPORATED INTO
NUMBER NO. NUMBER MANUAL
V2500 54- SERVICE BULLETIN LIST

Page 1
Feb 1/09
V2500 54- SERVICE BULLETIN LIST

Page 2
Feb 1/09
LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE
Title Page *1 Aug 1/09 Table of 1 Feb 1/09

2 BLANK Contents 2 Feb 1/09
3 Feb 1/09
Record of *1 Aug 1/09 4 Feb 1/09
Revisions 2 BLANK 5 Feb 1/09
6 Feb 1/09
Record of 1 Feb 1/09 7 Feb 1/09
Temporary 2 BLANK 8 Feb 1/09
9 Feb 1/09
Revisions 10 Feb 1/09
11 Feb 1/09
Service 1 Feb 1/09 12 Feb 1/09
Bulletin List 2 BLANK
54-00-00 1 Feb 1/09
List of *1 Aug 1/09 General 2 Feb 1/09
Effective Pages *2 Aug 1/09 3 Feb 1/09
*3 Aug 1/09 4 Feb 1/09
*4 Aug 1/09 5 Feb 1/09
*5 Aug 1/09 6 Feb 1/09
*6 Aug 1/09 7 Feb 1/09
*7 Aug 1/09 8 Feb 1/09
*8 Aug 1/09 9 Feb 1/09
*9 Aug 1/09 10 Feb 1/09
*10 Aug 1/09 11 Feb 1/09
*11 Aug 1/09 12 Feb 1/09
*12 Aug 1/09 13 Feb 1/09
*13 Aug 1/09 14 Feb 1/09
*14 Aug 1/09 15 Feb 1/09
*15 Aug 1/09 16 Feb 1/09
*16 Aug 1/09 17 Feb 1/09
*17 Aug 1/09 18 Feb 1/09
*18 Aug 1/09 19 Feb 1/09
*19 Aug 1/09 20 Feb 1/09
*20 Aug 1/09 21 Feb 1/09
*21 Aug 1/09 22 Feb 1/09
*22 Aug 1/09 23 Feb 1/09
*23 Aug 1/09 24 Feb 1/09
*24 Aug 1/09 25 Feb 1/09
*25 Aug 1/09 26 Feb 1/09
*26 Aug 1/09 27 Feb 1/09
*27 Aug 1/09 28 Feb 1/09
*28 Aug 1/09 29 Feb 1/09
*29 Aug 1/09 30 Feb 1/09
*30 BLANK 31 Feb 1/09
* Indicates revised page

(N)Indicates new page
54- LIST OF EFFECTIVE PAGES
Page 1
(D)Indicates deleted page Aug 1/09

54-00-00 32 Feb 1/09 54-02-00 201 Feb 1/09
General 33 Feb 1/09 General Repair 202 Feb 1/09
(Cont. ) 34 Feb 1/09 Procedures 203 Feb 1/09
35 Feb 1/09 204 Feb 1/09
36 Feb 1/09 205 Feb 1/09
37 Feb 1/09 206 Feb 1/09
38 Feb 1/09 207 Feb 1/09
39 Feb 1/09 208 Feb 1/09
40 Feb 1/09 209 Feb 1/09
41 Feb 1/09 210 BLANK
42 Feb 1/09
43 Feb 1/09 List of 201 Feb 1/09
44 Feb 1/09 Approved 202 BLANK
45 Feb 1/09 Repairs
46 Feb 1/09
47 Feb 1/09 Repair 001 201 Feb 1/09
48 Feb 1/09 202 Feb 1/09
49 Feb 1/09 203 Feb 1/09
50 Feb 1/09 204 Feb 1/09
51 Feb 1/09 205 Feb 1/09
52 Feb 1/09 206 Feb 1/09
53 Feb 1/09 207 Feb 1/09
54 Feb 1/09 208 Feb 1/09
55 Feb 1/09 209 Feb 1/09
56 Feb 1/09 210 Feb 1/09
57 Feb 1/09 211 Feb 1/09
58 Feb 1/09 212 Feb 1/09
59 Feb 1/09 213 Feb 1/09
60 BLANK 214 Feb 1/09
215 Feb 1/09
54-01-00 1 Feb 1/09 216 Feb 1/09
Damage 2 Feb 1/09 217 Feb 1/09
Inspection 3 Feb 1/09 218 Feb 1/09
4 Feb 1/09 219 Feb 1/09
5 Feb 1/09 220 Feb 1/09
6 Feb 1/09 221 Feb 1/09
7 Feb 1/09 222 BLANK
8 Feb 1/09
9 Feb 1/09 Repair 002 201 Feb 1/09
10 BLANK 202 Feb 1/09
203 Feb 1/09
54-01-01 1 Feb 1/09 204 Feb 1/09
Damage Cleanup 2 Feb 1/09 205 Feb 1/09
3 Feb 1/09 206 Feb 1/09
4 Feb 1/09

Page 2

Repair 003 201 Feb 1/09 Repair 008 203 Feb 1/09
202 Feb 1/09 (Cont.) 204 Feb 1/09
203 Feb 1/09
204 Feb 1/09 Repair 009 201 Feb 1/09
205 Feb 1/09 202 Feb 1/09
206 Feb 1/09 203 Feb 1/09
207 Feb 1/09 204 Feb 1/09
208 Feb 1/09 205 Feb 1/09
206 Feb 1/09
Repair 004 201 Feb 1/09 207 Feb 1/09
202 Feb 1/09 208 Feb 1/09
203 Feb 1/09 209 Feb 1/09
204 Feb 1/09 210 Feb 1/09
205 Feb 1/09 211 Feb 1/09
206 Feb 1/09 212 Feb 1/09
207 Feb 1/09 213 Feb 1/09
208 Feb 1/09 214 Feb 1/09
209 Feb 1/09 215 Feb 1/09
210 Feb 1/09 216 Feb 1/09
211 Feb 1/09 217 Feb 1/09
212 BLANK 218 Feb 1/09
202 Feb 1/09 202 Feb 1/09
203 Feb 1/09 203 Feb 1/09
204 Feb 1/09 204 Feb 1/09
205 Feb 1/09 205 Feb 1/09
206 Feb 1/09 206 Feb 1/09
207 Feb 1/09
208 Feb 1/09 Repair 011 201 Feb 1/09
202 Feb 1/09
Repair 006 201 Feb 1/09 203 Feb 1/09
202 Feb 1/09 204 Feb 1/09
203 Feb 1/09 205 Feb 1/09
204 Feb 1/09 206 BLANK
202 Feb 1/09 202 Feb 1/09
203 Feb 1/09 203 Feb 1/09
204 Feb 1/09 204 Feb 1/09
205 Feb 1/09 205 Feb 1/09
206 BLANK 206 Feb 1/09
207 Feb 1/09
Repair 008 201 Feb 1/09 208 Feb 1/09
202 Feb 1/09

Page 3

Repair 013 201 Feb 1/09 54-10-00 6.02 Feb 1/09
202 Feb 1/09 Inlet Cowl - 6.03 Feb 1/09
203 Feb 1/09 Structure 6.04 Feb 1/09
204 Feb 1/09 Identification 6.05 Feb 1/09
(Cont.) 6.06 Feb 1/09
54-10-00 1 Feb 1/09 6.07 Feb 1/09
Inlet Cowl - 1.01 Feb 1/09 6.08 Feb 1/09
Structure 1.02 Feb 1/09 6.09 Feb 1/09
Identification 1.03 Feb 1/09 6.10 Feb 1/09
1.04 Feb 1/09 6.11 Feb 1/09
1.05 Feb 1/09 6.12 Feb 1/09
1.06 Feb 1/09 6.13 Feb 1/09
1.07 Feb 1/09 6.14 Feb 1/09
1.08 Feb 1/09 6.15 Feb 1/09
1.09 Feb 1/09 6.16 Feb 1/09
1.10 Feb 1/09 6.17 Feb 1/09
1.11 Feb 1/09 7.01 Feb 1/09
1.12 Feb 1/09 7.02 Feb 1/09
2.01 Feb 1/09 7.03 Feb 1/09
2.02 Feb 1/09 7.04 Feb 1/09
3.01 Feb 1/09 7.05 Feb 1/09
3.02 Feb 1/09 7.06 Feb 1/09
4.01 Feb 1/09 7.07 Feb 1/09
4.02 Feb 1/09 7.08 Feb 1/09
4.03 Feb 1/09 7.09 Feb 1/09
4.04 Feb 1/09 7.10 Feb 1/09
4.05 Feb 1/09 7.11 Feb 1/09
4.06 Feb 1/09 7.12 Feb 1/09
4.07 Feb 1/09 7.13 Feb 1/09
4.08 Feb 1/09 7.14 Feb 1/09
4.09 Feb 1/09 7.15 Feb 1/09
4.10 Feb 1/09 7.16 Feb 1/09
5.01 Feb 1/09 7.17 Feb 1/09
5.02 Feb 1/09 7.18 Feb 1/09
5.03 Feb 1/09 7.19 Feb 1/09
5.04 Feb 1/09 8.01 Feb 1/09
5.05 Feb 1/09 8.02 Feb 1/09
5.06 Feb 1/09 8.03 Feb 1/09
5.07 Feb 1/09 8.04 Feb 1/09
5.08 Feb 1/09 8.05 Feb 1/09
5.09 Feb 1/09 8.06 Feb 1/09
5.10 Feb 1/09 8.07 Feb 1/09
5.11 Feb 1/09 9.01 Feb 1/09
5.12 Feb 1/09 9.02 Feb 1/09
6.01 Feb 1/09 9.03 Feb 1/09

Page 4

54-10-00 9.04 Feb 1/09 54-10-00 14.04 Feb 1/09
Inlet Cowl - 9.05 Feb 1/09 Inlet Cowl - 14.05 Feb 1/09
Structure 9.06 Feb 1/09 Structure 14.06 Feb 1/09
Identification 9.07 Feb 1/09 Identification 14.07 Feb 1/09
(Cont.) 10.01 Feb 1/09 (Cont.) 14.08 Feb 1/09
10.02 Feb 1/09 14.09 Feb 1/09
10.03 Feb 1/09 14.10 Feb 1/09
10.04 Feb 1/09 14.11 Feb 1/09
10.05 Feb 1/09 14.12 Feb 1/09
10.06 Feb 1/09 14.13 Feb 1/09
10.07 Feb 1/09 14.14 Feb 1/09
11.01 Feb 1/09 14.15 Feb 1/09
11.02 Feb 1/09 14.16 Feb 1/09
11.03 Feb 1/09 14.17 Feb 1/09
11.04 Feb 1/09 14.18 Feb 1/09
11.05 Feb 1/09 14.19 Feb 1/09
11.06 Feb 1/09 14.20 Feb 1/09
12.01 Feb 1/09 15.01 Feb 1/09
12.02 Feb 1/09 15.02 Feb 1/09
12.03 Feb 1/09 15.03 Feb 1/09
12.04 Feb 1/09 15.04 Feb 1/09
12.05 Feb 1/09 15.05 Feb 1/09
12.06 Feb 1/09 15.06 Feb 1/09
12.07 Feb 1/09 15.07 Feb 1/09
12.08 Feb 1/09 15.08 Feb 1/09
12.09 Feb 1/09 15.09 Feb 1/09
12.10 Feb 1/09 15.10 Feb 1/09
12.11 Feb 1/09 15.11 Feb 1/09
12.12 Feb 1/09 15.12 Feb 1/09
13.01 Feb 1/09 15.13 Feb 1/09
13.02 Feb 1/09 16.01 Feb 1/09
13.03 Feb 1/09 16.02 Feb 1/09
13.04 Feb 1/09 16.03 Feb 1/09
13.05 Feb 1/09 16.04 Feb 1/09
13.06 Feb 1/09 16.05 Feb 1/09
13.07 Feb 1/09 16.06 Feb 1/09
13.08 Feb 1/09 16.07 Feb 1/09
13.09 Feb 1/09 16.08 Feb 1/09
13.10 Feb 1/09 16.09 Feb 1/09
13.11 Feb 1/09 16.10 Feb 1/09
13.12 Feb 1/09 17.01 Feb 1/09
13.13 Feb 1/09 17.02 Feb 1/09
14.01 Feb 1/09 17.03 Feb 1/09
14.02 Feb 1/09 17.04 Feb 1/09
14.03 Feb 1/09 17.05 Feb 1/09

Page 5

54-10-00 17.06 Feb 1/09 54-10-00 21.05 Feb 1/09
Inlet Cowl - 17.07 Feb 1/09 Inlet Cowl - 21.06 Feb 1/09
Structure 17.08 Feb 1/09 Structure 21.07 Feb 1/09
Identification 17.09 Feb 1/09 Identification 21.08 Feb 1/09
(Cont.) 18.01 Feb 1/09 (Cont.) 21.09 Feb 1/09
18.02 Feb 1/09 21.10 Feb 1/09
18.03 Feb 1/09 21.11 Feb 1/09
18.04 Feb 1/09 22.01 Feb 1/09
18.05 Feb 1/09 22.02 Feb 1/09
18.06 Feb 1/09 22.03 Feb 1/09
18.07 Feb 1/09 22.04 Feb 1/09
18.08 Feb 1/09 22.05 Feb 1/09
18.09 Feb 1/09 22.06 Feb 1/09
18.10 Feb 1/09 22.07 Feb 1/09
18.11 Feb 1/09 22.08 Feb 1/09
18.12 Feb 1/09 22.09 Feb 1/09
19.01 Feb 1/09 22.10 Feb 1/09
19.02 Feb 1/09 23.01 Feb 1/09
19.03 Feb 1/09 23.02 Feb 1/09
19.04 Feb 1/09 23.03 Feb 1/09
19.05 Feb 1/09 23.04 Feb 1/09
19.06 Feb 1/09 23.05 Feb 1/09
19.07 Feb 1/09 23.06 Feb 1/09
19.08 Feb 1/09 23.07 Feb 1/09
19.09 Feb 1/09 23.08 Feb 1/09
19.10 Feb 1/09 23.09 Feb 1/09
19.11 Feb 1/09 23.10 Feb 1/09
20.01 Feb 1/09 23.11 Feb 1/09
20.02 Feb 1/09 23.12 Feb 1/09
20.03 Feb 1/09 23.13 Feb 1/09
20.04 Feb 1/09 24.01 Feb 1/09
20.05 Feb 1/09 24.02 Feb 1/09
20.06 Feb 1/09 24.03 Feb 1/09
20.07 Feb 1/09 24.04 Feb 1/09
20.08 Feb 1/09 24.05 Feb 1/09
20.09 Feb 1/09 24.06 Feb 1/09
20.10 Feb 1/09 24.07 Feb 1/09
20.11 Feb 1/09 24.08 Feb 1/09
20.12 Feb 1/09 24.09 Feb 1/09
20.13 Feb 1/09 24.10 Feb 1/09
20.14 Feb 1/09 24.11 Feb 1/09
21.01 Feb 1/09 24.12 Feb 1/09
21.02 Feb 1/09 24.13 Feb 1/09
21.03 Feb 1/09 24.14 Feb 1/09
21.04 Feb 1/09

Page 6

54-10-00 101 Feb 1/09 Repair 001 201 Feb 1/09
Inlet Cowl - 102 Feb 1/09 202 Feb 1/09
Allowable 103 Feb 1/09 203 Feb 1/09
Damage 104 Feb 1/09 204 Feb 1/09
105 Feb 1/09 205 Feb 1/09
106 Feb 1/09 206 Feb 1/09
107 Feb 1/09 207 Feb 1/09
108 Feb 1/09 208 Feb 1/09
109 Feb 1/09 209 Feb 1/09
110 Feb 1/09 210 Feb 1/09
111 Feb 1/09 211 Feb 1/09
112 Feb 1/09 212 Feb 1/09
113 Feb 1/09 213 Feb 1/09
114 Feb 1/09 214 Feb 1/09
115 Feb 1/09
116 Feb 1/09 Repair 002 201 Feb 1/09
117 Feb 1/09 202 Feb 1/09
118 Feb 1/09 203 Feb 1/09
119 Feb 1/09 204 Feb 1/09
120 Feb 1/09 205 Feb 1/09
121 Feb 1/09 206 Feb 1/09
122 Feb 1/09 207 Feb 1/09
123 Feb 1/09 208 BLANK
124 Feb 1/09
125 Feb 1/09 Repair 003 201 Feb 1/09
126 Feb 1/09 202 Feb 1/09
127 Feb 1/09 203 Feb 1/09
128 Feb 1/09 204 Feb 1/09
129 Feb 1/09 205 Feb 1/09
130 Feb 1/09 206 Feb 1/09
131 Feb 1/09 207 Feb 1/09
132 Feb 1/09 208 BLANK
54-10-00 Repair 004 201 Feb 1/09
General Repair 201 Feb 1/09 202 Feb 1/09
202 Feb 1/09 203 Feb 1/09
203 Feb 1/09 204 Feb 1/09
204 Feb 1/09 205 Feb 1/09
205 Feb 1/09 206 Feb 1/09
206 BLANK 207 Feb 1/09
208 Feb 1/09
List of 201 Feb 1/09 209 Feb 1/09
Approved 202 Feb 1/09 210 Feb 1/09
Repairs 203 Feb 1/09 211 Feb 1/09
204 BLANK 212 Feb 1/09

Page 7

(Cont.) 214 Feb 1/09 (CANCELLED) 202 BLANK
215 Feb 1/09
216 Feb 1/09 Repair 009 201 Feb 1/09
217 Feb 1/09 202 Feb 1/09
218 Feb 1/09 203 Feb 1/09
219 Feb 1/09 204 Feb 1/09
220 Feb 1/09 205 Feb 1/09
221 Feb 1/09 206 Feb 1/09
222 Feb 1/09 207 Feb 1/09
223 Feb 1/09 208 Feb 1/09
224 Feb 1/09 209 Feb 1/09
225 Feb 1/09 210 Feb 1/09
226 Feb 1/09 211 Feb 1/09
212 Feb 1/09
Repair 005 201 Feb 1/09 213 Feb 1/09
202 Feb 1/09 214 Feb 1/09
203 Feb 1/09
204 Feb 1/09 Repair 010 201 Feb 1/09
205 Feb 1/09 202 Feb 1/09
206 Feb 1/09 203 Feb 1/09
207 Feb 1/09 204 Feb 1/09
208 Feb 1/09 205 Feb 1/09
209 Feb 1/09 206 Feb 1/09
210 Feb 1/09 207 Feb 1/09
211 Feb 1/09 208 Feb 1/09
212 Feb 1/09 209 Feb 1/09
213 Feb 1/09 210 Feb 1/09
214 BLANK 211 Feb 1/09
212 Feb 1/09
Repair 006 201 Feb 1/09 213 Feb 1/09
(CANCELLED) 202 BLANK 214 Feb 1/09
202 Feb 1/09 (CANCELLED) 202 BLANK
203 Feb 1/09
204 Feb 1/09 Repair 012 201 Feb 1/09
205 Feb 1/09 202 Feb 1/09
206 Feb 1/09 203 Feb 1/09
207 Feb 1/09 204 Feb 1/09
208 Feb 1/09 205 Feb 1/09
209 Feb 1/09 206 Feb 1/09
210 Feb 1/09 207 Feb 1/09
211 Feb 1/09 208 Feb 1/09
212 Feb 1/09 209 Feb 1/09

Page 8

(Cont.) 211 Feb 1/09 (Cont.) 205 Feb 1/09
212 Feb 1/09 206 Feb 1/09
213 Feb 1/09 207 Feb 1/09
214 BLANK 208 Feb 1/09
209 Feb 1/09
Repair 013 201 Feb 1/09 210 Feb 1/09
202 Feb 1/09 211 Feb 1/09
203 Feb 1/09 212 Feb 1/09
204 Feb 1/09
205 Feb 1/09 Repair 016 201 Feb 1/09
206 Feb 1/09 202 Feb 1/09
207 Feb 1/09 203 Feb 1/09
208 Feb 1/09 204 BLANK
209 Feb 1/09
210 Feb 1/09 Repair 021 201 Feb 1/09
211 Feb 1/09 202 Feb 1/09
212 Feb 1/09 203 Feb 1/09
213 Feb 1/09 204 Feb 1/09
214 BLANK 205 Feb 1/09
206 Feb 1/09
Repair 014 201 Feb 1/09 207 Feb 1/09
202 Feb 1/09 208 Feb 1/09
203 Feb 1/09 209 Feb 1/09
204 Feb 1/09 210 Feb 1/09
205 Feb 1/09 211 Feb 1/09
206 Feb 1/09 212 BLANK
207 Feb 1/09
208 Feb 1/09 Repair 022 201 Feb 1/09
209 Feb 1/09 202 Feb 1/09
210 Feb 1/09 203 Feb 1/09
211 Feb 1/09 204 Feb 1/09
212 Feb 1/09 205 Feb 1/09
213 Feb 1/09 206 Feb 1/09
214 Feb 1/09 207 Feb 1/09
215 Feb 1/09 208 BLANK
216 Feb 1/09
217 Feb 1/09 Repair 023 201 Feb 1/09
218 Feb 1/09 202 Feb 1/09
219 Feb 1/09 203 Feb 1/09
220 BLANK 204 Feb 1/09
205 Feb 1/09
Repair 015 201 Feb 1/09 206 Feb 1/09
202 Feb 1/09 207 Feb 1/09
203 Feb 1/09 208 BLANK

Page 9

202 Feb 1/09 (Cont.) 205 Feb 1/09
203 Feb 1/09 206 Feb 1/09
204 Feb 1/09 207 Feb 1/09
208 Feb 1/09
Repair 026 201 Feb 1/09 209 Feb 1/09
202 Feb 1/09 210 BLANK
203 Feb 1/09
204 Feb 1/09 Repair 031 201 Feb 1/09
205 Feb 1/09 202 Feb 1/09
206 Feb 1/09 203 Feb 1/09
207 Feb 1/09 204 Feb 1/09
208 Feb 1/09 205 Feb 1/09
209 Feb 1/09 206 BLANK
210 Feb 1/09
211 Feb 1/09 Repair 032 201 Feb 1/09
212 Feb 1/09 202 Feb 1/09
203 Feb 1/09
Repair 027 201 Feb 1/09 204 Feb 1/09
202 Feb 1/09 205 Feb 1/09
203 Feb 1/09 206 Feb 1/09
204 Feb 1/09 207 Feb 1/09
205 Feb 1/09 208 Feb 1/09
206 Feb 1/09
207 Feb 1/09 Repair 033 201 Feb 1/09
208 Feb 1/09 202 Feb 1/09
209 Feb 1/09 203 Feb 1/09
210 Feb 1/09 204 Feb 1/09
211 Feb 1/09 205 Feb 1/09
212 Feb 1/09 206 Feb 1/09
207 Feb 1/09
Repair 029 201 Feb 1/09 208 Feb 1/09
202 Feb 1/09 209 Feb 1/09
203 Feb 1/09 210 Feb 1/09
204 Feb 1/09 211 Feb 1/09
205 Feb 1/09 212 Feb 1/09
206 Feb 1/09
207 Feb 1/09 Repair 034 201 Feb 1/09
208 Feb 1/09 202 Feb 1/09
209 Feb 1/09 203 Feb 1/09
210 Feb 1/09 204 Feb 1/09
205 Feb 1/09
Repair 030 201 Feb 1/09 206 Feb 1/09
202 Feb 1/09 207 Feb 1/09
203 Feb 1/09 208 Feb 1/09

Page 10

Repair 034 209 Feb 1/09 54-20-00 116 Feb 1/09
(Cont.) 210 Feb 1/09 Fan Cowl - 117 Feb 1/09
211 Feb 1/09 Allowable 118 Feb 1/09
212 Feb 1/09 Damage 119 Feb 1/09
213 Feb 1/09 (Cont.) 120 Feb 1/09
214 Feb 1/09 121 Feb 1/09
215 Feb 1/09 122 Feb 1/09
216 BLANK 123 Feb 1/09
124 Feb 1/09
54-20-00 1 Feb 1/09 125 Feb 1/09
Fan Cowl 2 Feb 1/09 126 Feb 1/09
Structure 3 Feb 1/09 127 Feb 1/09
Identification 4 Feb 1/09 128 Feb 1/09
5 Feb 1/09 129 Feb 1/09
6 Feb 1/09 130 Feb 1/09
7 Feb 1/09 131 Feb 1/09
8 Feb 1/09 132 BLANK
9 Feb 1/09
10 Feb 1/09 General Repair 201 Feb 1/09
11 Feb 1/09 202 Feb 1/09
12 Feb 1/09 203 Feb 1/09
13 Feb 1/09 204 Feb 1/09
14 Feb 1/09 205 Feb 1/09
15 Feb 1/09 206 BLANK
16 Feb 1/09
17 Feb 1/09 List of 201 Feb 1/09
18 Feb 1/09 Approved 202 Feb 1/09
19 Feb 1/09 Repairs 203 Feb 1/09
20 BLANK 204 Feb 1/09
54-20-00 101 Feb 1/09 Repair 001 201 Feb 1/09
Fan Cowl - 102 Feb 1/09 202 Feb 1/09
Damage 104 Feb 1/09 204 Feb 1/09
105 Feb 1/09 205 Feb 1/09
106 Feb 1/09 206 BLANK
107 Feb 1/09
108 Feb 1/09 Repair 002 201 Feb 1/09
109 Feb 1/09 202 Feb 1/09
110 Feb 1/09 203 Feb 1/09
111 Feb 1/09 204 Feb 1/09
112 Feb 1/09 205 Feb 1/09
113 Feb 1/09 206 Feb 1/09
114 Feb 1/09 207 Feb 1/09
115 Feb 1/09 208 Feb 1/09

Page 11

(Cont.) 210 Feb 1/09 (Cont.) 205 Feb 1/09
211 Feb 1/09 206 Feb 1/09
212 Feb 1/09 207 Feb 1/09
213 Feb 1/09 208 Feb 1/09
214 Feb 1/09 209 Feb 1/09
215 Feb 1/09 210 Feb 1/09
216 Feb 1/09 211 Feb 1/09
217 Feb 1/09 212 Feb 1/09
218 Feb 1/09 213 Feb 1/09
219 Feb 1/09 214 Feb 1/09
220 Feb 1/09 215 Feb 1/09
221 Feb 1/09 216 Feb 1/09
222 Feb 1/09 217 Feb 1/09
223 Feb 1/09 218 Feb 1/09
224 Feb 1/09
225 Feb 1/09 Repair 005 201 Feb 1/09
202 Feb 1/09 202 Feb 1/09
203 Feb 1/09 203 Feb 1/09
204 Feb 1/09 204 Feb 1/09
205 Feb 1/09 205 Feb 1/09
206 Feb 1/09 206 BLANK
207 Feb 1/09
208 Feb 1/09 Repair 007 201 Feb 1/09
209 Feb 1/09 202 Feb 1/09
210 Feb 1/09 203 Feb 1/09
211 Feb 1/09 204 Feb 1/09
212 Feb 1/09 205 Feb 1/09
213 Feb 1/09 206 Feb 1/09
214 Feb 1/09 207 Feb 1/09
215 Feb 1/09 208 Feb 1/09
216 Feb 1/09 209 Feb 1/09
217 Feb 1/09 210 Feb 1/09
218 Feb 1/09 211 Feb 1/09
219 Feb 1/09 212 Feb 1/09
220 Feb 1/09 213 Feb 1/09
221 Feb 1/09 214 Feb 1/09
222 BLANK 215 Feb 1/09
216 BLANK
Repair 004 201 Feb 1/09
202 Feb 1/09 Repair 008 201 Feb 1/09
203 Feb 1/09 202 Feb 1/09

Page 12

(Cont.) 204 Feb 1/09 (Cont.) 215 Feb 1/09
205 Feb 1/09 216 BLANK
206 Feb 1/09
207 Feb 1/09 Repair 012 201 Feb 1/09
208 Feb 1/09 202 Feb 1/09
209 Feb 1/09 203 Feb 1/09
210 Feb 1/09 204 Feb 1/09
211 Feb 1/09 205 Feb 1/09
212 Feb 1/09 206 Feb 1/09
213 Feb 1/09
214 Feb 1/09 Repair 013 201 Feb 1/09
215 Feb 1/09 202 Feb 1/09
216 Feb 1/09 203 Feb 1/09
217 Feb 1/09 204 Feb 1/09
218 BLANK 205 Feb 1/09
206 Feb 1/09
Repair 009 201 Feb 1/09 207 Feb 1/09
202 Feb 1/09 208 Feb 1/09
203 Feb 1/09 209 Feb 1/09
204 Feb 1/09 210 Feb 1/09
205 Feb 1/09 211 Feb 1/09
206 Feb 1/09 212 Feb 1/09
207 Feb 1/09 213 Feb 1/09
208 Feb 1/09 214 Feb 1/09
209 Feb 1/09 215 Feb 1/09
210 Feb 1/09 216 BLANK
211 Feb 1/09
212 Feb 1/09 Repair 014 201 Feb 1/09
213 Feb 1/09 202 Feb 1/09
214 BLANK 203 Feb 1/09
204 Feb 1/09
Repair 010 201 Feb 1/09 205 Feb 1/09
202 Feb 1/09 206 Feb 1/09
203 Feb 1/09 207 Feb 1/09
204 Feb 1/09 208 Feb 1/09
205 Feb 1/09 209 Feb 1/09
206 Feb 1/09 210 Feb 1/09
207 Feb 1/09 211 Feb 1/09
208 Feb 1/09 212 Feb 1/09
209 Feb 1/09 213 Feb 1/09
210 Feb 1/09 214 Feb 1/09
211 Feb 1/09
212 Feb 1/09 Repair 015 201 Feb 1/09
213 Feb 1/09 202 Feb 1/09

Page 13

(Cont.) 204 Feb 1/09 (Cont.) 204 Feb 1/09
205 Feb 1/09 205 Feb 1/09
206 Feb 1/09 206 Feb 1/09
207 Feb 1/09 207 Feb 1/09
208 Feb 1/09 208 Feb 1/09
209 Feb 1/09 209 Feb 1/09
210 Feb 1/09 210 Feb 1/09
211 Feb 1/09 211 Feb 1/09
212 Feb 1/09 212 Feb 1/09
213 Feb 1/09 213 Feb 1/09
214 Feb 1/09 214 Feb 1/09
215 Feb 1/09 215 Feb 1/09
216 Feb 1/09 216 Feb 1/09
217 Feb 1/09
Repair 016 201 Feb 1/09 218 Feb 1/09
220 Feb 1/09
Repair 017 201 Feb 1/09 221 Feb 1/09
223 Feb 1/09
Repair 018 201 Feb 1/09 224 Feb 1/09
202 Feb 1/09 225 Feb 1/09
203 Feb 1/09 226 Feb 1/09
204 Feb 1/09
205 Feb 1/09 Repair 021 201 Feb 1/09
206 Feb 1/09 202 Feb 1/09
207 Feb 1/09 203 Feb 1/09
208 Feb 1/09 204 Feb 1/09
209 Feb 1/09
210 Feb 1/09 Repair 022 201 Feb 1/09
211 Feb 1/09 202 Feb 1/09
212 Feb 1/09
213 Feb 1/09 Repair 023 201 Feb 1/09
214 Feb 1/09 202 Feb 1/09
215 Feb 1/09 203 Feb 1/09
216 Feb 1/09 204 Feb 1/09
217 Feb 1/09 205 Feb 1/09
218 Feb 1/09 206 BLANK
203 Feb 1/09
Repair 020 201 Feb 1/09 204 Feb 1/09
202 Feb 1/09 205 Feb 1/09

Page 14

(Cont.) 207 Feb 1/09 (Cont.) 204 Feb 1/09
208 Feb 1/09 205 Feb 1/09
209 Feb 1/09 206 Feb 1/09
210 Feb 1/09
211 Feb 1/09 Repair 030 201 Feb 1/09
212 Feb 1/09 202 Feb 1/09
213 Feb 1/09 203 Feb 1/09
214 Feb 1/09 204 Feb 1/09
215 Feb 1/09 205 Feb 1/09
216 Feb 1/09 206 BLANK
202 Feb 1/09 202 Feb 1/09
203 Feb 1/09 203 Feb 1/09
204 Feb 1/09 204 Feb 1/09
205 Feb 1/09 205 Feb 1/09
206 Feb 1/09 206 Feb 1/09
207 Feb 1/09 207 Feb 1/09
208 Feb 1/09 208 Feb 1/09
209 Feb 1/09 209 Feb 1/09
210 Feb 1/09 210 Feb 1/09
211 Feb 1/09 211 Feb 1/09
212 Feb 1/09 212 BLANK
213 Feb 1/09
214 Feb 1/09 Repair 033 201 Feb 1/09
215 Feb 1/09 202 Feb 1/09
216 BLANK 203 Feb 1/09
204 Feb 1/09
Repair 026 201 Feb 1/09
202 Feb 1/09 Repair 034 201 Feb 1/09
203 Feb 1/09 202 Feb 1/09
204 Feb 1/09 203 Feb 1/09
205 Feb 1/09 204 Feb 1/09
206 Feb 1/09 205 Feb 1/09
206 Feb 1/09
Repair 028 201 Feb 1/09 207 Feb 1/09
202 Feb 1/09 208 Feb 1/09
203 Feb 1/09
204 Feb 1/09 Repair 035 201 Feb 1/09
205 Feb 1/09 202 Feb 1/09
206 BLANK 203 Feb 1/09
204 Feb 1/09
Repair 029 201 Feb 1/09 205 Feb 1/09
202 Feb 1/09 206 Feb 1/09

Page 15

(Cont.) 208 Feb 1/09 202 Feb 1/09
209 Feb 1/09 203 Feb 1/09
210 Feb 1/09 204 Feb 1/09
211 Feb 1/09 205 Feb 1/09
212 Feb 1/09 206 Feb 1/09
213 Feb 1/09 207 Feb 1/09
214 Feb 1/09 208 Feb 1/09
215 Feb 1/09 209 Feb 1/09
216 Feb 1/09 210 Feb 1/09
217 Feb 1/09 211 Feb 1/09
218 Feb 1/09 212 Feb 1/09
219 Feb 1/09 213 Feb 1/09
220 BLANK 214 Feb 1/09
215 Feb 1/09
Repair 036 201 Feb 1/09 216 Feb 1/09
202 Feb 1/09 217 Feb 1/09
203 Feb 1/09 218 Feb 1/09
204 Feb 1/09 219 Feb 1/09
205 Feb 1/09 220 Feb 1/09
206 Feb 1/09 221 Feb 1/09
207 Feb 1/09 222 BLANK
208 Feb 1/09
209 Feb 1/09 Repair 039 201 Feb 1/09
210 Feb 1/09 202 Feb 1/09
211 Feb 1/09 203 Feb 1/09
212 Feb 1/09 204 Feb 1/09
213 Feb 1/09 205 Feb 1/09
214 Feb 1/09 206 BLANK
202 Feb 1/09 202 Feb 1/09
203 Feb 1/09 203 Feb 1/09
204 Feb 1/09 204 Feb 1/09
205 Feb 1/09 205 Feb 1/09
206 Feb 1/09 206 Feb 1/09
207 Feb 1/09 207 Feb 1/09
208 Feb 1/09 208 Feb 1/09
209 Feb 1/09 209 Feb 1/09
210 Feb 1/09 210 Feb 1/09
211 Feb 1/09 211 Feb 1/09
212 Feb 1/09 212 Feb 1/09
213 Feb 1/09 213 Feb 1/09
214 Feb 1/09 214 Feb 1/09
215 Feb 1/09

Page 16

Repair 055 216 Feb 1/09 54-30-00 *38 Aug 1/09
(Cont.) 217 Feb 1/09 Thrust Reverser *39 Aug 1/09
218 Feb 1/09 Structure *40 Aug 1/09
219 Feb 1/09 Identification *41 Aug 1/09
220 Feb 1/09 (Cont.) *42 Aug 1/09
221 Feb 1/09 *43 Aug 1/09
222 Feb 1/09 *44 Aug 1/09
*45 Aug 1/09
54-30-00 *1 Aug 1/09 *46 Aug 1/09
Thrust Reverser *2 Aug 1/09 *47 Aug 1/09
Structure *3 Aug 1/09 *48 Aug 1/09
Identification *4 Aug 1/09 *49 Aug 1/09
*5 Aug 1/09 *50 Aug 1/09
*6 Aug 1/09 *51 Aug 1/09
*7 Aug 1/09 *52 Aug 1/09
*8 Aug 1/09 *53 Aug 1/09
*9 Aug 1/09 *54 Aug 1/09
*10 Aug 1/09 *55 Aug 1/09
*11 Aug 1/09 *56 Aug 1/09
*12 Aug 1/09 *57 Aug 1/09
*13 Aug 1/09 *58 Aug 1/09
*14 Aug 1/09 *59 Aug 1/09
*15 Aug 1/09 *60 Aug 1/09
*16 Aug 1/09 *61 Aug 1/09
*17 Aug 1/09 *62 Aug 1/09
*18 Aug 1/09 *63 Aug 1/09
*19 Aug 1/09 *64 Aug 1/09
*20 Aug 1/09 *65 Aug 1/09
*21 Aug 1/09 *66 Aug 1/09
*22 Aug 1/09 *67 Aug 1/09
*23 Aug 1/09 *68 Aug 1/09
*24 Aug 1/09 *69 Aug 1/09
*25 Aug 1/09 *70 Aug 1/09
*26 Aug 1/09 *71 Aug 1/09
*27 Aug 1/09 *72 Aug 1/09
*28 Aug 1/09 *73 Aug 1/09
*29 Aug 1/09 *74 Aug 1/09
*30 Aug 1/09 *75 Aug 1/09
*31 Aug 1/09 *76 Aug 1/09
*32 Aug 1/09 *77 Aug 1/09
*33 Aug 1/09 *78 Aug 1/09
*34 Aug 1/09 *79 Aug 1/09
*35 Aug 1/09 *80 Aug 1/09
*36 Aug 1/09 *81 Aug 1/09
*37 Aug 1/09 *82 Aug 1/09

Page 17

54-30-00 *83 Aug 1/09 54-30-00 *133 Aug 1/09
Thrust Reverser *84 Aug 1/09 Thrust Reverser *134 Aug 1/09
Structure *85 Aug 1/09 Allowable *135 Aug 1/09
Identification *86 Aug 1/09 Damage (Cont.) *136 Aug 1/09
(Cont.) *87 Aug 1/09 *137 Aug 1/09
*88 Aug 1/09 *138 Aug 1/09
*89 Aug 1/09 *139 Aug 1/09
*90 Aug 1/09 *140 Aug 1/09
*91 Aug 1/09 *141 Aug 1/09
*92 Aug 1/09 *142 Aug 1/09
(N)93 Aug 1/09 *143 Aug 1/09
(N)94 Aug 1/09 *144 Aug 1/09
*145 Aug 1/09
54-30-00 *101 Aug 1/09 *146 Aug 1/09
Thrust Reverser *102 Aug 1/09 *147 Aug 1/09
Allowable *103 Aug 1/09 *148 Aug 1/09
Damage *104 Aug 1/09 *149 Aug 1/09
*105 Aug 1/09 *150 Aug 1/09
*106 Aug 1/09 *151 Aug 1/09
*107 Aug 1/09 *152 Aug 1/09
*108 Aug 1/09 *153 Aug 1/09
*109 Aug 1/09 *154 Aug 1/09
*110 Aug 1/09
*111 Aug 1/09 General Repair 201 Feb 1/09
*112 Aug 1/09 202 Feb 1/09
*113 Aug 1/09 203 Feb 1/09
*114 Aug 1/09 204 Feb 1/09
*115 Aug 1/09 205 Feb 1/09
*116 Aug 1/09 206 Feb 1/09
*117 Aug 1/09
*118 Aug 1/09 List of 201 Feb 1/09
*119 Aug 1/09 Approved 202 Feb 1/09
*120 Aug 1/09 Repairs 203 Feb 1/09
*121 Aug 1/09 204 Feb 1/09
*122 Aug 1/09 205 Feb 1/09
*123 Aug 1/09 206 Feb 1/09
*124 Aug 1/09
*125 Aug 1/09 Repair 001 201 Feb 1/09
*126 Aug 1/09 202 Feb 1/09
*127 Aug 1/09 203 Feb 1/09
*128 Aug 1/09 204 Feb 1/09
*129 Aug 1/09 205 Feb 1/09
*130 Aug 1/09 206 Feb 1/09
*131 Aug 1/09 207 Feb 1/09
*132 Aug 1/09 208 Feb 1/09

Page 18

203 Feb 1/09
204 Feb 1/09 Repair 006 201 Feb 1/09
205 Feb 1/09 202 Feb 1/09
206 Feb 1/09 203 Feb 1/09
207 Feb 1/09 204 Feb 1/09
208 Feb 1/09 205 Feb 1/09
209 Feb 1/09 206 Feb 1/09
210 Feb 1/09 207 Feb 1/09
211 Feb 1/09 208 Feb 1/09
212 Feb 1/09 209 Feb 1/09
213 Feb 1/09 210 Feb 1/09
214 Feb 1/09 211 Feb 1/09
215 Feb 1/09 212 Feb 1/09
216 Feb 1/09
217 Feb 1/09 Repair 007 201 Feb 1/09
218 Feb 1/09 202 Feb 1/09
203 Feb 1/09
Repair 003 201 Feb 1/09 204 Feb 1/09
202 Feb 1/09 205 Feb 1/09
203 Feb 1/09 206 Feb 1/09
204 Feb 1/09 207 Feb 1/09
205 Feb 1/09 208 BLANK
206 Feb 1/09
207 Feb 1/09 Repair 008 201 Feb 1/09
208 Feb 1/09 202 Feb 1/09
209 Feb 1/09 203 Feb 1/09
210 Feb 1/09 204 Feb 1/09
211 Feb 1/09 205 Feb 1/09
212 Feb 1/09 206 Feb 1/09
213 Feb 1/09 207 Feb 1/09
214 Feb 1/09 208 Feb 1/09
215 Feb 1/09 209 Feb 1/09
216 Feb 1/09 210 Feb 1/09
217 Feb 1/09 211 Feb 1/09
218 BLANK 212 Feb 1/09
213 Feb 1/09
Repair 004 201 Feb 1/09 214 Feb 1/09
202 Feb 1/09 215 Feb 1/09
203 Feb 1/09 216 Feb 1/09
204 Feb 1/09 217 Feb 1/09
205 Feb 1/09 218 Feb 1/09
206 BLANK 219 Feb 1/09
220 BLANK

Page 19

202 Feb 1/09 (Cont.) 205 Feb 1/09
203 Feb 1/09 206 Feb 1/09
204 Feb 1/09 207 Feb 1/09
205 Feb 1/09 208 Feb 1/09
206 Feb 1/09 209 Feb 1/09
207 Feb 1/09 210 Feb 1/09
208 Feb 1/09 211 Feb 1/09
209 Feb 1/09 212 Feb 1/09
210 Feb 1/09 213 Feb 1/09
211 Feb 1/09 214 Feb 1/09
212 Feb 1/09 215 Feb 1/09
216 Feb 1/09
Repair 010 201 Feb 1/09 217 Feb 1/09
202 Feb 1/09 218 Feb 1/09
203 Feb 1/09 219 Feb 1/09
204 Feb 1/09 220 Feb 1/09
205 Feb 1/09 221 Feb 1/09
206 Feb 1/09 222 Feb 1/09
207 Feb 1/09 223 Feb 1/09
208 Feb 1/09 224 BLANK
209 Feb 1/09
210 Feb 1/09 Repair 014 201 Feb 1/09
211 Feb 1/09 202 Feb 1/09
212 Feb 1/09 203 Feb 1/09
213 Feb 1/09 204 Feb 1/09
214 Feb 1/09 205 Feb 1/09
215 Feb 1/09 206 Feb 1/09
216 BLANK 207 Feb 1/09
208 Feb 1/09
Repair 011 201 Feb 1/09 209 Feb 1/09
211 Feb 1/09
Repair 012 201 Feb 1/09 212 Feb 1/09
202 Feb 1/09 213 Feb 1/09
203 Feb 1/09 214 Feb 1/09
204 Feb 1/09 215 Feb 1/09
205 Feb 1/09 216 Feb 1/09
206 Feb 1/09 217 Feb 1/09
207 Feb 1/09 218 Feb 1/09
208 Feb 1/09
Repair 015 201 Feb 1/09
Repair 013 201 Feb 1/09 202 Feb 1/09
202 Feb 1/09 203 Feb 1/09
203 Feb 1/09 204 Feb 1/09

Page 20

(Cont.) 206 Feb 1/09 (Cont.) 204 Feb 1/09
207 Feb 1/09 205 Feb 1/09
208 Feb 1/09 206 Feb 1/09
209 Feb 1/09 207 Feb 1/09
210 Feb 1/09 208 BLANK
211 Feb 1/09
212 Feb 1/09 Repair 021 201 Feb 1/09
213 Feb 1/09 202 Feb 1/09
214 Feb 1/09 203 Feb 1/09
204 Feb 1/09
Repair 016 201 Feb 1/09 205 Feb 1/09
202 Feb 1/09 206 Feb 1/09
203 Feb 1/09 207 Feb 1/09
204 Feb 1/09 208 Feb 1/09
205 Feb 1/09 209 Feb 1/09
206 Feb 1/09 210 BLANK
207 Feb 1/09
208 Feb 1/09 Repair 022 201 Feb 1/09
209 Feb 1/09 202 Feb 1/09
210 Feb 1/09 203 Feb 1/09
211 Feb 1/09 204 Feb 1/09
212 Feb 1/09 205 Feb 1/09
213 Feb 1/09 206 BLANK
214 Feb 1/09
215 Feb 1/09 Repair 023 201 Feb 1/09
216 Feb 1/09 202 Feb 1/09
217 Feb 1/09 203 Feb 1/09
218 Feb 1/09 204 Feb 1/09
219 Feb 1/09
220 Feb 1/09 Repair 024 201 Feb 1/09
221 Feb 1/09 202 Feb 1/09
222 Feb 1/09 203 Feb 1/09
204 Feb 1/09
Repair 017 201 Feb 1/09 205 Feb 1/09
202 Feb 1/09 206 Feb 1/09
203 Feb 1/09 207 Feb 1/09
204 Feb 1/09 208 Feb 1/09
205 Feb 1/09 209 Feb 1/09
206 Feb 1/09 210 Feb 1/09
207 Feb 1/09
208 Feb 1/09 Repair 025 201 Feb 1/09
202 Feb 1/09
Repair 020 201 Feb 1/09 203 Feb 1/09
202 Feb 1/09 204 BLANK

Page 21

202 Feb 1/09 (Cont.) 214 Feb 1/09
203 Feb 1/09 215 Feb 1/09
204 Feb 1/09 216 Feb 1/09
205 Feb 1/09 217 Feb 1/09
206 Feb 1/09 218 Feb 1/09
207 Feb 1/09 219 Feb 1/09
208 Feb 1/09 220 Feb 1/09
209 Feb 1/09 221 Feb 1/09
210 Feb 1/09 222 Feb 1/09
211 Feb 1/09 223 Feb 1/09
212 Feb 1/09 224 Feb 1/09
213 Feb 1/09 225 Feb 1/09
214 BLANK 226 Feb 1/09
227 Feb 1/09
Repair 027 201 Feb 1/09 228 Feb 1/09
202 Feb 1/09 229 Feb 1/09
203 Feb 1/09 230 Feb 1/09
204 Feb 1/09 231 Feb 1/09
205 Feb 1/09 232 Feb 1/09
206 Feb 1/09 233 Feb 1/09
207 Feb 1/09 234 Feb 1/09
208 BLANK 235 Feb 1/09
236 Feb 1/09
Repair 028 201 Feb 1/09 237 Feb 1/09
202 Feb 1/09 238 Feb 1/09
203 Feb 1/09
204 Feb 1/09 Repair 030 201 Feb 1/09
205 Feb 1/09 202 BLANK
206 Feb 1/09
207 Feb 1/09 Repair 031 *201 Aug 1/09
208 BLANK *202 Aug 1/09
*203 Aug 1/09
Repair 029 201 Feb 1/09 *204 Aug 1/09
202 Feb 1/09 *205 Aug 1/09
203 Feb 1/09 *206 Aug 1/09
204 Feb 1/09 *207 Aug 1/09
205 Feb 1/09 *208 Aug 1/09
206 Feb 1/09 *209 Aug 1/09
207 Feb 1/09 210 BLANK
208 Feb 1/09
209 Feb 1/09 Repair 032 *201 Aug 1/09
210 Feb 1/09 *202 Aug 1/09
211 Feb 1/09 *203 Aug 1/09
212 Feb 1/09 *204 Aug 1/09

Page 22

Repair 032 *205 Aug 1/09 Repair 033 *221 Aug 1/09
(Cont.) *206 Aug 1/09 (Cont.) *222 Aug 1/09
*207 Aug 1/09 *223 Aug 1/09
*208 Aug 1/09 *224 Aug 1/09
*209 Aug 1/09 *225 Aug 1/09
*210 Aug 1/09 *226 Aug 1/09
*211 Aug 1/09 *227 Aug 1/09
*212 Aug 1/09 *228 Aug 1/09
*213 Aug 1/09 *229 Aug 1/09
*214 Aug 1/09 *230 Aug 1/09
*215 Aug 1/09 (N)231 Aug 1/09
*216 Aug 1/09 (N)232 Aug 1/09
*217 Aug 1/09
*218 Aug 1/09 Repair 034 201 Feb 1/09
*219 Aug 1/09 202 Feb 1/09
*220 Aug 1/09 203 Feb 1/09
*221 Aug 1/09 204 Feb 1/09
*222 Aug 1/09 205 Feb 1/09
*223 Aug 1/09 206 Feb 1/09
*224 Aug 1/09 207 Feb 1/09
*225 Aug 1/09 208 Feb 1/09
*226 Aug 1/09 209 Feb 1/09
*227 Aug 1/09 210 Feb 1/09
*228 Aug 1/09 211 Feb 1/09
212 Feb 1/09
Repair 033 *201 Aug 1/09 213 Feb 1/09
*202 Aug 1/09 214 Feb 1/09
*203 Aug 1/09 215 Feb 1/09
*204 Aug 1/09 216 Feb 1/09
*205 Aug 1/09 217 Feb 1/09
*206 Aug 1/09 218 Feb 1/09
*207 Aug 1/09 219 Feb 1/09
*208 Aug 1/09 220 Feb 1/09
*209 Aug 1/09 221 Feb 1/09
*210 Aug 1/09 222 Feb 1/09
*211 Aug 1/09 223 Feb 1/09
*212 Aug 1/09 224 Feb 1/09
*213 Aug 1/09 225 Feb 1/09
*214 Aug 1/09 226 Feb 1/09
*215 Aug 1/09 227 Feb 1/09
*216 Aug 1/09 228 Feb 1/09
*217 Aug 1/09 229 Feb 1/09
*218 Aug 1/09 230 Feb 1/09
*219 Aug 1/09 231 Feb 1/09
*220 Aug 1/09 232 BLANK

Page 23

202 Feb 1/09 (Cont.) 215 Feb 1/09
203 Feb 1/09 216 Feb 1/09
204 Feb 1/09 217 Feb 1/09
205 Feb 1/09 218 Feb 1/09
206 Feb 1/09 219 Feb 1/09
207 Feb 1/09 220 Feb 1/09
208 Feb 1/09 221 Feb 1/09
209 Feb 1/09 222 Feb 1/09
210 Feb 1/09 223 Feb 1/09
211 Feb 1/09 224 Feb 1/09
212 Feb 1/09
213 Feb 1/09 Repair 038 201 Feb 1/09
214 Feb 1/09 202 Feb 1/09
215 Feb 1/09 203 Feb 1/09
216 Feb 1/09 204 Feb 1/09
205 Feb 1/09
Repair 036 201 Feb 1/09 206 Feb 1/09
202 Feb 1/09 207 Feb 1/09
203 Feb 1/09 208 BLANK
204 Feb 1/09
205 Feb 1/09
206 Feb 1/09 Repair 039 201 Feb 1/09
207 Feb 1/09 202 Feb 1/09
208 Feb 1/09 203 Feb 1/09
209 Feb 1/09 204 Feb 1/09
210 Feb 1/09 205 Feb 1/09
211 Feb 1/09 206 Feb 1/09
212 Feb 1/09 207 Feb 1/09
213 Feb 1/09 208 Feb 1/09
214 Feb 1/09 209 Feb 1/09
210 Feb 1/09
Repair 037 201 Feb 1/09
202 Feb 1/09 Repair 040 201 Feb 1/09
203 Feb 1/09 202 Feb 1/09
204 Feb 1/09 203 Feb 1/09
205 Feb 1/09 204 Feb 1/09
206 Feb 1/09 205 Feb 1/09
207 Feb 1/09 206 Feb 1/09
208 Feb 1/09 207 Feb 1/09
209 Feb 1/09 208 Feb 1/09
210 Feb 1/09 209 Feb 1/09
211 Feb 1/09 210 BLANK
212 Feb 1/09
213 Feb 1/09

Page 24

202 Feb 1/09 (Cont.) 216 Feb 1/09
203 Feb 1/09 217 Feb 1/09
204 Feb 1/09 218 BLANK
205 Feb 1/09
206 Feb 1/09 Repair 045 201 Feb 1/09
207 Feb 1/09 202 Feb 1/09
208 Feb 1/09 203 Feb 1/09
204 Feb 1/09
Repair 042 201 Feb 1/09 205 Feb 1/09
202 Feb 1/09 206 Feb 1/09
203 Feb 1/09 207 Feb 1/09
204 Feb 1/09 208 Feb 1/09
205 Feb 1/09 209 Feb 1/09
206 Feb 1/09 210 Feb 1/09
207 Feb 1/09 211 Feb 1/09
208 Feb 1/09 212 Feb 1/09
213 Feb 1/09
Repair 043 201 Feb 1/09 214 Feb 1/09
202 Feb 1/09 215 Feb 1/09
203 Feb 1/09 216 BLANK
204 Feb 1/09
205 Feb 1/09
206 Feb 1/09 Repair 046 201 Feb 1/09
207 Feb 1/09 202 Feb 1/09
208 Feb 1/09 203 Feb 1/09
209 Feb 1/09 204 Feb 1/09
210 Feb 1/09 205 Feb 1/09
211 Feb 1/09 206 Feb 1/09
212 Feb 1/09 207 Feb 1/09
208 Feb 1/09
Repair 044 201 Feb 1/09 209 Feb 1/09
202 Feb 1/09 210 Feb 1/09
203 Feb 1/09 211 Feb 1/09
204 Feb 1/09 212 Feb 1/09
205 Feb 1/09
206 Feb 1/09 Repair 047 201 Feb 1/09
207 Feb 1/09 202 Feb 1/09
208 Feb 1/09 203 Feb 1/09
209 Feb 1/09 204 Feb 1/09
210 Feb 1/09 205 Feb 1/09
211 Feb 1/09 206 Feb 1/09
212 Feb 1/09 207 Feb 1/09
213 Feb 1/09 208 Feb 1/09
214 Feb 1/09 209 Feb 1/09

Page 25

(Cont.) 211 Feb 1/09 (Cont.) 226 Feb 1/09
212 Feb 1/09
213 Feb 1/09 Repair 050 201 Feb 1/09
214 Feb 1/09 202 Feb 1/09
215 Feb 1/09 203 Feb 1/09
216 Feb 1/09 204 Feb 1/09
217 Feb 1/09 205 Feb 1/09
218 Feb 1/09 206 Feb 1/09
219 Feb 1/09 207 Feb 1/09
220 Feb 1/09 208 Feb 1/09
209 Feb 1/09
Repair 048 *201 Aug 1/09 210 Feb 1/09
*202 Aug 1/09 211 Feb 1/09
*203 Aug 1/09 212 Feb 1/09
*204 Aug 1/09 213 Feb 1/09
*205 Aug 1/09 214 Feb 1/09
*206 Aug 1/09 215 Feb 1/09
*207 Aug 1/09 216 Feb 1/09
*208 Aug 1/09 217 Feb 1/09
218 Feb 1/09
Repair 049 201 Feb 1/09
202 Feb 1/09 Repair 051 201 Feb 1/09
203 Feb 1/09 202 Feb 1/09
204 Feb 1/09 203 Feb 1/09
205 Feb 1/09 204 Feb 1/09
206 Feb 1/09 205 Feb 1/09
207 Feb 1/09 206 Feb 1/09
208 Feb 1/09 207 Feb 1/09
209 Feb 1/09 208 Feb 1/09
210 Feb 1/09 209 Feb 1/09
211 Feb 1/09 210 BLANK
212 Feb 1/09
213 Feb 1/09 Repair 052 201 Feb 1/09
214 Feb 1/09 202 Feb 1/09
215 Feb 1/09 203 Feb 1/09
216 Feb 1/09 204 Feb 1/09
217 Feb 1/09 205 Feb 1/09
218 Feb 1/09 206 Feb 1/09
219 Feb 1/09 207 Feb 1/09
220 Feb 1/09 208 Feb 1/09
221 Feb 1/09 209 Feb 1/09
222 Feb 1/09 210 Feb 1/09
221 Feb 1/09 211 Feb 1/09
224 Feb 1/09 212 Feb 1/09

Page 26

Repair 052 213 Feb 1/09 54-40-00 107 Feb 1/09
(Cont.) 214 Feb 1/09 Common Nozzle 108 BLANK
215 Feb 1/09 Assembly -
216 Feb 1/09 Allowable
217 Feb 1/09 Damage
218 BLANK (Cont.)
Repair 053 201 Feb 1/09 General Repair 201 Feb 1/09
202 Feb 1/09 202 Feb 1/09
203 Feb 1/09 203 Feb 1/09
204 Feb 1/09 204 Feb 1/09
205 Feb 1/09 205 Feb 1/09
206 Feb 1/09 206 BLANK
207 Feb 1/09
208 Feb 1/09 List of 201 Feb 1/09
209 Feb 1/09 Approved 202 BLANK
210 Feb 1/09 Repairs
211 Feb 1/09
212 Feb 1/09 Repair 001 201 Feb 1/09
213 Feb 1/09 202 Feb 1/09
214 Feb 1/09 203 Feb 1/09
215 Feb 1/09 204 Feb 1/09
216 Feb 1/09 205 Feb 1/09
217 Feb 1/09 206 Feb 1/09
218 Feb 1/09 207 Feb 1/09
219 Feb 1/09 208 Feb 1/09
220 BLANK 209 Feb 1/09
210 Feb 1/09
54-40-00 1 Feb 1/09 211 Feb 1/09
Mixed Exhaust 2 Feb 1/09 212 Feb 1/09
System - 3 Feb 1/09
Structure 4 Feb 1/09 Repair 002 201 Feb 1/09
Identification 5 Feb 1/09 202 Feb 1/09
6 Feb 1/09 203 Feb 1/09
7 Feb 1/09 204 Feb 1/09
8 Feb 1/09 205 Feb 1/09
9 Feb 1/09 206 Feb 1/09
10 Feb 1/09 207 Feb 1/09
208 Feb 1/09
54-40-00 101 Feb 1/09 209 Feb 1/09
Common Nozzle 102 Feb 1/09 210 Feb 1/09
Assembly - 103 Feb 1/09 211 Feb 1/09
Damage 105 Feb 1/09 213 Feb 1/09
106 Feb 1/09 214 Feb 1/09

Page 27

(Cont.) 216 Feb 1/09 202 Feb 1/09
217 Feb 1/09 203 Feb 1/09
218 Feb 1/09 204 Feb 1/09
219 Feb 1/09 205 Feb 1/09
220 BLANK 206 Feb 1/09
207 Feb 1/09
Repair 003 201 Feb 1/09 208 Feb 1/09
202 Feb 1/09 209 Feb 1/09
203 Feb 1/09 210 Feb 1/09
204 Feb 1/09 211 Feb 1/09
205 Feb 1/09 212 BLANK
206 Feb 1/09
207 Feb 1/09 Repair 006 201 Feb 1/09
208 Feb 1/09 202 Feb 1/09
209 Feb 1/09 203 Feb 1/09
210 Feb 1/09 204 Feb 1/09
211 Feb 1/09 205 Feb 1/09
212 Feb 1/09 206 Feb 1/09
213 Feb 1/09 207 Feb 1/09
214 Feb 1/09 208 BLANK
215 Feb 1/09
216 BLANK Repair 007 201 Feb 1/09
202 Feb 1/09
203 Feb 1/09
Repair 004 201 Feb 1/09 204 Feb 1/09
202 Feb 1/09 205 Feb 1/09
203 Feb 1/09 206 Feb 1/09
204 Feb 1/09 207 Feb 1/09
205 Feb 1/09 208 Feb 1/09
206 Feb 1/09 209 Feb 1/09
207 Feb 1/09 210 Feb 1/09
208 Feb 1/09 211 Feb 1/09
209 Feb 1/09 212 Feb 1/09
210 Feb 1/09 213 Feb 1/09
211 Feb 1/09 214 Feb 1/09
212 Feb 1/09 215 Feb 1/09
213 Feb 1/09 216 Feb 1/09
214 Feb 1/09
215 Feb 1/09 Repair 008 201 Feb 1/09
216 Feb 1/09 202 Feb 1/09
217 Feb 1/09 203 Feb 1/09
218 Feb 1/09 204 Feb 1/09
219 Feb 1/09 205 Feb 1/09
220 BLANK 206 Feb 1/09

Page 28

Repair 008 207 Feb 1/09
(Cont.) 208 Feb 1/09
209 Feb 1/09
210 Feb 1/09
211 Feb 1/09
212 Feb 1/09
213 Feb 1/09
214 Feb 1/09
215 Feb 1/09
216 Feb 1/09
Repair 009 201 Feb 1/09

202 Feb 1/09
203 Feb 1/09
204 Feb 1/09
205 Feb 1/09
206 Feb 1/09
207 Feb 1/09
208 BLANK
Repair 010 201 Feb 1/09

202 Feb 1/09
203 Feb 1/09
204 Feb 1/09
205 Feb 1/09
206 Feb 1/09
207 Feb 1/09
208 BLANK
Repair 011 201 Feb 1/09

202 Feb 1/09
203 Feb 1/09
204 Feb 1/09
205 Feb 1/09
206 Feb 1/09
207 Feb 1/09
208 Feb 1/09
209 Feb 1/09
210 Feb 1/09
211 Feb 1/09
212 BLANK

Page 29
V2500 54- LIST OF EFFECTIVE PAGES

Page 30
Aug 1/09
TABLE OF CONTENTS
Subject Page.
No.
Nacelle Introduction................................ 54-00-00 1
Abbreviations................................... 2
Nacelle Parts.................................... 3
Major Engineering Drawings....................... 4
Principle Nacelle Dimensions.................... 6
Nacelle Stationlines............................. 6
Nacelle Radials.................................. 6
Nacelle Zones and Panels......................... 10
Aerodynamic Smoothness........................... 17
Damage Types..................................... 29
Bulk Material Supplier’s List.................... 30
Consumable Materials Index....................... 30
Alphanumeric Index............................... 32
Materials Index.................................. 38
Suppliers Names Addresses........................ 50
Cautions, Warnings and Dangers................... 56
Damage Inspection................................... 54-01-00 1
Types of Damage.................................. 1
Corrosion Damage................................. 4
Composite Structure Tap Test..................... 4
Heat Damage...................................... 7
Acoustic Treatment Blockage Area Limits.......... 8
Damage Cleanup...................................... 54-01-01 1
Nick, Scratch, and Gouge Removal................. 1
Corrosion Damage Removal......................... 4
General Repair Procedures........................... 54-02-00 201

Protective Treatment of Metals................... 201
V2500 54- TABLE OF CONTENTS

Page 1
Feb 1/09
TABLE OF CONTENTS (CONT.)

Subject Page.
No.
Stop Drill Cracks................................ 54-02-00 203
Repair Sealant................................... 204
Formed/Extruded Section Repair................... 208
Honeycomb Repair................................. 208
List of Approved Repairs......................... 201
Repair No. 001 - Edge Erosion Repair Leading
Edge of Composit Repair Parts.... 201
Repair No. 002 - Moisture Removal Process...... 201
Repair No. 003 - Surface Preparation of
Aluminum Details Using
Phosphoric Acid Non Tank Anodize 201
(Panta).........................
Repair No. 004 - Composite Repairs Vacuum
Bagging Procedures.............. 201
Repair No. 005 - Paste and/or Liquid Adhesive
Mixing and curing............. 201
Repair No. 006 - Adhesive Primer Applications.. 201
Repair No. 007 – Wet Layup Process............. 201
Repair No. 008 - Fabrication and Installation
of Back-up Plate................ 201
Repair No. 009 - Honeycomb Core Repair Process. 201
Repair No. 010 – Pre-Impregnated Material
Handling and Curing............. 201
Repair No. 011 – Structural Adhesive Handling
and Curing...................... 201
Repair No. 012 – General Damage Blend Repair
for Mettalic Parts.............. 201
Repair No. 013 – Local Passivation Using
Pasajell 101 Method............. 201

Page 2
Feb 1/09

Subject Page.
No.
Inlet Cowl.......................................... 54-10-00 1
Structure Identification......................... 1
Allowable Damage................................. 101
Repairs.......................................... 201
Repair - General................................. 201
Repair No. 001 – Air Intake Cowl Aft Bulkhead
Surface Damage on the Composite
Repair........................ 201
Repair No. 002 - Air Intake Cowl Delamination
Repair.......................... 201
Repair No. 003 - Air Intake Cowl Edge
Delamination Repair............. 201
Repair No. 004 - Air Intake Cowl Aft Bulkhead
Honeycomb Repair................ 201
Repair No. 005 - Air Intake Cowl Outer Barrel
Surface Damage Repair........... 201
Repair No. 006 - DELETED -Air Intake Cowl
Acoustic Structure Hole Repair- 201
REFER TO VRS7504................
Repair No. 007 - Air Intake Cowl Crack and
Delamination Repair............. 201
Repair No. 008 - DELETED -Air Intake Cowl
Acoustic Structure Edge Damage 201
Repair....
Repair No. 009 - Air Intake Cowl Probe Access
Panel Opening Interface Land
Repair.......................... 201
Repair No. 010 - Air Intake Cowl Probe Access
Panel Interface Land Repair.... 201
Repair No. 011 - DELETED -Air Intake Cowl Outer
Barrel Splice Lands 201
Repair............

Page 3
Feb 1/09

Subject Page.
No.
Repair No. 012 - Air Intake Cowl Stiffener Area 54-10-00
Repair........................ 201
Repair No. 013 - Air Intake Cowl Access Panels
Surface Damage Repair.......... 201
Repair No. 014 - Air Intake Cowl Access Panels
Hole Repair.................... 201
Repair No. 015 - Air Intake Cowl Acoustic
Structure Surface Damage Repair 201
Repair No. 016 - Air Intake Cowl Hand Blend and
Polish Procedure Repair........ 201
Repair No. 021 - Air Intake Cowl Aerodynamic
Sealant Replacement............ 201
Repair No. 022 - Air Intake Cowl - Replace Pin
Receptacles.................... 201
Repair No. 023 - Air Intake Cowl - Coolant Duct
Replacement.................... 201
Repair No. 025 - Air Intake Cowl - Lip Skin
Inner Surface Rivet
Replacement Repair............ 201
Repair No. 026 - Air Intake Cowl - Lip Skin
Outer Surface Rivet
Replacement Repair............ 201
Repair No. 027- Acoustic Liner Wire Mesh/Facing
Sheet Delamination Repair...... 201
Repair No. 029 - Air Intake Cowl - Acoustic
Liner Facing Sheet Hole Damage
Repair......................... 201
Repair No. 030 - Air Intake Cowl – Worn Capping
Strap Repair................... 201
Repair No. 031 - Air Intake Cowl – Surface
Damage Blend Repair on the
Titanium Aft Bulkhead.......... 201
Repair No. 032 - Air Intake Cowl Titanium Aft
Bulkhead Web-Hole Repair....... 201

Page 4
Feb 1/09

Subject Page.
No.
Repair No. 033 - Air Intake Cowl-Titanium Aft 54-10-00
Bulkhead Damage Web Repair
Section Replacement............ 201
Repair No. 034 - Air Intake Cowl-Inner Barrel
Acoustic structure Hole
Repair........................ 201
Fan Cowl............................................ 54-20-00 1

Repair - General................................. 201
Repair No. 001 - Fan Cowl Edge Erosion Damage
Repair.......................... 201
Repair No. 002 - Fan Cowl Main Area Full
Penetration Repair.............. 201
Repair No. 003 - Fan Cowl Surface Damage Repair 201
Repair No. 004 - Fan Cowl Honeycomb Dent Repair 201
Repair No. 005 - DELETED -Left Fan Cowl
Scratches or Gouges Repair...... 201
Repair No. 006 - Fan Cowl Scratches or Gouges
Repair.......................... 201
Repair No. 007 - Fan Cowl Access Panel Opening
Lands Surface Damage Repair..... 201
Repair No. 008 - Left Fan Cowl Oil Filler and
Chip Detector Access Panel Land
repair.......................... 201
Repair No. 009 - Fan Cowl Access Panel
Interface Land Repair........... 201
Repair No. 010 - Left Fan Cowl Access Panels
Main Area Surface Damage Repair. 201
Repair No. 012 - Fan Cowl Edge Delamination
Repair......................... 201

Page 5
Feb 1/09

Subject Page.
No.
Repair No. 013 - Fan Cowl Delamination Repair.. 54-20-00 201
Repair No. 014 - Fan Cowl Door Lands Surface
Damage Repair.................. 201
Repair No. 015 - Fan Cowl Access Panel Lands
Repair No. 016 - DELETED -Fan Cowl Door Lands
Repair No. 017 - DELETED- Fan Cowl Access Panel
Openings Interface Lands 201
Repair.........
Repair No. 018 - Fan Cowl Aft Door Lands Repair 201
Repair No. 019 - DELETED -Fan Cowl Access Panel
Lands Surface Damage Repair.... 201
Repair No. 020 - Fan Cowl Part Penetration
Repair......................... 201
Repair No. 021 - Fan Cowl External Paint Damage
Repair......................... 201
Repair No. 022 - Fan Cowl Drains Mast Wall
Damage Repair.................. 201
Repair No. 023 - Left Fan Cowl Latch Bearing
Plate Replace.................. 201
Repair No. 024 - Air-Start Blow-off Door
Interface-Land Repair.......... 201
Repair No. 025 - Right Fan Cowl Access Panels
Main Area Surface Damage Repair. 201
Repair No. 026 - Right Fan Cowl Access Panels
Install Oversize Fasteners..... 201
Repair No. 028 - Air-Start Blow-Off Door Hinge
Repair......................... 201
Repair No. 029 - Left Fan Cowl Panels Install
Oversize Fasteners............. 201
Repair No. 030 - Oil Filler Hinge Door Repair.. 201

Page 6
Feb 1/09

Subject Page.
No.
Repair No. 031 - Fan Cowls Lightning Strike 54-20-00
Protection Repair.............. 201
Repair No. 033 - Fan Cowls Door Latch Handles
Paint Repair................... 201
Repair No. 034 - Fan Cowls Door Leading Edge
Erosion Repair................. 201
Repair No. 035 - Left Fan Cowl Laminate Oil
Filler Access Door Land Repair.. 201
Filler Access Door Main Area
Filler Access Door Lands Surface
Damage Repair.................. 201
Repair No. 038 - Fan Cowl Main Area Disbond
Repair......................... 201
Repair No. 039 - Fan Cowls-Replace the Corner
Plates......................... 201
Repair No. 055 - Fan Cowl Main Area Filler 201
Plate Repair . . . . . . . . . .
Thrust Reverser..................................... 54-30-00 1

Repairs.......................................... 201
Repair - General................................. 201
Repair No. 001 - Fixed Duct Heatshield Repair.. 201
Repair No. 002 - Fixed Duct Acoustic Panel
Perforate Skin Partial 201
Penetration Repair..............
Repair No. 003 - Fixed Duct Acoustic Panel Full
Penetration Repair.............. 201

Page 7
Feb 1/09

Subject Page.
No.
Repair No. 004 - Fixed Duct Woven Wire Scratch, 54-30-00
Rip, or Tear Repair............. 201
Repair No. 005 - DELETED-Fixed Duct Acoustic
Panel Bond Separation Repair 201
REFER TO V2500-NAC-78-0231 FOR
DISPOSITION....................
Perforated Skin Crack Repair.... 201
Outer Perforated Skin Small Hole
Repair......................... 201
Repair No. 008 - Translating Sleeve Outer
Barrel Laminated Skin Full
Penetration Hole Repair......... 201
Solid Skin Crack Repair......... 201
Partial Penetration through the
Solid Inner Skin Repair........ 201
Repair No. 011 - DELETED-Fixed Duct Aluminum
Skin/Honeycomb Bond Separation
Repair......................... 201
REFER TO V2500-NAC-78-0231 FOR
DISPOSITION
Repair No. 012 - Solid Inner Skin Small Hole
Repair Not Fully Through Panel
Left or Right Fixed Duct
Acoustic Panel................. 201
Barrel Full Penetration Hole 201
Repair.........................
Barrel Partial Penetration Hole 201
Repair.........................

Page 8
Feb 1/09

Subject Page.
No.
Repair No. 015 - Translating Sleeve Outer 54-30-00
Barrel Laminated Skin Surface
Damage Repair.................. 201
Barrel Forward/Aft Edge Repair. 201
Repair No. 017 - Outer Barrel Composite Skin
Delamination Repair Left or
Right Translating Sleeve....... 201
Repair No. 020 - Translating Sleeve Acoustic
Panel Perforated Inner Skin
Small Hole Repair.............. 201
Repair No. 021 - Translating Sleeve Acoustic
Panel Bond Separation Repair... 201
Repair No. 022 - Translating Sleeve Woven Wire
Scratch, Rip, or Tear Repair... 201
Repair No. 023 - Translating Sleeve External
Paint Replacement.............. 201
Repair No. 024 - Upper Hoist Point Nutplate
Replacement Repair Left or Right
Thrust Reverser................ 201
Repair No. 025 - Thrust Reverser Hinge Access
Panel Nutplate Replacement..... 201
Repair No. 026 - Aft Latch Fastener Replacement
Repair Left or Right Translating
Sleeve......................... 201
Repair No. 027 - Cascade Assembly Surface
Damage Blend Repair............ 201
Repair No. 028 - Cascade Assembly Cracked Vane
or Rail (Blades) Removal Repair. 201
Repair No. 029 - Woven Wire Replacement
DYNAROHRTM R/H and L/H Fixed Duct
Assemblies..................... 201
Repair No. 030 - Refer to SRM 54-02-00 Repair
No. 001 (VRS2082).............. 201

Page 9
Feb 1/09

Subject Page.
No.
Repair No. 031 - Edge Sealant Replacement 54-30-00
Repair 7th and 10th Stage Bleed
Valve Cutouts.................. 201
Repair No. 032 - Torque Ring Inner Fairing
Patch and Forward Frame Repair.. 201
Repair No. 033 - Torque Ring Forward Frame and
Inner Fairing Replacement
Repair......................... 201
Repair No. 034 - Torque Ring Inner Fairing and
Forward Frame Segment Repair... 201
Repair No. 035 - C-Duct Heatshield Weld Patch
Repair......................... 201
Repair No. 036 - Full Penetration Damage Repair
Of Composite Cone And Outer
Fairing C-duct Fixed Structure -
Left And Right Torque Ring
Assemblies..................... 201
Repair No. 037 - VRS2338 Doubler Repair Around
RH C-Duct 7th and 10th Stage
Bleed Valve.................... 201
Repair No. 038 - C-Duct, Pan-down Engine Bumper
Repair......................... 201
Repair No. 039 - Composite Cone And Composite
Fairing Partial Penetration
Repair C-duct Fixed Structure
Left And Right Torque Ring
Assemblies(Repair With M20 Pre-
impregnated Fabric)............ 201
Repair No. 040 - Bleed Port Closure
Installation Upper 7th Stage 201
Bleed Valve....................
Repair No. 041 - Left C-duct Fixed Structure
Repalce The Lower Track Nutplate
With A Blind Nut Assembly....... 201
Repair No. 042 - C-duct Fixed Structure Replace
Pivot Fitting.................. 201

Page 10
Feb 1/09

Subject Page.
No.
Repair No. 043 - VRS2323 Translating Sleeve 54-30-00
Blister Fairing Crack Repair... 201
Repair No. 044 - VRS2324 C-Duct, Pre-cooler
Duct Leading Edge Erosion Repair 201
Repair No. 045 - C-Duct Torque Ring, Metallic
Two-piece Inner Fairing Repair. 201
Repair No. 046 - Translating Sleeve (Config 2),
Outer Skin, Aft Section Metallic
Patch Repair................... 201
Repair No. 047 - Translating Sleeve Lower Area
Bottom Edge - Near Double Latch
Heat Damage Wet Layup Repair.... 201
Repair No. 048 - Translating Sleeve Missing And
Or Loose Rivets Repair......... 201
Repair No. 049 - Thrust Reverser, C-duct,
Pre-cooler Duct Leading Edge Wet
Lay-up Repair.................. 201
Repair No. 050 - Composite Blank Cascade Full
Penetration Repair............. 201
Repair No. 051 - Thrust Reverser, C-duct,
Torque Ring Tie-in Bracket Crack 201
Repair..........................
Repair No. 052 - Composite Blank Cascade
Partial Penetration Repair...... 201
Repair No. 053 - Thrust Reverser, Translating 201
Sleeve, Forward Edge Erosion
Repair..........................
Mixed Exhaust System................................ 54-40-00 1

Repairs.......................................... 201
Repair - General................................. 201

Page 11
Feb 1/09

Subject Page.
No.
List of Approved Repairs......................... 54-40-00 201
Repair No. 001 - Common Nozzle Assembly Pen Nib
Fairing Crack Repair............ 201
Repair No. 002 - Common Nozzle Assembly Exit
Nozzle Outer Skin - External
Patch Repair.................... 201
Nozzle Rivet Replacement Repair 201
Nozzle Outer Skin Replacement
Repair.......................... 201
Repair No. 005 - Common Nozzle Assembly Replace
the Rivets on the Pen Nib
Fairing......................... 201
Repair No. 006 - Common Nozzle Assembly Pen Nib
Fairing Tail Piece Replacement
Repair.......................... 201
Repair No. 007 - Common Nozzle Assembly 201
Vectored Exit Nozzle Outer Skin
Flush Patch Repair..........
Repair No. 008 - Common Nozzle Assembly
Non-Vectored Exit Nozzle Outer
Skin Flush Patch Repair......... 201
Repair No. 009 - Common Nozzle Assembly Aft
Ring Blend Repair............... 201
Repair No. 010 - Common Nozzle Assembly Rubbing
Block Repair.................... 201
Repair No. 011 - Common Nozzle Assembly Outer
Barrel, Outer Skin, Metallic
Patch Repair.................... 201

Page 12
Feb 1/09
1. Introduction
A. Purpose
The purpose of this Structural Repair Manual is to give field

repair instructions for the nacelle of a V2500 A1 or A5
engine installed on an A320 or A321 aircraft.
B. Organization and Use
(1) This manual was prepared in accordance with Air

Transport Association (ATA) Specification 100. Revision
23.
(2) The contents of the Structural Repair Manual are

approved by the DIRECTION GENERALE DE L’AVIATION CIVILE
(D.G.A.C.).
(3) The manual is organized using six digit, three element

numbers at the bottom of the pages.
(a) The first element of the three element number

system indicates the ATA 100 chapter designation.
(b) The second element designates the section of the

chapter.
(c) The third element indicates the specific subject

within the section.
54-10-03
- Subject
- Section (Inlet Cowl)
- Chapter (Nacelle)
V2500 54-00-00 INTRODUCTION

Page 1
Feb 1/09
(4) The sections about the inlet cowl, fan cowl, and thrust
reverser are further subdivided into topic identified by
page number blocks:
Page Block Topic

1-99 Structure Identification
101-199 Allowable Damage
201-299 Repairs
C. Service Bulletins
A service bulletin list in the front of the manual shows the

effect of service bulletins on the manual and the incorporation
date, if applicable.
D. Revisions
Regularly scheduled revisions usually occur every three months.

Other data that become available at unscheduled times will be
given through temporary revisions. These temporary revisions
are then incorporated into the manual usually at the next
regularly scheduled revision.
2. Abbreviations
A list of the abbreviations used in this manual follows:
BL - Buttline - A vertical plane which runs alongside

the nacelle longitudinal centerline.
Buttline 100 is the vertical centerline
of the nacelle. Other butt-lines are
measured in inches from BL 100, the
numbers increase to the right side of
the centerline and decrease to the left
side.
CL - Centerline - A vertical or horizontal plane which
passes through the longitudinal center
of a structure.
FWD - Forward - At or toward the front of the structure.

Page 2
Feb 1/09
ID - Inside Diameter The measurement across the center of

- the smaller of two circles, as of a
pipe.
LE - Leading Edge - The edge of a structure that is farthest
forward.
MAX - Maximum - The greatest or ultimate quantity
permitted.
MIN - Minimum - The smallest or least quantity
permitted.
NAC - Nacelle - The aerodynamic structure which covers
an aircraft engine.
RAD - Radial - A line from the center of a circle which
marks a specified number of degrees. On
the engine, the zero degree radial is
vertical and radials are numbered
clockwise as you look forward.
STA - Station - A vertical plane which cuts across the
longitudinal centerline of a structure.
It is used to designate a specified
location along a structure.
SL - Station line - A vertical line which represents a
station of a structure. It is usually
named as a measurement from a base or
zero station line.
WL - Waterline - A horizontal line or plane parallel to
the ground. It is used for the height
measurements along the length of the
nacelle. Waterline 100 is the
horizontal centerline of the nacelle.
Other waterlines are measured in inches
from WL 100, numbers increase above the
centerline and decrease below it.
3. Nacelle Parts
Figure 1 identifies the nacelle major parts.

Page 3
Feb 1/09
4. Major Engineering Drawings
A. The details of parts, materials, fasteners, locations, and

processes used in the assembly of the V2500 nacelle are shown
of the following engineering drawings:
DRAWING TITLE DRAWING NUMBER

A1 A5
Propulsion System Installation 740-7000 745-7000
Fully Equipped Nose Cowl 740-3000 745-3000
Fan Cowl Door Installation 740-4000 745-4000
Fan Cowl Door Assembly, RH 740-4001 745-4001
Fan Cowl Door Assembly, LH 740-4002 745-4002
Thrust Reverser Installation 740-0001 745-0001
Demountable Power Plant 740-6001 745-6001
Installation
Engine Buildup Installation 740-5000 745-5000

Page 4
Feb 1/09
13526A
Nacelle Parts
Figure 1

Page 5
Feb 1/09
5. Principal Nacelle Dimensions
Figure 2 shows the principal dimensions of the nacelle in inches, with

millimeters in parentheses.
6. Nacelle Stationlines
Figure 2 shows the location of nacelle stations, buttlines and

waterlines.
7. Nacelle Radials
Figure 4 shows the nacelle radials as you look forward.

Page 6
Feb 1/09
13527A
Nacelle Principal Dimensions

Figure 2

Page 7
Feb 1/09
13528A
Stationline, Buttline, and Waterline Locations

Figure 3

Page 8
Feb 1/09
TOP
NAC RAD 360° NAC BUTT LINE 100.0
NAC RAD 0° VERTICLE CENTERLINE
OF NACELLE
NAC RAD 45° NAC RAD 315°
NAC WL 100.0
NAD RAD 90° NAC RAD 270°
HORIZONTAL
CENTERLINE
OF NACELLE
NAC RAD 135° NAC RAD 225°
NAC RAD 180°

BOTTOM
VIEW LOOKING FORWARD ALONG INTERSECTION OF

NACELLE VERTICAL AND HORIZONTAL CENTERLINES
13529A
Nacelle Radials
Figure 4

Page 9
Feb 1/09
8. Nacelle Zones and Panels
A. The surface of the nacelle is divided into zones to help you to

designate work areas and to identify access doors and panels.
See Figures 5 and 6.
B. The zone number has five letters and numbers. See the table
that follows.
Aircraft Aircraft Nacelle Zone Nacelle

Part Nacelle, Side and Sequence Side
Part Part
4 = Nacelle 3 = L-FC, IC 1 = L-TR A = First, L = LT
top-bottom,
5= L-TR 7 = L-FC front-rear R = RT
4 = R-FC, IC 2 = R-TR Z = IC
6 = R-TR 8= R-FC
3 = IC
5 = CNA
(1) The first digit is always 4, which indicates nacelle.
(2) The second digit indicates which nacelle and the nacelle
part.
(3) The third digit indicates the side of the nacelle and the
nacelle part.
(4) The first letter indicates the sequence of the access door
within the zone, when you move from top to bottom and from
front to rear.
(5) The second letter indicates the side of the nacelle, left
or right.
C. Inlet Cowl Access Doors - Left Wing Nacelle
(1) 434AR - P2T2 Probe Access
(2) 438BR - Anti-Ice Duct Access

Page 10
Feb 1/09
D. Fan Cowl Access Doors - Left Wing Nacelle
(1) 437AL - Left Fan Cowl Door
(2) 437Bl - Oil Tank Access
(3) 437CL - Master Chip Detector Access Door
(4) 438AR - Right Fan Cowl Door
(5) 438BR - Pressure Relief/Manual Starter Shut Off Valve

Access Door
E. Thrust Reverser Access Doors - Left Wing Nacelle
(1) 451AL - Left Thrust Reverser Door
(2) 451BL - Upper Actuator Access Door
(3) 451CL - Lower Actuator Access Door
(4) 452AR - Right Thrust Reverser Door
(5) 452BR - Upper Actuator Access Door
(6) 452CR - Lower Actuator Door
(7) 452DR - Pressure Relief/Latch Access Door
F. Inlet Cowl Access Doors - Right Wing Nacelle
(1) 444AR - P2T2 Probe Access
(2) 444BR - Anti-Ice Duct Access
G. Fan Cowl Access Doors - Right Wing Nacelle
(1) 447AL - Left Fan Cowl Door
(2) 447BL - Oil Tank Access
(3) 447CL - Master Chip Detector Access Door
(4) 448AR - Right Fan Cowl Door

Page 11
Feb 1/09
(5) 448BR - Pressure Relief/Manual Starter Shut Off Valve

Access Door
H. Thrust Reverser Access Doors - Right Wing Nacelle
(1) 461AL - Left Thrust Reverser Door
(2) 461Bl - Upper Actuator Access Door
(3) 461CL - Lower Actuator Access Door
(4) 462AR - Right Thrust Reverser Door
(5) 462BR - Upper Actuator Access Door
(6) 432CR - Lower Actuator Access Door
(7) 462DR - Pressure Relief/Latch Access Door
I. Exhaust Nozzle Zones
(1) 455 - Left Wing Nacelle Exhaust Nozzle
(2) 465 - Right Wing Nacelle Exhaust Nozzle

Page 12
Feb 1/09
13530
Access Doors - Left Wing Nacelle, Left Side

Figure 5 (Sheet 1 of 2)

Page 13
Feb 1/09
13531
Access Doors - Left Wing Nacelle, Right Side


Page 14
Feb 1/09
13532
Access Doors - Right Wing Nacelle, Left Side


Page 15
Feb 1/09
13533
Access Doors - Right Wing Nacelle, Right Side


Page 16
Feb 1/09
9. Aerodynamic Smoothness
This section covers the smoothness conditions for the parts of the
nacelle that are in the air stream.
A. Smoothness is put into three groups:
Mismatch at joints
Waviness of skins
Height of flush-head fasteners
B. The smoothness conditions for each group are divided as

follows. This relates the aerodynamic importance of the area to
other areas. See Figure 7.
Class 1: - Inside and outside of the inlet cowl from the leading
edge to a line 18,000 inches (457.2 mm) aft of and
parallel to the inlet cowl leading edge.
- Common Nozzle Assembly internal surface.
Class 2: - Inlet cowl aft from a line 18.000 inches (457.2 mm)
aft and parallel to the inlet cowl loading edge up to
the leading edge of the fan cowl.
- Fan cowl.
- Thrust Reverser outside and inside surfaces.
- Thrust Reverser pylon skirt.
- Exhaust Cone and outside surfaces of Common Nozzle

Assembly.

Page 17
Feb 1/09
THRUST REVERSER
THRUST REVERSER
FAIRING
INLET COWL
18.000
FAN COWL COMMON NOZZLE
ASSEMBLY
OUTSIDE
WL 100
INSIDE
COMMON NOZZLE
ASSEMBLY INTERNAL
AREAS DEFINITION
ALL SURFACES NOT SPECIFICALLY
DESIGNATED BY CLASS 1 ARE CLASS II
CLASS I CLASS II
13553
Aerodynamic Smoothness
Figure 7

Page 18
Feb 1/09
C. Mismatch or step, is the difference between the surface levels

of two adjacent doors or panels where they come against each
other.
(1) The step is positive (+) when the surface of the panel
which is aft of the point where the two panels come
together is in the airflow. It is negative (-) when it is
out of the airflow. See Figure 8. (P) shows a step is
parallel to the direction of airflow.
(2) The gap is the linear difference between two adjacent

doors or panels where they come against each other. (P)
shows a gap is parallel to the direction of airflow.
(3) The mismatch limits for the nacelle are as follows:
Inlet Cowl Nose Lip +0.000 inch (0.00 mm) max.

-0.020 inch (0.51 mm) max.
P0.030 inch (0.76 mm) max.
GAP 0.000 inch (0.00 mm) to
0.030 inch (0.76 mm)
P0.000 inch (0.00 mm) to
P0.040 inch (1.02 mm)
Outer Barrel aft edge to fan +0.030 inch (0.76 mm) max.
cowl Leading Edge (On 80%)
+0.065 inch (1.65 mm) max.
(On 20%)
-0.060 inch (1.52 mm) max.
0.130 inch (3.30 mm)
Outer Barrel aft edge to fan +0.100 inch (2.54 mm) max.
Cowl Leading Edge Upper
Corner to a point measured
4.0 in. (101,6 mm) down
circumferentially

Page 19
Feb 1/09
Inlet Cowl Nominal Fan Case +0.020 inch (0.51 mm) max.
(On 70%)
+0.030 inch (0.76 mm) max.
(On 20%)
+0.035 inch (0.89 mm) max.
(On 10%)
-0.020 inch (0.51 mm) max.
(On 70%)
-0.030 inch (0.76 mm) max.
(On 20%)
-0.035 inch (0.89 mm) max.
(On 10%)
0.042 inch (1.07 mm)
TAI Access Doors +0.010 inch (0.25 mm) max.
-0.030 inch (0.76 mm) max.
P0.030 inch (0.76 mm) max.
0.060 inch (1.52 mm)
P0.010 inch (0.25 mm) to
P0.060 inch (1.52 mm)
Access Doors +0.020 inch (0.51 mm) max.
-0.040 inch (1.02 mm) max.
P0.060 inch (1.52 mm) max.
0.110 inch (2.79 mm)
P0.040 inch (1.02 mm) to
P0.110 inch (2.79 mm)
Fan Cowl Between Fan Cowl Doors P0.060 inch (1.52 mm) max.
(On 80%)
P0.080 inch (2.03 mm) max.
(On 20%)
GAP P0.100 inch (2.54 mm)
to P0.350 inch (8.89 mm)
Fan Cowl Fan Cowl to Pylon Skirt P0.120 inch (3.04 mm) max.
GAP P0.43 inch (10.92 mm)
to P0.51 inch (12.95 mm)
(On 70%)
P0.43 inch (10.92 mm) to
P0.59 inch (14.99 mm)
(On 30%)

Page 20
Feb 1/09
Fan Cowl aft Edge to +0.040 inch (1.02 mm) max.

Translating Sleeve Leading (On 80%)
Edge. +0.065 inch (1.65 mm) max.
(On 20%)
-0.100 inch (2.54 mm) max.
0.250 inch (6.35 mm)
(On 80%)
0.030 inch (0.76 mm) to
0.310 inch (.87 mm)
(On 20%)
Thrust Reverser Between Upper Edge and -0.090 inch (2.29 mm) max.
Between right and left Thrust 0.080 inch (2.03 mm) max.
Reverser Doors
Common Nozzle CNA Outer Barrel to (HOT)
Assembly (CNA) Translating Sleeve Aft Edge +0.030 inch (0.76 mm) max.
Outer Surface -0.060 inch (1.52 mm) max.
(COLD)
-0.160 inch (4.06 mm) max.
Common Nozzle CNA Outer Barrel to (HOT)
Assembly (CNA) Translating Sleeve Aft Edge +0.030 inch (0.76 mm) max.
Inner Surface -0.060 inch (1.52 mm) max.
(COLD)
-0.160 inch (4.06 mm) max.
Common Nozzle CNA Inner Barrel to Thrust (HOT)
Assembly (CNA) Reverser Trailing Edge Inner +0.045 inch (1.14 mm) max.
Barrel -0.175 inch (4.44 mm) max.
(COLD)
-0.245 inch (6.22 mm) max.
D. Waviness of Skin Limits. See Figure 10.

(1) Waviness of skin is a smooth variation in the flat or curved
surfaces of a part.
(a) One wavelength (L) is the distance between adjacent high
points.
(b) Slope is a measure of the incline of the wave at any given
point.
(c) Amplitude (H) is the vertical height from the top of a
high point to the bottom of the next low point.

Page 21
Feb 1/09
(2) These are the maximum waviness values for the four areas:
Max Max Max

Amplitude (H) H/L Slope
Class 1 0.064 inch(1.6 mm) 0.003 0.012 inch per inch
Class 2 0.090 inch(2.29 mm) 0.006 0.024 inch per inch
E. Height of Flush-Head Fasteners
(1) The fasteners step is positive (+) when it is in the airflow

(above the surface of the panel). It is negative (-) when it
is out of the airflow (below the surface of the panel).
(2) Fasteners other than latches are to be flush within ±.003 inch
(±0.076 mm) for 90% of the fasteners. 10% may be flush within
+0.003 inch t -0.005 inch (+0.076 to 0.127 mm).
(3) Max local dishing at rivets or other fasteners may be added to

the nacelle waviness data with a depth of 0.010 inch (0.254
mm) over a max diameter of 1 inch (25.4 mm).
(4) Solid flush-head rivet height limits:
Class 1 +0.003 inch (+0.076 mm)

-0.001 inch (-0.025 mm)
None to exceed + 0.006 inch (+0.152 mm)
.010 x 25.4
Class 2 +0.004 inch (+0.102 mm)
-0.001 inch (-0.025 mm)
None to exceed + 0.006 inch (+0.152 mm)

Page 22
Feb 1/09
(5) Latch Mismatch limits:
Class 1 +0.030-inch (0.76mm)

-0.030-inch (0.76mm)
Class 2 +0.040 inch (1.02 mm)
-0.050 inch (1.27 mm)

Page 23
Feb 1/09
Mismatch
Figure 8

Page 24
Feb 1/09
Nacelle Mismatch Limits


Page 25
Feb 1/09


Page 26
Feb 1/09


Page 27
Feb 1/09
Waviness of Skin Limits

Figure 10

Page 28
Feb 1/09
10. Damage Types
A. Damage is any distortion or thickness change of a structural

member. Damage types are:
Allowable damage
Repairable damage
Damage which makes the replacement of parts necessary
B. Allowable Damage
(1) Damage or distortion that can be left as it is or which

can be repaired by a simple procedure.
(2) The limits of allowable damage are given in the allowable

damage section for each of the major assemblies and
component parts contained in this Structural Repair
Manual.
C. Repairable Damage
(1) There are two types of repairs that can be done on the
nacelle. These are:
(a) External Repair -
- Can be quickly applied
- Can be used to minimize down time of the

aircraft
- Can be above the repair surface
- Can be replaced later for appearance or for

aerodynamic considerations
(b) Smooth Repairs -
- The repair makes a continuous surface with the

surface of the component
- Can be used to replace an external repair

for aerodynamic reasons.

Page 29
Feb 1/09
(2) External and smooth repairs are structurally airworthy.

However, aircraft performance may be changed by external
repairs in critical areas.
(3) Some repairs are time limited. These repairs are given as
practical solution to field repair problems.
(a) Time limited repairs must be replaced with a

permanent repair after a specified time.
(b) Inspection of the repair is necessary at specified

times until a permanent repair is installed.
D. Non-repairable Damage
(1) Replacement of the part is recommended when the part is

complex or the damage is extensive so that the repair is
not practical or economical
(2) Items not contained in the repair instruction are non-

repairable and should be replaced.
11. Bulk Material Supplier’s List
To be supplied
12. Consumable Material Index
A. The Consumable Materials Index gives details of all the

consumable materials that are required during structural repair
of the engine nacelle assembly
B. The index is divided into three sections:
(1) An alpha numeric index which lists the consumable

materials in alphabetical order.
(2) A materials index, which lists the consumable materials by

CoMat, number.
(a) V01 - Processing and Cleaning Materials
(b) V02 - Processing Sundries

Page 30
Feb 1/09
(c) V04 - Jointing Compounds and Greases
(d) V05 - Polishing, Abrasives, and Blasting
(e) V06 - Inspecting
(f) V07 - Paints, Varnishes, and Thinners
(g) V08 - Bonding Adhesives, Fillers, and Sealers
(h) V10 - Oils, Fluids, and Lubricants
(i) V12 - Packing
(3) A list of Suppliers Names and Addresses which are in order

alphanumerically by SUPPLIER CODE.

Page 31
Feb 1/09
13. Alphanumeric Index
DESIGNATION ITEM NUMBER

463-6-27 base, Use 07-140 08-029
90-006 Sealant, Two Part Pack 08-030
A1-clad sheet 02-357
Acetone 01-031
Adhesive 08-034
Adhesive 08-121
Adhesive, EA9396 08-131
Adhesive, EA9321 08-078
Adhesive Film, FM300-2M OMAT: 8/238 08-136
Adhesive Primer, BR-127 OMAT: 8/238 08-137
Aerodynamic smoothing compound, PR-340 08-073
Alodine 1200 Chemical conversion coating, MIL-C-5541 07-028
Aluminum Alloy plate, 2024-0, 0.125 in. 02-172
Aluminum Alloy sheet, 2024-T3, 0.050 in. 02-214
Aluminum Alloy sheet, 2219-T62, 0-064 in. 02-219
Aluminum Alloy sheet, 2219-T81 02-245
Aluminum honeycomb core, AL 5052 4.1 PCF 0.0025 in foil 02-324
Aluminum honeycomb core, 1/4 in. -5056-0.0025 (5.2 PCF)0.76 08-063
Aluminum honeycomb core, 3/16 in.-5052-0.0015 (3.1 PCF)0.5 08-071
Aluminum Laminated Shim 02-257
Aluminum oxide abrasive paper 05-073

Page 32
Feb 1/09

Aluminum oxide abrasive paper, 180 grit 05-074
Aluminum Sheet, 2024-T, 0-050 in. 02-321
Aluminum Sheet, 2024-T3 0.025 in. 02-322
Aluminum Sheet, 2024-0 0.010 to 0.100 in. thick sheet 02-360
Bleeder Material 08-132
Bonding Film Adhesive, EA9589 08-085
Bonding Film Adhesive, FM350 NA OMAT: 8/225 08-087
Breather cloth, RC-3000-10 02-166
Breather fabric, Airbleed 10 08-057
Catalyst, EC-117 07-139
Catalyst, EC-213 07-137
Ceramic Coating, Ceram-Kote 54 TZM Part A 07-160
Ceramic Coating, Ceram-Kote 54 TZM Part B 07-161
Cheese cloth 02-349
Chromate conversion coating, Alodine 1000 07-106
Chromate conversion coating, Alodine 1200S 01-275
Chromate conversion coating, MIL-C5541, Alocrom/MP0002 07-023
Cleaner/Passivator 01-471
Cleaner/Passivator 01-477
Cleaning Cloth 02-091
Clear Polyurethane 07-098
Cushioning felt, BS 4060 A97/2G 12-012
Distilled or Deionized water 01-201
Dry carbon fiber fabric, 3K-135-8H (Dry) 08-059
Dry carbon fiber fabric, 3K-70-PW (Dry) 08-058
EA9321 Adhesive 08-078
EA934NA Adhesive, Hysol, EA 934 NA Two Part Pack 08-021

Page 33
Feb 1/09

EA9390 resin, Hysol, Part A and B 08-050
EA9394 Epoxy Paste Adhesive Hysol 08-104
EA956 Adhesive, two Part Epoxy, Hysol, EA956 08-028
EA956/L3 adhesive, Hysol, Two-Part Epoxy 08-034
EA9689 Supported Hysol, Bonding Film adhesive 08-085
Emery Paper 05-112
Epoxy primer, 10-P4-2 07-140
Epoxy VArnish, TVZ 119/121 07-085
Expanded Copper Screen (ESC) 02-300
Eye glasses, safety 02-111
Fiberglass fabric, Type 181 02-167
Foil (pattern), CRES Sheet Type 321, 0.016 in. 12-029
Foaming Film Adhesive, FM-410-1, Grade 100 OMAT: 8/224 08-089
Foaming Film Adhesive, MA562, Grade 50 08-090
Fumed Silica 01-508
Foil (plain), AMS 5510, .003/.004 in. smooth 321 12-030
Garnet paper, 60 grit, Grade 0.5, A-A1201 Class 2 05-016
Glass Fibers 08-075
Graphite fabric AH370-5H, 0.0145 in. 02-165
I Primer Class M 08-093
I Primer Class M, Primer Converter EC-178 07-115
Indicator paper 02-206
Indicator paper 02-207
Isopropanol Alcohol 01-012
Jointing compound, DTD 900/4586, Hylomar Aero grade Medium 04-005
Lint free cloth 02-099
Lint free gloves 02-097
Lockwire 02-147
Lockwire, MS20995N32 (0.8 mm) 02-156

Page 34
Feb 1/09

Lockwire, MS9226-03 (0.025 mm) 02-127
Lockwire, MS226-04 (0.032 mm) 02-119
M-20 Glass, Prepreg Fabric, Fiberglass 08-139
Marker 02-129
Marking pen, Sharpie Maker No. 3001 Black, No. 30002 Red, 06-131
No. 30003 Blue
Masking Tape 02-134
Masking Tape Polyester Film (Mylar) 02-036
Masking Tape, No. 250 02-178
Metal foil tape 02-182
Metal marking crayon, Best White 352 Col-Erase 1286 white 05-127
Methylethylketone TT-M-261 01-076
Non-perforated release film, FEP 100-R-WT/A4000 white 08-052
Non-porous parting film 02-168
Non-porous parting film 02-367
Nylon bagging film. 2 mil 02-163
Perforated release film, NF.0025 (P) 08-061
Phenolic microballons (135 micron), Use 02-164 -DELETED 08-056
Phenolic microballons, 5 mil 02-164
Phosporic acid 01-452
Plastic, Kraft paper 02-107
Porous film release 02-334
Porous parting film 02-169
Potting compound, CG 1305 2 - part 08-072
Potting compound, Epocast 1614-A1 08-143A
Polystop LP Sikkens Stopper 08-144
Pre-impregnated graphite fabric, M20/39%/120 Glass 08-139
Primer base, DC1200 08-032
Primer base 463-7-26, Use 07-137 07-071

Page 35
Feb 1/09

Primer base, 10P20-13 07-138
Primer Base 07-152
Primer Base 08-029
Primer Converter 07-067
Primer Converter 910X456 07-157
Primer converter X-369, Use 07-138 07-072
Primer, DC 1200 08-032
Primer thinner 07-066
Red Fluorescent Paint and Clear Lacquer 07-152
Sealant, 90-006, Two Part Pack 08-030
Sealant, DC 93-006-1, Two Part Pack 08-033
Sealant, PR1995 Class B Primerless 08-140
Sealant, Polysulphide, Two Part, Proseal 870 B-1/2 08-141
Sealant, Polysulphide, PR - 1826 G B2 08-146
Sealant PR-1422 08-024
Sealant PR-1422B-1/2 08-125
Sealant tape, GS-213 08-051
Scotch brite, MIL-A-9962A, Type 1, Grade A 05-126
Silicone Adhesive Polyester Tape 02-224
Silicone rubber sheet, 0.125 in. thick 02-170
Silicone rubber Compound 08-031
Solvent, Methyl Isobutyl Ketone 01-457
Solvent, Turco Solvent No. 6646 01-438
Stainless steel wire brush 02-331
Syringe, Injection 02-162
Tacky tape, Bag Sealant 12-024
Tape, Double layer 02-265
Teflon tape, Self Adhesive Coated Glass Fabric Tape 02-007
Teflon tape, Tynaflor P.T.F.E., 0.5 in 02-160

Page 36
Feb 1/09

Teflon tape, Tynaflor P.T.F.E., 2.0 in 02-161
Temporary marker, No Blot Ink Pencil, Style No. 705 02-122
Thermal insulation material, MIN-K, 36 x 36 x 1/8 in. 12-028
Thinner TL-102 07-073
Thinner TR-19 07-116
Thinner 020X364 07-158
Titanium Sheet 02-255
Titanium Sheet 02-320
TL52-66 Primer thinner, Use 07-139 07-066
Tymex nylon brush, 1/2 x 1 -3/4 02-087
Tymex nylon brush, 1 x 1 -3/4 02-088
Water Soluble Primer 44-GN-11 (base) 07-126
Water Soluble Primer 44-GN-11 (catalyst) 07-127
Water Soluble Primer DM water (Thinner) 07-128
Waterproof silicone carbide abrasive paper, 150 grit, 05-081
A-A-1047
Waterproof abrasive paper 05-022
A-A-1047
Waterproof silicone carbide abrasive paper, 240grit, 05-064
A-A-1047
A-A-1047A
A-A-1047A
Wiping cloth 02-091
X337 Primer converter, Use 07-140 07-067

Page 37
Feb 1/09
14. Materials Index
ITEM SUPPLIER
NUMBER DESIGNATION SPECIFICATION USAGE CODE
01-012 Isopropanol Alcohol Analar Grade OMAT Solvent Cleaner VK6835
VU1185
LOcal
01-031 Acetone Commercial Grade Thin ceramic V70657
mixture for K6835
spray V81348
application LOCAL
01-076 Methylethelketone TT-M-261 To clean a Local
mechanical
components
01-201 Distilled or Commercial grade To clean V06337
Deionized water components LOCAL
01-275 Chromate Conversion Alodine 1200S Use for V71410
Coating coating VK0519
Aluminum VK6835
VK7625
01-438 Solvent Turco Solvent 6646 Pre-bond V71410
solvent cleaner
01-452 Phosporic acid Turco W0-1 Solvent cleaner IVAE347
01-457 Solvent Methyl Isobutyl Pre-bond V71361
Ketone solvent cleaner
01-471 Cleaner/Passivator PASA-JELL 101 To clean VIAE367
surface
01-477 Cleaner/Passivator PASA-JELL 101 To clean IVAE367
OMAT:1/276 surface
01-508 Fumed Silica Cab-o-sil grade M5 To clean VIAE462
surface
02-007 Teflon Tape Self Adhesive Coated To prevent over VK2096
Glass Fabric tape run of resin
02-036 Masking Tape Scotch No. 8402 or To prevent V76381
Polyester Film 8403 overspray V07963
(MYLAR)

Page 38
Feb 1/09
ITEM SUPPLIER
02-087 Tymex nylon brush 1/2 x 1-3/4 To clean the Local
components
02-088 Tymex nylon brush 1 x 1-3/4 To clean the Local
components
02-091 Cleaning cloth Cleaning cloth To clean the Local
components
02-097 Lint free gloves Lint free gloves To give Local
Misc 00127-00 protection to
the hands and
materials
02-099 Lint free cloth Lint free cloth To clean the Local
Misc 00125 components
02-107 Plastic, Kraft Paper Plastic Kraft paper To mask area Local
that is not
damaged
02-111 Eye Glasses safety To give Local
protection to
the eyes
02-119 Lockwire MS9226-04 (0.032 in) To lock with Local
wire
02-122 Temporary marker No Blot Ink Pencil, To identify VK6835
Style No. 705 processes
02-127 Lockwire MS9226-03 (0.025 in.) To lock with Local
wire
02-129 Marker Airmarker LN 9051 To identify VIAE28
MTH 337 (MTU Ref) process
02-134 Masking Tape TESA 7469 P-35 To hold the V83334
PMC4134 patch in V99742
position VIAE358
02-147 Lockwire MS 20995C32 To Lock with Local
wire
02-156 Lockwire MS20995N32 (0.8mm) To Lock with Local
wire

Page 39
Feb 1/09
ITEM SUPPLIER
02-158 Release Agent Frekote 33 To clean V51563
surface
02-160 Teflon tape Tynaflor P.T.F.E. To prevent Local,
0.5 in. unwanted epoxy VK6835
bond
02-161 Teflon tape Tynaflor P.T.F.E To prevent Local,
2.0 in unwanted epoxy VK6835
bond
02-162 Syringe, Injection To fill voids Local
with epoxy
02-163 Nylon bagging film 2 mil To contain a V85670
vacuum
02-164 Phenolic 5 mil To fill V80524
microballoons structural
repairs
02-165 Graphite fabric AH370-5H, 0.0145 in. Structural V0CZA6
material
02-166 Breather cloth RC-3000-10 To vacuum and V85670
cure repair
processes
02-167 Fiberglass fabric Type 181 Structural Local
layer
02-168 Nonporous parting To cure repair Local
film materials
02-169 Porous parting film To remove Local
excess resin
02-170 Silicone rubber 0.125 in. thick To ensure Local
sheet 0.125 in. wrinkle free
thick pressure
02-171 Aluminum alloy sheet 2024-T3, 0.063 in To maintain Local
contour
02-172 Aluminum alloy plate 2024-0, 0.125 in Misc. use Local
02-178 Masking Tape No. 250 To prevent local
overspray

Page 40
Feb 1/09
ITEM SUPPLIER
02-182 Metal foil tape Aluminum foil tape Misc use 76381
no. 428B
02-206 Indicator paper ALKACID Misc Use Local
02-207 Indicator paper pHYDRION Misc Use Local
02-214 Aluminum alloy sheet 2024-T3, 0.050 in. Misc use Local
02-216 Aluminum alloy sheet 2219-T81, 0.050 in Misc use Local
02-224 Silicone Adhesive Flashtape 2 To prevent V85670
Polyester Tape unwanted
cleaner or
passivator
02-245 Aluminum Alloy 2219-T81 Misc use Local
02-255 Titanium Sheet 0.05 in (2,27 mm) Misc use Local
Thick (AMS4901)
02-257 Aluminum Laminated 1.01n Wide, 0.094 in Misc use Local
Shim Thick Comp I, Type
II, Class I MIL-S-
22499
02-265 Tape, Double Layer D/W 498 pressure To secure an V60890
Sensitive Tape PMC object
4480-1 Thru -8
02-300 Expanded Copper CU 040CX Lightning- V0KWM1
Screen (ECS) strike
protection
02-320 Titanium Sheet, Ti- AMS 4919, Duplex Use to patch Local
6A1-Sn-4Zr-2Mo, Annealed, 0.063 IN. damaged skin
0.63 in.
02-321 Aluminum Sheet 2024-T, 0.050 in Misc use local
Thick
02-322 Aluminum sheet 2024-T3 0.025 in. Misc use Local

Page 41
Feb 1/09
ITEM SUPPLIER
02-323 Aluminum Sheet 2024-T3 0.045 in. Misc Use Local
02-324 Aluminum Honeycomb AL 5052 4.1 PCF Misc use Local
core 0.0025 in. foil
02-331 Stainless Steel Wire Gordon “18 To remove scale VIAE418
Brush or surface
damage
02-334 Porous film release A5000P3 To prevent VIAE78
OMAT 2/154 (RR-REF) unwanted resin VIAE74
02-349 Cheese Cloth unsized 40X 32 Misc use V2A851
Yarns/inch V4N020
GA 100-2 V80769
Local
02-357 Al-clad sheet Misc use
02-360 Aluminum Sheet 2024-0 0.010 to 0.100 Misc use Local
in. thick sheet
02-367 Non-porous parting A5000 To prevent VIAE78
Film OMAT: 2/131A (RR Ref) unwanted resin VIAE74
04-005 Jointing Compound DTD 900/4586, Hylomar To fill joint VK3504,
Aerograde Medium gaps VK6835
05-016 Garnet paper 60 grit, Grade 0.5, To remove Local
A-A-1201 Class 2 corrosion and
to smooth
scratches
05-019 Waterproof silicon 400 grit, A-A-1047A To finish Local
carbide abrasive smoothing
paper process
05-020 Waterproof Silicon 320 grit, A-A-1047A To contour Local
carbide abrasive composite
paper repairs
05-021 Waterproof silicon 240 grit, A-A-1047 To contour Local
paper repairs
05-022 Waterproof abrasive Aluminum Oxide No. To roughen the V62596
paper 240 surface

Page 42
Feb 1/09
ITEM SUPPLIER
05-057 Jointing Compound DELETED
05-064 Waterproof Silicon 240 grit, A-A-1047A To contour Local
paper repairs
05-073 Aluminum Oxide 300 grit To finish Local
Abrasive Paper smoothing
process
05-074 Aluminum Oxide 180 grit To remove Local
abrasive paper material
05-081 Waterproof silicon 150 grit, A-A-1047 To remove Local
carbide abrasive carbon material
paper
05-112 Emery Paper A-A-1049 To roughen the V4197
Grade 0 surface VA2549
Grit size 400 IAE302
05-126 Scotch Brite MIL-A-9962A, Type 1, To clean Local,
Grade A surfaces VK0993
05-127 Metal Marking Crayon Best White -352 To mark V70362,
Col-Erase 1286 White temporarily V32988
05-128 Aluminum Oxide 240 Grit To finish Local

Abrasive Paper smoothing 06565
process 51563
05-129 Aluminum Oxide 320 Grit To finish V06565
Abrasive Paper smoothing V51563
process VK3895
06-028 Chromate Conversion DELETED
Coating 1000 for
Aluminum
06-127 Metal Marking Crayon DELETED
06-131 Marking Pen Sharpie Marker No. To mark V86874
30001 Black, No. permanently
30002 Red, No. 30003
Blue

Page 43
Feb 1/09
ITEM SUPPLIER
07-023 Chromate conversion MIL-C-5541, Alocrom To increase Local,
coating 1200/MP0002 corrosion V71410
resistance and
prepare for
paint
07-028 Alodine 1200 MIL-C-5541 To increase Local
Chemical conversion corrosion
coating resistance and
prepare for
paint
07-066 Primer thinner, Use TL52-66 To thin primer
07-139 for spray
application
07-067 Primer converter, X337 Catalyst for
Use 07-140 primer system
07-071 Primer base, Use 463-7-26 Base component
07-137 of coating
system
07-072 Primer converter, X-369 Catalyst for
Use 07-138 primer system
07-073 Thinner TL-102 To thin primer Local
for spray
application
07-085 Epoxy Varnish TVZ 119/121 Protective VK4585
coating for VK1270
composite
materials
07-098 Clear Polyurethane Polyurethane 683-3-2 Base component V98502
of coating
system
07-106 Chromate conversion Alodine 1000 To increase Local
coating corrosion
resistance and
prepare for
paint

Page 44
Feb 1/09
ITEM SUPPLIER
07-115 I Primer Class M Primer Converter V0S4B8
EC-178
07-116 Thinner TR-19 V0S4B8
07-126 Water Soluble Primer 44-GN-11(Base) BAse component V5M511
of coating
system
07-127 Water Soluble Primer 44-GN-11 (Catalyst) Catalyst V5M511
component of
primer system
07-128 Water Soluble Primer DM Water (Thinner) To thin primer V5M511
07-137 Catalyst EC-213 Catalyst V91342
component of
primer system
07-138 Primer base 10-P20-13 Base component V91342
of coating
system
07-139 Catalyst EC-117 Catalyst V91342
component of
primer system
07-140 Epoxy primer 10-P4-2 Base component V91342
of coating
system
07-152 Red Fluorescent Color no 38903 Paint VIAE431
Paint and clear VK6835
lacquer
07-156 Primer Base 513X54 Base component VONYS9
of coating
system
07-157 Primer Converter 910X456 Catalyst for VONYS9
910X456 primer system
07-158 Thinner 020X364 To thin primer VONYS9
07-160 Ceramic Coating CeRam-Kote 54 TZM Protective VIAE438
Part A agent VIAE439

Page 45
Feb 1/09
ITEM SUPPLIER
07-161 Ceramic Coating CeRam-Kote 54 TZM Protective VIAE438
Part B agent VIAE439
08-021 EA934NA Adhesive Two Part Pack, Hysol To bond V33564
EA 934 NA composites and
metals
08-024 Sealant PR-1422 To seal VONYS9
V51563
08-028 EA956 Adhesive Two Part Epoxy, Hysol To bond V33564
EA956 composites and
metals
08-029 Primer base, 463-6-27 Base component
Use 07-140 of coating
system
08-030 Sealant 90-006, Two Part Pack To seal and V71984,
waterproof VK6835
08-031 Silicone Rubber DOW CORNING RTV 732 To seal and V51563
Compound liquid proof VK6835
VK7550
08-032 Primer DC 1200 Base component V71984,
of coating Vk6835
system
08-033 Sealant DC 93-006-1, Two Part To seal and V71984,
Pack waterproof VK6835
08-034 Adhesive EA956/L3,Hysol, Two- To bond V3364,
Part Epoxy composite VK4585
materials
08-043 Cold Curing Silicone Deleted
Compound
08-050 Resin EA9390, Hysol, Part A To repair V3364,
and B composite VK4585
materials
08-051 Sealant tape GS-213 To seal vacuum VK4585
bag

Page 46
Feb 1/09
ITEM SUPPLIER
08-052 Non-perforated FEP 100-R-WT/A4000 VIAE252
release film White VIAE74
VK4585
08-056 Phenolic Deleted
microballoons, Use
02-164
08-057 Breather fabric Airbleed 10 To ensure gas VIAE78
removal
08-058 Dry carbon fiber 3K-70-PW (Dry) Structural VK4585
fabric material
08-059 Dry carbon fiber 3K-135-8H (Dry) Structural VK4585
fabric material
08-061 Perforated release NF.0025(P) To aid spread VIAE480
film of bonding VK4585
agent
08-063 Aluminum honeycomb 1/4 in. - 5056-0.0025 Structural V04621,
core (5.2 PCF) 0.76 material VK4585
08-071 Aluminum Honeycomb 3/16 in Structural V04621
Core 5052-0.0015 material VK4585
(3.1PCF) 0.5
08-072 Potting compound CG 1305 2-Part Filler or VK1007,
adhesive VK4585
08-073 Aerodynamic PR-340 To fill and VK2096

smoothing Compound smooth surface
areas
08-075 Glass Fibers 731 EC Structural VK6835
Endmill Fibre Glass material VIAE453
08-078 Adhesive EA9321 For potting, V33564
core splice and
faying surface

Page 47
Feb 1/09
ITEM SUPPLIER
08-085 Bonding Film EA9589 For metal, V33564
Adhesive composite and VU3167
honeycomb VK3504
bonding IAE200
08-087 Bonding Film FM350 NA Use for bonding V28174
Adhesive OMAT: 8/225
08-088 Forming Adhesive FM-410-1, Grade 50 Use for bonding V28174
OMAT: 8/224
08-089 Foaming Film FM-410-1, Grade 100 Use for bonding V28174
Adhesive OMAT: 8/224
08-090 Foaming Film MA562, Grade 50 Use for bonding VS0090
Adhesive
08-093 I primer Class M Catalyst for
bonding agent
08-104 Epoxy Paste Adhesive EA9394 Hysol Use for bonding V33564
VU3167
VK3504
IAE200
08-121 Adhesive Loctite 680 Use for bonding V05972
08-125 Sealant PR-1422B-1/2 (SEMKIT Use to seal VF0229
CARTRIDGE)
08-127 Fine-Mad Scotch Deleted
Brite
08-131 Adhesive EA9396 Use for bonding V33364
OMAT: 8/197
08-132 Bleeder material DRY G120 Glass/105 To aid bleed IAE421
GSM/ Crow Foot bonding agent K6835
MIL-C-908AC TYpe III
OMAT: 2/155
08-136 Adhesive Film FM300-2M Use for bonding V84518
OMAT: 8/238
08-137 Adhesive Primer BR-127 Use for bonding V84518
OMAT: 8/238

Page 48
Feb 1/09
ITEM SUPPLIER
08-138 Pre-impregnated M20/39%/G904 Structural V84518
graphite fabric OMAT: 8/242 material
08-139 M20 Glass, Prepreg M20/39%/120 Glass Structural V84518
Fabric, Fiberglass material
08-140 Sealant PR1995 Class B To seal VONYS9
Primerless
08-141 Sealant, Proseal 870 B-1/2 Seal surface VONYS9
Polysulphide two areas
part
08-143A Potting Compound, EPOCAST 1614-A1 Edge and VIAE432
Epocast 1614-A1 cavity filler
08-144 Polystop LP Sikkens POLYSTOP LP SIKKENS Filler VIAE436
Stopper Stopper
08-146 Sealant, PR-1436 G B2 Seal Surface VONYS9
Polysulphide area
12-012 Cushioning felt BS 4060 A97/2G To absorb VIAE266
vibration or
reduce impact
between
composites
12-024 Tacky tape Bag sealant To seal vacuum V53309
bag
12-028 Thermal insulation MIN-K To control V75165
material 36 x 36 x 1/8 in. heating of
selected areas
12-029 Foil (pattern) CRES sheet type 321, To protect Local
0.016 in. thermal
insulation
12-030 Foil (plain) AMS 5510, .003/.004 To protect the Local
in. smooth 321 thermal
insulation

Page 49
Feb 1/09
15. Supplier Names and Addresses
CODE NAME AND ADDRESS

V0CZA6 Hercules Aerospace Co.
Composite Products Grp
Bacchus Works
P.O. Box 98
Magna, UT 84044-0098
USA
V0KWM1 Astroseal Product MFG Co. Inc.

6 Custom Drive
Old Saybrook, CT 06475 USA
V0S4B8 Crown Metro Aerospace

Incorporated
315 Echelon Rd
Grenville
Sc 29605
USA
V02684 Huntsman Advanced Materials
Americas Inc (Formerly
Vantico)
4917 Dawn Ave
East Lansing
MI 48823-5691
USA
V04621 Hexcal Corp
2350 Airport FWY
Suite 550
Bedford, TX 76022-6027
USA
V05972 Henkel Corp
1001 Trout Brook Crossing
Rocky Hill
CT 06067-3910
USA

Page 50
Feb 1/09

V06123 PRC Desoto International
5430 San Fernado Rd.
P.O. Box 1800
Glendale, CA 91203-1521
USA
V1HS43 SIA Adhesives Inc.
123 W. Bartgesstreet
Akron,Oh 44311-1081
V23354 PPG Aerospace
PRC DeSoto
823 Eastgate Drive
Mt. Laurel,
NJ 08054
USA
V28174 Imation Corp Color
Technologies Div
Saint Paul 55128-3421
Washington
V32988 Faber-Castell Corp.
551 Spring Palce Rd.
P.O. Box 330
Lewisburg, TN 37091
USA
V33123 Rol-Lift Corporation
12300 Amelia Drive
Houston,TX 77045
V33461 Deft Inc
Chemical Coating Division
17451 Von Karman Ave
Irvine, CA 92614
USA
V33564 Dexter Aerospace
Material Division
2850 Willow Pass Rd.
Pittsburg, CA 94565-0031
USA

Page 51
Feb 1/09

V44197 Saint-Gobain Industrial
Cermaics Inc.
1 New Bond St.
P.O. Box 15008
Worcester, MA, 01615-0008
USA
V51563 Goodrich Corporation
850 Lagoon Drive
Chula Vista, CA 91910-2028
USA
V53309 Schnee-Morehead, Inc.
111 N. Nursary Rd.
Irving, TX 750060-3176
USA
06565 Saint-Gobain Abrasives
P.O. Box 808
Troy, NY 12181
USA
V70362 Dixon Ticonderoga Co.
Sandusky Division
1706 Hayes Ave.
Sandusky, OH 44870-4732
USA
V71361 MCGEAN-ROHCO INC
2910 HARVARD AVE
CLEVELAND
OH 44105-3010
USA
V71410 Parker + AMCHEM
Div of Henkel Corp.
32100 Stephenson Hwy.
Madison Hgts, MI 48071
USA
V71984 Dow Corning Corp.
2200 W. Salzburg Rd.
Midland, MI 48686-0994
USA

Page 52
Feb 1/09

V75165 Schuller International, Inc.
717 17th Street
Dever, CO 80202-3330
USA
V80524 Union Corp.
Chemicals and Plastics Div.
Bound Brook Plant
River Rd.
Bound Brook, NJ 08805
USA
V84518 Hexcel Composites
815 Lawrence St
Lancaster, OH 43130
USA
V85670 Richmond-Div of Dixico, Inc.
Colton and Opal sts.
P.O. Box 1129
Redlands, CA 92373
USA
V86874 Sandford Corp.
2711 Washington Blvd.
Bellwood, IL 60104-1940
USA
V91342 Dexter Aerospace Materials
Aerospace Coatings Div.
1-7 East Water St.
Waukegan, IL 60085-5614
USA
V91874 Lucas Milhaupt
5656 S. Pennsylvania Ave
Cudahy
Wi 53110-2453
USA
V98502 Akzo Nobel Coatings INc
PO Box 7062
Troy, MI 48084
USA

Page 53
Feb 1/09

VA2549 Saint Gobain
4 Via Per Cesano Boscone
20094 Corsico
Milano, Italy
VF0229 Joint Francais Le LJF Groupe
HUTC Inson
2 R Balzac
Paris 8 75008
France
VK8888 Sawley Packaging Co., Ltd.
Nottingham Road
Derby DE21 6AS
United Kingdom
VK0993 3M (UK) PLC
28 Great Jackson Street
Manchester M15 4PA
United Kingdom
VK1007 Vantico
Duxford Cambridge CB2 4QA
United Kingdom
VK2096 Tzgavac Advanced Materials Ltd
Kingsway West Business Park
Moss BR GE Road
Rochdale OL16 SLX
United Kingdom
VK3504 Indestructible Paint Co.,LTD.
23/25 Pentos Drive
Sparkhill Birmingham B11 3TA
United Kingdom
VK3895 English Abrasive and
Chemicals Ltd
Division of Saint Gobain
Doxey Rd, Stafford St 1EA
Great Britain
VK4585 Bombrardier Aerospace Shorts
P.O. Box 241
Belfast BT3 9DZ
United Kingdom

Page 54
Feb 1/09

VK5635 PPG Aerospace - PRC Desoto Int
Darlington Rd.
Shildon DL4 2QP
United Kingdom
VK6835 Med-Lab Ltd.
Copeland St
Derby DE1 2PU
United Kingdom
VIAE266 Sawley Packaging Co Ltd
Nottingham Road
Derby, DE2 6AS
Great Britain
VIAE302 Saint Gobain Schleifmittel
GMBH Dirkenstrasse
4950839 Wesseling
Germany
VIAE431 Aerosheres (UK) Ltd.
Aerospace House
24 Tudor Road
Harrow, Middlesex HA3 5PE
England
VIAE436 NYCO S.A.
London, E1 7 HW
VIAE438 Freedom Inc
P.O. Box 2119
Industrial Airpark
Building 1103
Big Spring, TX 79720
USA
VIAE439 Ceram-Kote Europe GMBH
Daimlerring 9
D-32289 Rodinghausen
Germany
VU3167 Aero Consultants UK Ltd
13/14 Clifton Road
Huntingdon,Cambs PE29 7EJ
Great Britain
VU9290 Aerovac Systems (Keighly)Ltd.
500 Bradford Road Sandeeds
Keighley BD20 5NG
United Kingdom

Page 55
Feb 1/09
16.) Cautions, Warnings and Dangers
NOTICE!! Carefully read and obey all CAUTION and WARNING

statements in this manual. Refer to the descriptions of
these statements that follow:
- A "CAUTION" statement is given to prevent damage to
equipment.
- A "WARNING" statement is given to prevent personal
injury or illness
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INCLUDE
MANUFACTURER'S INSTRUCTIONS, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY
CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY
INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES INSTRUCTIONS
ON HOW TO SAFELY USE, KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW TO SAFELY USE,
KEEP, AND DISCARD CHEMICALS.
CADMIUM - Obey the warnings below before you touch or do maintenance
on parts that are cadmium plated. The Occupational, Safety, and
Health Administration (OSHA) sets mandatory limits on exposure to
cadmium dust (29 CFR 1910.1027).
WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT IS
SWALLOWED CAN CAUSE KIDNEY OR REPRODUCTIVE SYSTEM
DISEASE. AFTER YOU TOUCH CADMIUM PLATED PARTS, WASH YOUR
HANDS BEFORE YOU EAT OR SMOKE. GET SAFETY INSTRUCTIONS
FROM YOUR EMPLOYER. OBEY GOVERNMENT AND OSHA REGULATIONS
WHEN YOU DISCARD PARTS THAT CONTAIN CADMIUM.
WARNING: DO NOT INHALE CADMIUM PARTICLES, FUMES, OR DUST. THESE
PARTICLES, FUMES, OR DUST CAN CAUSE LUNG OR KIDNEY
DISEASE. IF MAINTENANCE PROCEDURES CREATE CADMIUM
PARTICLES, FUMES, OR DUST, TELL YOUR EMPLOYER TO SUPPLY
RESPIRATORS, VENTILATION, AND/OR PROCEDURES TO PREVENT
EXPOSURE TO PERSONNEL.
The Occupational, Safety, and Health Administration (OSHA) has an
applicable DANGER warning (29 CFR 1910.1027 (m)(3)(ii)) as follows:
DANGER: CONTAINS CADMIUM. CANCER HAZARD. AVOID CREATING DUST. CAN
CAUSE LUNG AND KIDNEY DISEASE.

Page 56
Feb 1/09
ASBESTOS - Obey the warning below before you touch or do maintenance

on parts that contain asbestos. Some old assembly components may
contain asbestos. The Occupational, Safety, and Health
Administration (OSHA) sets mandatory limits on exposure to asbestos
dust (29 CFR 1910.1001).
WARNING: DO NOT BREATHE ASBESTOS DUST. THIS DUST CONTAINS ASBESTOS
FIBERS THAT CAN CAUSE CANCER AND LUNG DISEASE. DO NOT USE
COMPRESSED AIR TO CLEAN PARTS OR ASSEMBLIES THAT POSSIBLY
CONTAIN ASBESTOS DUST. IF MAINTENANCE PROCEDURES EXPOSE
PERSONNEL TO ASBESTOS DUST, TELL YOUR EMPLOYER TO SUPPLY
EXPOSURE TO PERSONNEL. OBEY GOVERNMENT AND OSHA
REGULATIONS WHEN YOU DISCARD PARTS THAT CONTAIN ASBESTOS.
The Occupational, Safety, and Health Administration (OSHA) has an
applicable DANGER warning (29 CFR 1910.1001 (j)(4)(ii)) as follows:
DANGER: CONTAINS ASBESTOS FIBERS. AVOID CREATING DUST. CANCER AND
LUNG DISEASE HAZARD.
BERYLLIUM or BERYLLIUM COPPER ALLOYS - Obey the warning below before
you touch or do maintenance on parts that contain beryllium. Bronze
bearings and bushings may contain beryllium or beryllium copper
alloys. The Occupational, Safety, and Health Administration (OSHA)
sets mandatory limits on exposure to dust or fumes from beryllium or
beryllium copper alloys
(29 CFR 1910.1000).
WARNING: DO NOT BREATHE BERYLLIUM PARTICLES OR DUST. THESE
PARTICLES OR DUST CAN CAUSE CANCER OR LUNG DISEASE. IF
MAINTENANCE PROCEDURES MAKE BERYLLIUM PARTICLES OR DUST,
TELL YOUR EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION,
AND/OR PROCEDURES TO PREVENT EXPOSURE TO PERSONNEL. OBEY
GOVERNMENT AND OSHA REGULATIONS WHEN YOU DISCARD PARTS
THAT CONTAIN BERYLLIUM. READ AND OBEY THE NEWEST
APPLICABLE MATERIAL SAFETY DATA SHEET (MSDS) THAT IS
AVAILABLE FROM BRUSH WELLMAN INC. (REFER TO THE ADDRESS
BELOW).
The newest MSDS for beryllium is available from:
Brush Wellman Inc. Tel.: (800) 862-4118
Product Stewardship Department Fax: (419) 862-4414
14710 W. Portage River S. Road www.brushwellman.com
Elmore, Ohio 43416-9502
USA

Page 57
Feb 1/09
CERAMIC FIBERS - Obey the warning below before you do maintenance on

parts that contain ceramic fibers. Heat resistant cloth and foil
covered heat shields and thermal blankets may contain ceramic
fibers. The Occupational, Safety, and Health Administration (OSHA)
and the Refractory Ceramic Fibers Coalition (RCFC) have a voluntary
personnel protection program (PSP 2002, Feb. 11, 2002). This program
gives limits on personnel exposure to ceramic fibers.
WARNING: DO NOT BREATHE CERAMIC FIBER DUST. THIS DUST CONTAINS
CERAMIC FIBERS THAT MAY CAUSE CANCER. DO NOT USE
COMPRESSED AIR TO CLEAN PARTS OR ASSEMBLIES THAT POSSIBLY
CONTAIN CERAMIC FIBERS. IF MAINTENANCE PROCEDURES EXPOSE
PERSONNEL TO CERAMIC FIBERS, TELL YOUR EMPLOYER TO SUPPLY
EXPOSURE TO PERSONNEL. OBEY GOVERNMENT AND OSHA
REGULATIONS WHEN YOU DISCARD PARTS THAT CONTAIN CERAMIC
FIBERS. READ AND OBEY THE NEWEST APPLICABLE MATERIAL
SAFETY DATA SHEET (MSDS).
CHROMATES (HEXAVALENT CHROMIUM) - Obey the warnings below before you
touch or do maintenance on parts that contain hexavalent chromium.
Stainless steel parts often contain hexavalent chromium. The
Occupational Safety and Health Administration (OSHA) sets mandatory
limits on exposure to chromium dust (29 CFR 1910.1000).
WARNING: DO NOT GET HEXAVALENT CHROMIUM ON YOUR SKIN. REPEATED
SKIN CONTACT CAN CAUSE DERMATITIS AND SKIN ULCERS.
DIRECT EYE CONTACT WITH HEXAVALENT CHROMATE DUSTS CAN
CAUSE EYE DAMAGE. AFTER YOU TOUCH HEXAVALENT CHROMIUM
PARTS. CLEAN YOUR HANDS BEFORE YOU EAT OR SMOKE. GET
SAFETY INSTRUCTIONS FROM YOUR EMPLOYER. OBEY GOVERNMENT
AND OSHA REGULATIONS WHEN YOU DISCARD PARTS THAT CONTAIN
HEXAVALENT CHROMIUM.
WARNING: DO NOT BREATHE HEXAVALENT CHROMIUM PARTICLES, FUMES OR
DUST. THESE PARTICLES, FUMES OR DUST CAN CAUSE CANCER OR
LUNG DISEASE. IF MAINTENANCE PROCEDURES MAKE HEXAVALENT
CHROMIUM PARTICLES, FUMES OR DUST, TELL YOUR EMPLOYER TO
SUPPLY RESPIRATORS, VENTILATION AND/OR PROCEDURES TO
PREVENT EXPOSURE TO PERSONNEL.
CRYSTALLINE SILICA (Quartz) - Obey the warning below before you
touch or do maintenance on parts that contain crystalline silica.
Primers, sealants, static conditioners, and fillers may contain
crystalline silica. The Occupational, Safety, and Health
Administration (OSHA) sets limits on exposure to crystalline silica
dust (29 CFR 1910.1000 Table Z-3).

Page 58
Feb 1/09
WARNING: DO NOT BREATHE CRYSTALLINE SILICA PARTICLES OR DUST.

THESE PARTICLES OR DUST CAN CAUSE SILICOSIS AND OTHER
LUNG DISEASE. IF MAINTENANCE PROCEDURES MAKE CRYSTALLINE
SILICA PARTICLES OR DUST, TELL YOUR EMPLOYER TO SUPPLY
RESPIRATORS, VENTILATION AND/OR PROCEDURES TO PREVENT
LEAD - Obey the warnings below before you touch or do maintenance on
parts that contain lead. Soldered components and high temperature
dry lubricants may contain lead. The Occupational, Safety, and
Health Administration (OSHA) sets limits on exposure to lead (29 CFR
1910.1025).
WARNING: DO NOT GET LEAD IN YOUR MOUTH. LEAD THAT IS SWALLOWED CAN
CAUSE REPRODUCTIVE OR BLOOD SYSTEM DISEASE. AFTER YOU
TOUCH LEAD PARTS, CLEAN YOUR HANDS BEFORE YOU EAT OR
SMOKE. GET SAFETY INSTRUCTIONS FROM YOUR EMPLOYER. OBEY
GOVERNMENT AND OSHA REGULATIONS WHEY YOU DISCARD PARTS
THAT CONTAIN LEAD.
WARNING: DO NOT BREATHE LEAD PARTICLES, FUMES OR DUST. THESE
PARTICLES, FUMES OR DUST CAN CAUSE REPRODUCTIVE OR BLOOD
SYSTEM DISEASE. IF MAINTENANCE PROCEDURES MAKE LEAD
PARTICLES, FUMES OR DUST, TELL YOUR EMPLOYER TO SUPPLY
RESPIRATORS, VENTILATION AND/OR PROCEDURES TO PREVENT

Page 59
Feb 1/09

Page 60
Feb 1/09
DAMAGE INSPECTION
1. Types of Damage
The terms specified here are guides to help you determine the type of
damage that the component has.
A. Composite Structures
Abrasion - Damage which causes a thickness

change because the part has been
scuffed, rubbed, scraped or other
surface erosion has occurred.
Crack - A fracture or complete break in the
material.
Delamination - A separation of the bonded plies.
Disbond - A separation of the bonded skin
from the honeycomb core.
Gouge - Removal of material, usually caused
by a sharp object which hits the
material and makes a channel-like
groove.
Hole - A complete penetration of the
material.
Nick - A local gouge with sharp edges. A
series of nicks in a line is a
gouge.
Scratch - Light, narrow, shallow mark or
marks in the surface of a part. It
is usually caused by a very sharp
object which passes across the
surface. Material is displaced but
not removed.
B. Sheet Metal Structures
Buckle - Damage equivalent to a dent but is

caused by overstress.
V2500 54-01-00 DAMAGE INSPECTION

Page 1
Feb 1/09

material.
Dent - A damage area which is pushed in
from its normal contour. There is a
no thickness change in the material
and the area edges are smooth. It
is usually the result when a smooth
object hits the material.
groove.
material.
gouge.
not removed.

Page 2
Feb 1/09
C. Bonded Acoustic Panels

material.
Delamination - A separation of the bonded touching
plies from each other.
Disbond - A separation of the bonded skin
from the honeycomb core.
groove.
material.
gouge.
not removed.
Dent - A damage area which is pushed in
from its normal contour. There is a
no thickness change in the material
and the area edges are smooth. It
is usually the result when a smooth
object hits the material.
Rip/Tear - A line of damage to woven wire with
a continuous, ragged separation of
wire fibers.

Page 3
Feb 1/09
Void - Separation of the face sheet from

honeycomb core or faying surfaces.
2. Corrosion Damage
A. You will have to inspect the part after it is cleaned to decide

if the part can be repaired or must be replaced.
B. All remaining corrosion must be removed completely or the

corrosion process will continue even though the affected
surface is refinished.
C. Corrosion damage is grouped as follows:
(1) Light Corrosion - Pits or discoloration to a depth of

0.001 inch maximum. Remove it with abrasive paper or use a
minimum of chemical treatment.
(2) Moderate Corrosion - Blisters or signs of scale or flakes.

Pit depths may be as deep as 0.010 inch. Remove it with
abrasive paper either by hand or machine.
(3) Severe Corrosion - Severe blisters, exfoliation, and scale

or flakes. Pit depths will be deeper than 0.010 inch.
Remove severe corrosion mechanically with abrasive paper
or grinder.
3. Composite Structure Tap Test
A. Equipment
A small rod, with 0.375 inch (9.52 mm) diameter ball on one end.
It may be bought locally or made from mild steel or brass.
B. Tap Test Procedure (See Figure 1.)
(1) Test the underside of a panel which has visible damage or

defects.
(a) Tap the panel surface with the ball end of the rod.
(b) Tap the tops of the hat section reinforcements which

may be on the underside of a panel.

Page 4
Feb 1/09
(c) Note any change of pitch in the sound given out from
the panel. This shows a delamination at that
location.
(d) Mark any delaminations which you find.
(2) Test the outer surface of the panel. Mark the areas that
indicates a change in pitch of the sound.
NOTE: It is easier to check for delaminations if you

mark a six inch grid on the panel. This controls
the search pattern and makes it less likely that
an area will be missed and not searched.
(3) See the allowable damage section for delaminations to

decide if the part is usable or if it must be repaired.

Page 5
Feb 1/09
Delamination Tap Test

Figure 1

Page 6
Feb 1/09
4. Heat Damage
A. Inspect the damaged area for change in the color of metal or

paint.
(1) The general heat ranges necessary to change the color of

primer paints are as follows:
PRIMER STANDARD COLOR HEAT-CHANGED TEMPERATURE

COLOR
FR Epoxy Green Brown Above 400ºF
(200ºC)
Phenolic Rust Red Black Above 600ºF
(315ºC)
Zinc Chromate Light Green Tan Above 300ºF
(150ºC)
(2) The acceptable color changes to titanium because of heat

damage are as follows:
COLOR QUALITY
Metallic Acceptable
Straw Acceptable
Gold Acceptable
Blue Acceptable
Green Acceptable
Purple Acceptable
Reddish Brown Reject
Dark Gray Reject
Light Gray Reject
White Reject
B. If heat damage is found, a tap test is necessary for all

composite parts in the overheated area.

Page 7
Feb 1/09
5. Acoustic Treatment Blockage Area Limits
A. Independent repair to each treatment zone is permitted within

the limit for blocked area specified in column A. The repair
limit on each zone assumes all other zones are repaired to the
limits specified in column A. (See Figure 2.)
B. Additional repair blockage in a given treatment zone(s) can be

accommodated by reverting to the cumulative repair limit
specified in column B. Cumulative repair blockage is limited by
the following 3 criteria. All 3 criteria must be met for
compliance.
(1) 7.29 x (Inlet area) + 0.12 x (Fan Case + TR area)

+ 0.87 x (CNA area < 1000
(2) 0.98 x (Inlet area) + 0.38 x (Fan Case + TR area)

+ 4.67 x (CNA area) < 1000
(3) For a given zone the absolute maximum allowable blocked

area is given in column B. (This maximum area assumes no
other zones are repaired.) However, in practice a
significantly lower target maximum should be adopted to
facilitate repair to other areas within the above
cumulative limit.
NOTE: If the cumulative limit is invoked, then the

independent repair limit no longer applies to any
treatment zone.
C. Removal of stainless steel mesh on zones 1 and 3 must be

considered a repaired (blocked) area.

Page 8
Feb 1/09
2
3
4
REPAIR ZONE ZONE INDEPENDENT CUMULATIVE

LOCATION DESCRIPTION REPAIR LIMIT REPAIR LIMIT
(A) (B)
2 2
in in
(cm 2) (cm 2)
1 AIR INTAKE COWL 112 137

(722) (883)
2 FAN CASE 300 600

(1935) (3870)
3 THRUST REVERSER 500 2040
(3225) (13158)
4 COMMON NOZZLE 100 214
(645) (1380)
ASSEMBLY
13935
Acoustic Treatment Blockage Area Limits

Figure 2

Page 9
Feb 1/09

Page 10
Feb 1/09
DAMAGE CLEANUP
1. Nick, Scratch and Gouge Removal
A. Aluminum Alloys
(1) Sand the paint in the damage areas, as necessary, to a

smooth surface. See Figure 1.
(2) Polish the damage with aluminum wool.
(3) Apply protective coating. See Protective Treatment of

Metal Parts (See Figure 54-02-00.)
B. Titanium
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY

ALL SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS),
AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY
TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE
NOT OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST
SAFELY USE, KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP, AND DISCARD CHEMICALS.
WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE)

WHEN YOU DO THIS TASK. BEFORE YOU USE PPE, READ,
UNDERSTAND AND OBEY ALL INSTRUCTIONS FOR ITS USE. THESE
MANUFACTURER, YOUR EMPLOYER AND GOVERNMENT REGULATIONS.
YOU CAN GET INJURED IF YOU DO NOT USE PPE. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.
(1) Do not grind titanium parts.
(2) Do not use stainless steel wool or 350 mesh or finer

pumice.
(3) Use cloth or paper backed silicon carbide or aluminum

oxide abrasive, 80-grit or finer. See Figure 1.
V2500 54-01-01 DAMAGE CLEANUP

Page 1
Feb 1/09
(4) Support disks for disk sanders must be rubber or other

flexible material.
(5) Support drums for drum sanders must have an outer layer of
rubber or other flexible material at least 0.10 inch
thick.
(6) Do not stay in one area too long and do not use too much
pressure or speed (2000 surface feet per minute, maximum)
on local areas. Parts with heat marks which cannot be
removed with methyl ethyl ketone (MEK) must be replaced.

Page 2
Feb 1/09
ABRASIVE PAPER OR CLOTH WOOL PUMICE
V2500
METAL OR 350 SCOTCH-
MATERIALS ABRASIVE STAIN- MESH BRITE
TO BE ALUMINUM SILICON FABRIC ALUMI- LESS OR TYCRO
PROCESSED RESTRICTIONS OPERATION OXIDE CARBIDE GARNET OR PAD NUM STEEL FINER WHEELS
FERROUS DO NOT USE CORROSION

ALLOYS ACID BASE REMOVAL 150- 150- FINE TO X X X
HEAT RUST REMOVERS. OR FINER FINER ULTRAFINE
TREATED TO DO NOT USE FAIRING
220,000 PSI HAND-HELD
AND ABOVE POWER TOOLS FINISHING 400 X X X
CORROSION
FERROUS DOES NOT APPLY 150-
REMOVAL 180- FINE TO X X X 5A OR 75
NICKEL TO STEEL HEAT FINER
OR FINER ULTRAFINE MEDIUM
AND TREATED TO
FAIRING
COBALT STRENGHTS TO
ALLOYS 220,000 PSI 7S
AND ABOVE FINISHING 400 X X X
FINE
ALUMINUM CORROSION
DO NOT USE 60- VERY FINE 5A
ALLOYS REMOVAL 7/0 X X
SILICON CARBIDE FINER AND MEDIUM
OR FINER
EXCEPT ABRASIVE. ULTARFINE
FAIRING
CLAD GRINDING IS
ALUMINUM NOT PERMITTED
FINISHING 400 X X
Figure 1
SANDING LIMITED CORROSION
7/0 VERY FINE X
TO THE REMOVAL REMOVAL 240-
CLAD FINER AND
OF MINOR OR FINER
ALUMINUM ULTARFINE
SCRATCHES. FAIRING
54-01-01
GRINDING IS
NOT PERMITTED FINISHING 400 X
DO NOT USE CORROSION

VERY FINE
Abrasives for Sanding or Scouring

CARBON STEEL REMOVAL 240- X X
BRUSHES OR FINER AND
OR
MAGNESIUM
CARBIDE ULTARFINE
FAIRING
ALLOYS ABRASIVES.
GRINDING IS
NOT PERMITTED FINISHING 400 X X
CORROSION
REMOVAL 80- 80- 5A OR 75
OR FINER FINER MEDIUM
TITANIUM GRINDING IS FAIRING
NOT PERMITTED
CLEANING 150- 7S
AND 180-
13559
FINER FINER FINE
FINISHING
DAMAGE CLEANUP
Feb 1/09
Page 3
(7) Surface finish to 32 micro-inches (AA).
(8) The direction of the finished sanded edge must be parallel

to the edge of the material.
C. Composites.
For cleanup of damage to composite structures, see the

allowable damage section for the component.
2. Corrosion Damage Removal
A. Aluminum and Steel
(1) Remove the corrosion with rotary files, rubber backed disc
sanders, carbide tipped scrapers, aluminum wool, aluminum
oxide abrasive papers, etc. See Figure 1.
(2) Combine several corrosion spots together to obtain an

elliptical saucer-like rework surface.
(a) Blend the edges of the damage area into the areas
which adjoin it.
(b) Make the rework surface equivalent to 125 RMS or

better per MIL-STD-10.
(c) The rework depression is equivalent to a gouge on

the allowable damage table.
B. See the allowable damage section to make sure that the part is
serviceable after the corrosion has been removed. Corrosion
damage is the same as a gouge.
C. Repair the part or replace as necessary.

Page 4
Feb 1/09
GENERAL REPAIR
1. Protective Treatment of Metals
A. Metal surfaces that touch other metal surfaces
(1) Metals are divided into four groups:
Group 1 Magnesium and its alloys, Aluminum

alloys 5052, 5056, 5356, 6061 and
6063, and Beryllium
Group 2 Cadmium, Zinc and Aluminum and their
alloys. (Includes the Aluminum
alloys of Group 1)
Group 3 Steel, Lead, Tin and their alloys,
(except Stainless Steels), diffused
Nickel-Cadmium
Group 4 Copper, Chromium, Nickel, Silver,
Gold, Platinum, Titanium, Cobalt and
Rhodium and their alloys, Stainless
Steels, Graphite, Monel, Inconel,
Brass, Bronze
(2) The necessary protective finishes for metals are as

follows:
MATERIAL SIMILAR METALS DISSIMILAR METALS

Group 1 Apply Alodine and Apply Alodine and two
one coat of 463-6- coats of 463-6-27*
27* Primer to each primer to each surface
surface.
Group 2 Cadimum plate and Cadmium plate and
Group 3 apply one coat of apply one coat of 463-
463-6-27* primer to 6-27* primer to each
each surface surface
Stainless None Necessary Apply two coats of
Steel 463-6-27* primer to
each surface
V2500 54-02-00 GENERAL REPAIR

Page 201
Feb 1/09
Group 4 None Necessary Apply two coats of

463-6-27* primer to
each surface
* Use Phenolic Primer 204-001 in place of 463-6-27
Primer in areas where the temperature is more than 300
degrees F (150ºC).
B. Fastener Installation
(1) The requirements for protective treatment of fasteners

are:
FASTENER Group 1 Group 2 Group 3 Group 4

MATERIAL
Aluminum A B A A
Except 5056
Aluminum B B A A
Alloy 5056
Cadmium or Zinc A C A A
Plate
Chrome Plate A A A B
Stainless Steel A A A B
Nickel or Cobalt A A A B
Base Alloys
Titanium A A A B
A = Protective treatment is necessary.
B = Protective treatment is not necessary.
C = Protective treatment is not necessary except
for cadmium plated alloy steel bolts through
aluminum alloys.
(2) Fasteners in areas less than 300ºF (150ºC) that need

protective treatment should be installed wet with 463-6-27
Primer.

Page 202
Feb 1/09
(3) Fasteners in areas more than 300ºF (150ºC) that need

protective treatment should be installed wet with Phenolic
Primer 204-001 (DeSoto Chemical Co., Berkeley, CA 94710).
(4) Install fasteners that you can remove on exterior

unpainted surfaces with corrosion preventive compound,
MIL-G-16173, grade 2.
C. Primer Application
Fluid-resistant epoxy (FR) primer (CAT-A-LAC 463, Sikkens

Aerospace Finishes, Torrance, CA) is recommended for areas
where temperatures are less than 300ºF (150ºC).
(1) Application of FR Primer
(a) Mix the primer and the catalyst separately before

you mix them together.
(b) Add one part catalyst to one part primer in a metal

or glass container.
(c) Stir the mixture thoroughly and let it stand for 15

minutes.
NOTE: The material will remain usable for eight

hours if it is stored in a closed
container.
(d) Apply mixed FR Primer to the repair surface with a

brush or spray.
2. Stop Drill Cracks
A. The procedure that follow gives instructions to remove small

cracks and damaged material at fastener holes.
(1) Ream the hole 1/64 inch (0.40 mm) oversize.
(2) If no other cracks are found, make the hole 1/16 inch
(1.58 mm) larger.
(3) If cracks are found, make the hole larger by 1/16 inch
(1.58 mm) increments until the crack is removed.

Page 203
Feb 1/09
(4) Ream the hole to the finished size for installation of the
fastener.
B. The growth of a crack may be stopped if you drill a hole at the

end of the crack as follows:
(1) Drill a 0.25 inch (6.12 mm) hole at each end of the crack.
Make sure the centers of the holes are 0.10 inch (2.45 mm)
beyond the end of the crack.
(2) Check to see if the crack has continued to the other side
of the hole.
(a) If the crack has not continued, drill the hole to

0.312 inch (76.2 mm).
(b) If the crack has continued, make the hole larger by

1/16 inch (1.58 mm) increments until the crack is
removed.
3. Repair Sealant
A. Remove the old sealant from the part surface.
B. Remove all grease, oil, dirt, and other foreign materials from
the part surface.
C. Taper the ends of the remaining seal for a minimum of 0.5 inch
overlap onto the new sealant.
NOTE: Send the ends of the remaining seal to help the new
seal to stick to it.
D. Apply silastic silicone primer RTV 1203 to the surface where

RTV sealant is to be used.
E. Apply the sealant between adjacent metal parts. See Figure 1.
(1) Apply the sealant to one of the parts.
(2) Spread the sealant over the surface to a thickness of 1/64

inch (0.4 mm)
(3) Attach the two parts together.

Page 204
Feb 1/09
F. Fillet seal. See Figure 2.
(1) Apply the sealant into the seam between the two parts.
(2) Press the sealant into place with a fairing tool.
G. Injection seal. See Figure 2.
(1) Inject the sealant into one end of a hole until it comes
out from other end of the hole.

Page 205
Feb 1/09
Seal Between Adjacent Metal Parts

Figure 1

Page 206
Feb 1/09
SEALANT COMES
OUT THIS SIDE FLOW GUN
INJECTION
HOLE
FLOW GUN
BLOCK OFF WITH

CAVITY INJECTION SEAL FINGER OR SPATULA
WHEN ONE OPENING SPATULA
IS FILLED
HOLE INJECTION SEAL
INJECTION SEAL
APPLY SEALANT WITH FLOW GUN PRESS SEALANT INTO PLACE

FILLET SEAL
13561
Injection and Fillet Seal

Figure 2

Page 207
Feb 1/09
H. Slot seal. See Figure 3.
(1) Cover the surface next to the slot with masking tape.
(2) Apply the sealant to the slot.
(3) Smooth the sealant and press it into the slot with a
spatula.
(4) Remove the masking tape before the sealant cures.
I. Fastener seal. See Figure 3.
(1) Clean the fastener of all oil, grease, dirt and other
foreign material.
(2) Apply the sealant to the fastener hole.
(3) Apply the sealant to the fastener, washers, and nut.
(4) Install the fastener into the hole.
4. Formed/Extruded Section Repair
To be supplied
5. Honeycomb Repair
To be supplied

Page 208
Feb 1/09
Slot and Fastener Seal

Figure 3

Page 209
Feb 1/09

Page 210
Feb 1/09
GENERAL - LIST OF APPROVED REPAIRS
NOTE: You must refer to 54-01-00 Acoustic Treatment Blockage Area Limits
before you do repairs to acoustic areas of the thrust reverser.
REPAIR NO. REPAIR DESCRIPTION
001 Edge Erosion Repair

(VRS2082)
002 Moisture Removal Process
(VRS2371)
003 General - Surface Preparation Of Aluminum
(VRS2369) Details Using Phosphoric Acid Non Tank Anodize
(Panta)
004 General - Composite Repairs Vacuum Bagging
(VRS2370) Procedures
005 General - Paste And/or Liquid Adhesive Mixing
(VRS2373) And Curing
006 General - Adhesive Primer Application
(VRS2374)
007 General - Wet Layup Process
(VRS2375)
009 General - Honeycomb Core Repair Process
(VRS2372)
010 General - Pre-impregnated Material Handling And
(VRS2378) Curing
011 General - Structural Adhesive Handling And
(VRS2376) Curing
012 General - Damage Blend Repair For Metallic Parts
(VRS2548)
013 General - Local Passivation Using Pasajell 101
(VRS2330) Method
V2500 54-02-00 LIST OF REPAIRS

Page 201
Feb 1/09

Page 202
Feb 1/09
REPAIR 001
EDGE EROSION REPAIR
LEADING EDGE OF COMPOSITE PARTS
(VRS2082)
1. General
A. This repair procedure is used to repair erosion caused by rain

or grit on the leading edges of carbon laminate parts by
applying a ceramic-epoxy coating.
B. This repair is applicable to erosion damage on the forward

outboard edges of the Inlet Cowl, Fan Cowl or Thrust Reverser.
C. This type of damage is repaired by removing erosion damaged or

cracked paint on the outboard forward edges of the Inlet Cowl,
Fan Cowl or Thrust Reverser, and applying a
CoMat 07-160 ceramic coating, polyurethane clear coat and an
aerodynamic sealant to protect the fwd edges from further
erosion. Repair any damage to the carbon laminate per the
appropriate section of the SRM prior to applying the
CoMat 07-160 ceramic coating.
D. There are not any limitations to the size of this repair except
those described in the context of this repair.
E. Color matching of the CoMat 07-160 ceramic coating can be

accomplished by contacting the manufacturer.
2. Reference Information
VRS2082
3. Equipment and Material
NOTE: Equivalent materials and equipment can be used.
A. Standard tools
Paint brush
Spray tools
Standard shop tools
Wet film thickness gauge
V2500 54-02-00 REPAIR 001

Page 201
Feb 1/09
B. Consumable materials (Reference Overhaul Processes and

Consumable Index)
CoMat 07-160 CeRam-Kote 54 TZM Part A

CoMat 07-161 CeRam-Kote 54 TZM Part B
CoMat 01-012 Isopropanol alcohol
CoMat 01-031 Acetone
CoMat 01-457 Solvent; Alternative for CoMat 01-438
CoMat 01-438 Solvent
CoMat 02-088 Nylon brush
CoMat 02-097 Lint free gloves
CoMat 02-099 Lint free cloth
CoMat 02-178 Masking tape
CoMat 02-321 Aluminium sheet
CoMat 05-020 Waterproof silicon carbide abrasive paper
CoMat 06-131 Marking pen
CoMat 07-098 Clear polyurethane
CoMat 08-140 Sealant
C. Special tools - none
D. Expendable parts - none
E. Component Material
PART IDENT MATERIAL

Inlet Cowl Composite Material
Fan Cowl Composite Material
Thrust Reverser Composite Material
F. Repair Parts - None
V2500 54-02-00 REPAIR 001

Page 202
Feb 1/09
4. Prepare the Damaged Area for Repair, (See Figure 202)
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS), AND
GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU
OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED.
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USED,
KEEP, AND DISCARD CHEMICALS. GET
USE, KEEP AND DISCARD CHEMICALS.
WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN

YOU DO THIS TASK. BEFORE YOU USE PPE, READ,
NECESSARY.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
A. Remove any remaining aerodynamic sealant from between the

lipskin and outer barrel.
B. Clean the surface with a Comat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface clean and dry
before the solvent dries.
C. Apply 02-178 masking tape to cover the rivet row behind the
leading edge of the part to prevent the CoMat 07-160 ceramic
coating from being applied to the heads of the Monel rivets.
V2500 54-02-00 REPAIR 001

Page 203
Feb 1/09
D. Remove the paint, primer and any remaining aerodynamic sealant

from the leading edge area by lightly sanding with CoMat 05-081
silicon carbide abrasive paper. Do not abrade into the Graphite
fibers underneath the primer.
NOTE: 1. The CoMat 07-160 ceramic coating will not adhere to

surfaces contaminated with silicone. It is important
to remove all residue from the
aerodynamic sealant.
2. If there is damage to the Graphite fibers then

repair the damage in accordance with the proper SRM
repair prior to performing this repair.
E. Radius of Chamfer the edge according to the applicable

illustrations in figures 201 - 205. Use Comat 05-081 silicon
carbide abrasive paper.
F. Perform a water break test to the repair area. A surface is

water break free if a thin unbroken film of water can stay on
the surface for at least 30 seconds. If the water breaks free
from the surface, repeat the sanding and cleaning procedures in
this step until a thin, unbroken film of water can remain on the
surface for at least 30 seconds.
G. Clean the repair area with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Clean the surfaces before the
solvent dries.
5. Prepare the CoMat 07-160 Ceramic Coating
V2500 54-02-00 REPAIR 001

Page 204
Feb 1/09

NECESSARY.
A. Mix the CoMat 07-160 ceramic coating Part A. Use a paint shaker
machine to mix thoroughly for four to six minutes at 72°F
(22°C).
NOTE: 1. It may be required to shake the Comat 07-160 ceramic

coating part A for longer periods of time in order
to get it to mix completely. All ceramic particles
in part A must be completely suspended in the resin
mixture before mixing with
CoMat 07-161 part B.
2. When shaking the CoMat 07-160 ceramic coating part A

for more than 30 minutes at a time, it can become
warm causing reduced pot life. Allow the CoMat 07-
160 ceramic coating part A to cool to ambient
temperature before mixing it with CoMat 07-161 part
B. Prior to mixing with CoMat 07-161 part B, shake
the CoMat 07-160 ceramic coating part A for another
4 to 6 minutes.
3. Failure to properly mix part A will prevent the

Comat 07-160 ceramic coating from performing or
curing properly.
4. For best results, it is recommended to use the

coating in quantities of pints or quarts and to use
the unmixed coating within 2 years of the date of
delivery.
CAUTION: ALWAYS POUR COMAT 07-160 CERAMIC COATING PART A INTO COMAT
07-161 PART B. DO NOT MIX BY POURING COMAT 07-161 PART B
INTO COMAT 07-160 CERAMIC COATING PART A.
V2500 54-02-00 REPAIR 001

Page 205
Feb 1/09
B. Follow the manufacturers instructions to mix CoMat 07-160

ceramic coating part A with the CoMat 07-161 part B catalyst.
Mix the combined part A and CoMat 07-161 part B by hand for one
minute then mechanically shake the mixture for two to four
minutes at 72°F (22°C).
NOTE: 1. Do not shake the catalyzed mixture too much. Shaking

the mixed coating too much can cause heat to build
up and cause an exothermic reaction to occur. This
will make the resin cure faster than it should.
2. The pot life of mixed CoMat 07-160 ceramic coating

is approximately 4 to 6 hours at 72°F (22°C).
3. If it is necessary to thin the mixture for spraying,

use CoMat 01-012 isopropanol alcohol or CoMat 01-457
solvent or Comat 01-031 acetone. Thin only as
needed. Do not thin more than 5% of the total
volume. If too much thinner is used, it can damage
the CoMat 07-160 ceramic coating and cause it to
improperly bond to the repair surface.
C. Pour mixed CoMat 07-160 into the spray equipment. Use a

standard paint strainer to remove any lumps or foreign material
in the mixed coating.
6. Test Spray Equipment and Coating Thickness
V2500 54-02-00 REPAIR 001

Page 206
Feb 1/09

NECESSARY.
CAUTION: COMAT 07-160 CERAMIC COATING MUST BE APPLIED ONLY WHEN THE
AMBIENT TEMPERATURE AND THE REPAIR SURFACE IS ABOVE 40ºF
(4ºC). DO NOT APPLY COMAT 07-160 CERAMIC COATING IF THE
REPAIR SURFACE IS WET OR IF THE RELATIVE HUMIDITY IS
GREATER THAN 85%.
CLEANED REPAIR SURFACE. THIS PREVENTS CONTAMINATION.
A. Spray one coat of CoMat 07-160 ceramic coating to a piece of

prepared Comat 02-321 aluminum sheet.
NOTE: 1. The CoMat 07-160 ceramic coating can be applied

using a Comat 02-088 nylon brush or paint roller.
The preferred method to apply the CoMat 07-160
ceramic coating is by spraying it with a paint spray
gun. Using a brush or paint roller will cause
inconsistent results in the thickness of the
finished coating.
2. If a paint roller is used to apply the ceramic coat,

use a short nap roller with a 0.250 in. (6,35 mm)
nap thickness.
B. Use a wet film thickness gauge to measure the depth of the CoMat
07-160 ceramic coating. Apply more coats as necessary until a
film thickness of 6 to 8 mils (152 to 203 microns) is reached.
Make a note of how many coats were applied to obtain the proper
thickness.
V2500 54-02-00 REPAIR 001

Page 207
Feb 1/09
NOTE: 1. If the CoMat 07-160 ceramic coating is applied too

thick, it will crack when it cures. If it is too
thin, the CoMat 07-160 ceramic coating will not
provide the proper erosion resistance. It is
important to obtain the proper thickness of 6 to 8
mils (152 to 203 microns)
2. The compressed air source for spray equipment must

be filtered and be free of any moisture.
7. Apply the CoMat 07-160 Ceramic Coating to the Repair Area

INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE MANUFACTURER,
YOUR EMPLOYER AND GOVERNMENT REGULATIONS. YOU CAN GET
INJURED IF YOU DO NOT USE PPE. GET
NECESSARY.
AMBIENT TEMPERATURE AND THE REPAIR SURFACE IS ABOVE 40ºF
(4ºC). DO NOT APPLY COMAT 07-160 CERAMIC COATING IF THE
GREATER THAN 85%.
CAUTION: DO NOT USE A TACK RAG ON THE PREPARED AREA. CONTAMINATION

OF THE SURFACE WILL RESULT AND PINHOLES WILL FORM IN THE
COMAT 07-160 CERAMIC COATING.
V2500 54-02-00 REPAIR 001

Page 208
Feb 1/09
A. Examine the CoMat 02-178 masking tape and replace any that was
damaged from preparing the repair surfaces. Make sure all rivet
heads are covered with CoMat 02-178 masking tape. Refer to
figures 201, 203, 204 and 205 for proper application of CoMat
02-178 masking tape.
B. Clean the repair area with a CoMat 02-099 lint free cloth made
solvent dries.
C. Apply the CoMat 07-160 ceramic coating by spraying it onto the

repair area. Refer to step 6 B to apply the number of coats
needed to obtain a 6 to 8 mil (152 to 203 microns) thickness.
NOTE: 1. If the CoMat 07-160 ceramic coating is applied too

thin, the CoMat 07-160 ceramic coating will not
provide the proper erosion resistance. It is
important to obtain the proper thickness of 6 to 8
mils (152 to 203 microns). The maximum thickness
must not exceed 9 mils (229 microns) is exceeded,
cracking in the cured surface may occur.
2. The compressed air source for spray equipment must

be filtered and be free of any moisture.
D. Measure the CoMat 07-160 ceramic coating thickness in several

places to verify that the proper thickness has been obtained.
Use a wet film thickness gauge. Repeat step 7C as necessary
until required thickness is reached. If the coating is applied
too thick, remove the coating while it is still wet using a 02-
099 lint free cloth made moist with 01-457 solvent and apply
the Comat 07-160 ceramic coating again as described in step 7C.
NOTE: Some pinholes may occur in the coating and are

considered acceptable. If you find a large number of
pinholes, it is an indication that the repair surface
was contaminated prior to the application of the CoMat
07-160 ceramic coating. Remove the coating in the
affected area as described in this step and apply the
Comat 07-160 ceramic coating again.
V2500 54-02-00 REPAIR 001

Page 209
Feb 1/09
E. Remove the CoMat 02-178 masking tape from the edge of the
repair 20 minutes after the final spray of the CoMat 07-160
ceramic coating has been applied to allow the edge of the
coating to feather itself onto the surface of the part.
F. Air-dry the CoMat 07-160 ceramic coating for a minimum of 4

hours at the same temperature and humidity that the coating was
applied. Refer to figure 206 for cure times and temperatures.
The coating has a finish that is dry to the touch in 3 hours at
72ºF (22ºC). Make a note of the temperature and relative
humidity once the final coat of the CoMat 07-160 ceramic
coating has been applied.
G. Cure the CoMat 07-160 ceramic coating in a drying room after it

has been air-dried. Fully cure the Comat 07-160 ceramic coating
at a maximum temperature of 120ºF (48.8º C) for a minimum of 7
hours. The CoMat 07-160 ceramic coating can be cured at room
temperature of 72ºF (22ºC) for 12 hours. Refer to figure 206
for appropriate temperatures and cure times.
NOTE: The CoMat 07-160 ceramic coating will lose its

viscosity if the temperature is elevated too soon after
application. This will cause the coating to drip and
sag off of the repair area. The Comat 07-160 ceramic
coating is very difficult to remove once it has cured.
Make sure the surface is dry to the touch before
elevating the temperature to cure the coating.
H. Clean the spray equipment within 15 minutes after spraying the

final coat of the CoMat 07-160 ceramic coating. Thoroughly
flush and clean the spray equipment with CoMat 01-0457 MEK or
CoMat 01-031 acetone.
NOTE: Do not allow the CoMat 07-160 ceramic coating to harden

in the spray equipment. If the coating is allowed to
harden, it will cause permanent damage to the spray
equipment.
V2500 54-02-00 REPAIR 001

Page 210
Feb 1/09
8. Apply Clear Polyurethane Coating

NECESSARY.
CAUTION: DO NOT USE A TACK RAG ON THE COMAT 07-160 CERAMIC COATING.
DO NOT APPLY ANY SOLVENTS TO THE CERAMIC SURFACE. THE NEW
CERAMIC SURFACE IS ABLE TO ACCEPT THE COMAT 07-098 CLEAN
POLYURETHANE COATING WITHOUT FURTHER PREPARATION.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE COMAT
07-160 CERAMIC COATING. THIS PREVENTS CONTAMINATION.
A. Mix the CoMat 07-098 clear polyurethane coating, catalyst, and

reducer according to the manufacturers instruction. Set the
mixed CoMat 07-098 clear polyurethane coating aside for 15
minutes.
NOTE: 1. For best results, the CoMat 07-098 clear

polyurethane components must be mixed and applied
when the ambient temperature is between 60ºF and
95ºF (15ºC to 35ºC).
2. The pot life for CoMat 07-098 clear polyurethane is

4 hours at 75ºF (25ºC).
V2500 54-02-00 REPAIR 001

Page 211
Feb 1/09
B. Apply one coat of the Comat 07-098 clear polyurethane coating

onto the cured CoMat 07-160 ceramic coating. Use a CoMat 02-088
nylon brush. Make the CoMat 07-098 clear polyurethane overlap
onto the painted surface of the part a minimum of 0.250 in.
(6,35 mm). Refer to figures 201, 203, 204 and 205.
NOTE: 1. Do not use spray equipment to apply the CoMat 07-098

clear polyurethane coat.
2. Use the sample created in step 6 to test the CoMat

07-098 clear polyurethane coating prior to applying
to the repair area to make sure that is applied to
the CoMat 07-160 ceramic coating properly.
C. Air-dry the CoMat 07-098 clear polyurethane coating for 15

minutes before handling or moving the part. Allow the CoMat 07-
098 clear polyurethane coating to cure dry to the touch for 3
hours at 77ºF (25ºC). The CoMat 07-098 clear polyurethane
coating can be cured in a drying room at 120ºF (48.8ºC) for 30
minutes.
D. After the CoMat 07-098 clear polyurethane coating is fully

cured, do a visual examination of the CoMat 07-098 clear
polyurethane coating. If there are any areas missing in the
CoMat 07-098 clear polyurethane coating, reapply the CoMat 07-
098 clear polyurethane coating as required until the CoMat 07-
160 ceramic coating is completely covered.
NOTE: Full cure of the CoMat 07-098 clear polyurethane

coating is not necessary. The uncured coating is
structurally and functionally acceptable.
V2500 54-02-00 REPAIR 001

Page 212
Feb 1/09
9. Repairs to the CoMat 07-160 Ceramic Coating After Full Cure

NECESSARY.
A. Pinholes in the CoMat 07-160 ceramic coating:
1. Use CoMat 05-020 abrasive paper to remove contamination

and to make surface area around the pinholes rough.
2. Use a CoMat 02-099 lint-free cloth made moist with CoMat

01-438 solvent. Rub the surface clean and dry before the
solvent dries.
3. Apply the CoMat 07-160 ceramic coating and CoMat 07-098

clear polyurethane coating again by following steps 7 and
8.
B. Large area repairs:
1. Remove damaged or contaminated CoMat 07-160 ceramic

coating entirely by using a CoMat 05-081 silicon carbide
abrasive paper as described in step 4.
V2500 54-02-00 REPAIR 001

Page 213
Feb 1/09
2. Re-apply the CoMat 07-160 ceramic coating and the CoMat

07-098 clear polyurethane coating again by following steps
5 through 9. Do not damage the existing graphite epoxy
skin.
10. Apply the Aerodynamic CoMat 08-140 Sealant to the Leaded Edge Area

NECESSARY.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE NEW
COMAT 07-160 CERAMIC COATING. THIS PREVENTS
CONTAMINATION.
A. Make sure that all old CoMat 08-140 sealant has been
successfully removed from the joint area (refer to step 4A).
NOTE: CoMat 08-140 sealant does not require the use of a

primer.
B. Apply the CoMat 08-140 sealant to the joint between the lip
segment and the outer barrel fwd edge. Make the CoMat 08-140
sealant flush with the aft edge of the lipskin and the fwd edge
of the outer barrel. Refer to 54-00-00 for Aerodynamic
Smoothness requirements.
V2500 54-02-00 REPAIR 001

Page 214
Feb 1/09
11. Examine the Repair
A. Visually examine the repair area to make sure that the

procedures in this repair are done. If necessary, do the
applicable steps again.
12. Identify the Repair
A. Write VRS2082 adjacent to the assembly number. Use a

CoMat 06-131 marking pen using a color that contrasts.
A. Write VRS2082 adjacent to the assembly number. Use a CoMat 06-

131 marking pen using a color that contrasts.
V2500 54-02-00 REPAIR 001

Page 215
Feb 1/09
Inlet Outer Barrel Edge Erosion Ceramic Coating Repair

Figure 201
V2500 54-02-00 REPAIR 001

Page 216
Feb 1/09
Fan Cowl Leading Edge Erosion Ceramic Coating Repair

Figure 202
V2500 54-02-00 REPAIR 001

Page 217
Feb 1/09
Fan Cowl Leading Edge Erosion Ceramic Coating Repair-Option 1

Figure 203
V2500 54-02-00 REPAIR 001

Page 218
Feb 1/09
Fan Cowl Leading Edge Erosion Ceramic Coating Repair-Option 2

Figure 204
V2500 54-02-00 REPAIR 001

Page 219
Feb 1/09
Thrust Reverser Leading Edge Erosion Ceramic Coating Repair

Figure 205
V2500 54-02-00 REPAIR 001

Page 220
Feb 1/09
Thrust Reverser Leading Edge Erosion Ceramic Coating Repair

Figure 206
V2500 54-02-00 REPAIR 001

Page 221
Feb 1/09
V2500 54-02-00 REPAIR 001

Page 222
Feb 1/09
REPAIR 002
MOISTURE REMOVAL PROCESS
(VRS2371)
1. General
A. This procedure provides instructions for drying the repair area

before preparing the bagging of a composite structure repair.
Reference Title
PCI-V2500-1IA (PCI) Overhaul Processes and Consumables Index
SAE ARP4977 Drying of Thermosetting Composite Materials
A. Standard tools
Standard shop tools

Heat blanket
Temperature controller
Temperature recorder
Thermocouples
Vacuum probe
Vacuum pump
Rigid perforated screen

Consumable Index)

CoMat 02-163 Nylon bagging film
CoMat 02-166 Breather cloth
CoMat 08-132 Bleeder material
CoMat 12-024 Vacuum bag sealant
C. Special Tools - None
D. Expendable Parts - None
V2500 54-02-00 REPAIR 002

Page 201
Feb 1/09
4. For Locally Applied Heat Cure Process Only
A. Bag part locally or completely under 20 to 29 in.Hg (10 to 12

PSI) vacuum Figure 1 or 2.
1. Ensure bagging is done to prevent damage to structure.

Refer to SRM 54-02-51 Vacuum Bagging Procedure.
2. Place at least (3) thermocouples and a minimum of (1)

thermocouple for each 10 square feet of area.
3. Thermocouples with a monitoring device, either a chart

recorder or digital read out shall be placed to cover
areas of highest and lowest heat up rate.
4. A minimum of (2) vacuum ports are required, (1) located at

the thickest area of part.
B. Drying of part locally 12 in. (30 cm) around damaged area using
heat blanket.
1. While maintaining 20 to 29 in.Hg vacuum, raise part

temperature to 190º ± 10ºF, at a rise rate of 1º to 4ºF
per min. (based on coldest thermocouple).
2. At 180ºF begin at 4 hour hold at 190º ± 10ºF.
3. After 4 hours hold, verify part for liquid contamination.

Repeat drying process if you think that the part is still
contaminated. Desiccant salt can also be used in series
with vacuum line to detect water vapor. To prevent damage,
repeat drying procedures until part is completely dry.
C. Inspect
1. Inspect generated drying chart for time, temperature and

vacuum.
2. Inspect dried using tap test method, SRM 54-01-00

Composite Structure Tap Test, to confirm that no damage
occurred during procedures.
V2500 54-02-00 REPAIR 002

Page 202
Feb 1/09
3. Bonding process should be performed not more than 4 hours

after drying. If not, dried component must be stored in a
clean room environment and bonded within 7 days. Repeat
complete drying process if these conditions are not met.
4. RECORD DRYING DATE:
5. For Oven or Autoclave Cure Only
A. Bag part completely under 20 to 29 in.Hg (10 to 12 PSI) vacuum

Figure 1 or 2.
1. Ensure bagging is done to prevent damage to structure.

Refer to SRM 54-02-51 Vacuum Bagging Procedures.
2. Place at least (3) thermocouples and a minimum of (1)

thermocouple for each 10 square feet of area.
3. Thermocouples with a monitoring device, either a chart

recorder or digital read out shall be placed to cover
areas of highest and lowest heat up rate.
4. A minimum of (2) vacuum ports are required, (1) located at

the thickest area of part.
B. Drying of part using oven or autoclave.
1. While maintaining 20 to 29 in.Hg vacuum, raise part

temperature to 190º ± 10ºF, at a rise rate of 1º to ºF per
min. (based on coldest thermocouple). If an autoclave is
used, do not pressurize the chamber.
2. At 180º begin a 4 hour hold at 190º ± 10ºF.
3. After 4 hours hold, verify part for liquid contamination.

Repeat drying process if you think that the part is still
contaminated. Desiccant salt can also be used in series
with vacuum line to detect water vapor. To prevent damage,
repeat drying procedures until part is completely dry.
V2500 54-02-00 REPAIR 002

Page 203
Feb 1/09
C. Inspect
1. Inspect generated drying chart for time, temperature and

vacuum.
2. Inspect dried area using tap test method, SRM 54-01-00

Composite Structure Tap Test, to confirm that no damage
occurred during drying procedures.
3. Bonding process should be performed not more than 4 hours

after drying. If not, dried component should be stored in
a clean room environment and bonded within 7 days. Repeat
complete drying process if these conditions are not met.
4. RECORD DRYING DATE:
V2500 54-02-00 REPAIR 002

Page 204
Feb 1/09
HEAT BLANKET
COMAT 02-166 COMAT 02-163
VACUUM INTAKE VENT

LINE LINE
THERMOCOUPLES RIGID PERFORATED SCREEN
ABSORBED MOISTURE REMOVAL - METHOD 1

VACUUM BAG AND HEATING BLANKET
(USING A RIGID SCREEN)
HEAT BLANKET COMAT 02-163

ADJUSTABLE
VACUUM COMAT 02-166 INTAKE VENT
LINE LINE
PIECE OF HONEYCOMB
THERMOCOUPLES

(USING A HONEYCOMB PLUG)
A5S124
NOTE: Use rigid screen as required to prevent core damage during cure
cycle.
Figure 201
V2500 54-02-00 REPAIR 002

Page 205
Feb 1/09
PIECE OF HONEYCOMB
COMAT 02-163
ADJUSTABLE
VACUUM COMAT 02-166 INTAKE VENT
LINE LINE
VACUUM
COMAT 02-166 THERMOCOUPLES LINE
HEAT BLANKET
VACUUM BAG

(ACCESS BOTH SIDES)
A5S125
NOTE: Use rigid screen as required to prevent core damage during cure
cycle.
Figure 202
V2500 54-02-00 REPAIR 002

Page 206
Feb 1/09
REPAIR 003
GENERAL - SURFACE PREPARATION OF ALUMINUM DETAILS USING PHOSPHORIC
ACID NON TANK ANODIZE (PANTA)
(VRS2369)
1. General
A. This section contains general requirements for surface

preparation of aluminum details using phosphoric acid.
NOTE: The general procedures listed herein are to be used with the
general repairs and specific repairs included in this
Structural Repair Manual.
Refer to the specific repair section for the repair limits and
material of the component before using these repair
instructions.
Reference Title
SAE ARP1575 Rev A Surface Preparation and Priming of Aluminium
Alloy Parts for High Durability Structural
Adhesive Bonding - Hand Applied Phosphoric
Acid Anodizing
NOTE: It is possible that some materials in the Consumable Materials

chart cannot be used for some or all of the necessary
applications. Before you use the materials, make sure the
types, quantities, and applications of the materials necessary
are legally permitted in your location. All persons must obey
all applicable federal, state, local, and provincial laws and
regulations when it is necessary to work with these materials.
A. Standard tools - None
V2500 54-02-00 REPAIR 003

Page 201
Feb 1/09

Consumable Index)
CoMat 01-201 Distilled or deionized water

CoMat 01-438 Solvent Turco 6646
CoMat 01-477 PasaJell 105
CoMat 02-097 Lint-free gloves
CoMat 02-182 Metal foil tape
CoMat 02-206 Indicator paper
CoMat 02-207 Indicator paper, alternate to
CoMat 02-206
CoMat 08-349 Cheese cloth
CoMat 08-127 Fine - Mad Scotchbrite
CoMat 01-508 Cab-O-Sil grade M5
C. Special Tools - 4 to 6 volts DC power source
4. Instructions
A. Remove surface finishes in the repair area.
CAUTION: IF APPLICABLE, DO NOT USE CHEMICAL STRIPPERS FOR FINISH

REMOVAL ON PERFORATED SKIN. PAINT REMOVE CAN CAUSE DAMAGE
TO BONDLINE.
1. Solvent clean the repair area using CoMat 01-438 or CoMat

01-457 solvent and CoMat 02-0999 clean lint-free cloth.
2. Apply CoMat 02-182 tape around the repair area

approximately 3 in, (76,2 mm) from bond faying surface.
Additionally mask any other areas that can be contaminated
by this procedure.
3. If required, remove paint or other organic coatings. Refer

to SPPM TASK 70-11-29-300-503.
NOTE: Verify aluminum surface for clad. If clad exists,

ensure to remove it completely from bonding surface.
V2500 54-02-00 REPAIR 003

Page 202
Feb 1/09
4. If required, wipe dust with clean lint-free cloth.
5. Solvent clean the repair area using CoMat 01-438 or CoMat

01-457 solvent and CoMat 02-099 clean lint-free cloth.
6. Lightly abrade surface with a nylon abrasive pad such as

CoMat 08-127 Scotchbrite.
7. Wipe area with CoMat 02-099 clean lint-free cloth.
B. Surface preparation process
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USED, KEEP, AND
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON
HOW YOU MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
CAUTION: DO NOT LET COMAT 01-477 PASAJELL GO ON ADJACENT AREAS OR

INTO THE HONEYCOMB CORE. COMAT 01-477 WILL CAUSE DAMAGE TO
THE SURFACES.
USE COMAT 02-097 CLEAN WHITE GLOVES THAT ARE LINT-FREE TO

MOVE OR TOUCH SURFACES THAT HAVE BEEN PREPARED BY THIS
PROCEDURE OR CONTAMINATION WILL OCCUR.
1. Apply CoMat 01-477 PasaJell paste on surfaces using a

saturated CoMat 02-099 lint-free cloth. Dab on do not rub.
2. Leave CoMat 01-477 PasaJell paste on surface for 10 to 15

minutes.
NOTE: Prevent any surface area from discoloring or becoming

dry by applying fresh paste to the region.
V2500 54-02-00 REPAIR 003

Page 203
Feb 1/09
3. After 10 to 15 minutes have elapsed, remove paste using a

piece of CoMat 02-099 clean lint-free cloth saturated with
CoMat 01-201 distilled water. If possible, and without
contaminating other areas of the structure, flush the area
with CoMat 01-201 distilled water for 2 minutes to remove
acid paste. Ensure to properly flush honeycomb core cells.
Continue to wipe or flush to remove the material until no
traces remain.
NOTE: Ensure no paste is entrapped inside core cell. Damage

can occur to the structure and/or bondline if not
properly flushed.
4. Confirm the removal of paste by use of CoMat 02-206 or

CoMat 02-207 indicator paper. Using a new saturated wipe
cloth, wipe surface and insert CoMat 02-206 or
02-207 indicator paper into the wipe cloth. If the
indicator paper turns pink, continue flushing and/or
wiping the surface with CoMat 01-201 distilled water and
CoMat 02-099 clean lint-free cloth until all traces of
paste have been removed.
5. Air-dry for 30 minutes.
C. Make a 12% phosphoric acid. Refer to SAE ARP1575 Rev A for

preparation instructions.
CAUTION: DO NOT LET THE PHOSPHORIC ACID GO ON ADJACENT AREAS OR

INTO THE HONEYCOMB CORE. ACID WILL CAUSE DAMAGE TO THE
SURFACES.
1. Apply a uniform coat of jelled phosphoric acid. Jelled

acid can be made by adding CoMat 01-508 to the phosphoric
acid.
V2500 54-02-00 REPAIR 003

Page 204
Feb 1/09
2. Place a layer of CoMat 02-349 cheesecloth on top of the

coating, followed by more jelled acid. Work the jelled
acid with a brush or squeegee to saturate the cloth.
Alternate cloth and jelled acid until 2 or 3 layers of
cloth have been laid down. Make sure the cloth is
completely saturated. Refer to Figure 201.
3. Attach a stainless steel screen over the coating ensuring

screen does not touch the aluminum surface. Apply another
coat of jelled acid. Refer to Figure 202.
4. Connect the screen as a cathode (-) and aluminum as anode

(+) to a DC power source. Apply a current potential of 4
to 6 volts for 10 to 12 minutes. A rectifier of sufficient
capacity to supply 1 to
7 amps/ft² is recommended. In an emergency, fresh or fully
charged storage batteries may be used to anodize small
areas. Refer to Figure 202.
5. Preferred temperature range of part being anodized is 80ºF

(27ºC), but 75ºF (24ºC) to 100ºF (38ºC) is permissible.
Apply additional jelled acid if cloth begins to dry out.
NOTE: Ensure no acid paste is entrapped inside core cell.

Damage can occur to the structure and/or bondline if not
flushed properly.
6. Shut off power supply at end of anodization and

immediately remove the screen and cloth. Start rinse
within 2 minutes of power shut off. Rinse surface a
minimum of 5 minutes, using a gentle distilled water
spray. Ensure to properly flush honeycomb core cells.
7. Continue rinse, checking with CoMat 02-206 or CoMat

02-207 indicator paper, until all traces of acid have been
removed.
8. Air-dry a minimum of 30 minutes at room temperature or

force-air oven dry at 140ºF (60ºC) to 160ºF (71ºC). Dry
until no water is visible on surface.
V2500 54-02-00 REPAIR 003

Page 205
Feb 1/09
9. A properly anodized surface will show a change in color

from original to complementary when view through a
polarizing filter rotated 90º. Use a low angel of incident
fluorescent or daylight for viewing. Refer to Figure 203.
NOTE: If no color change is noticed, scrub surface with CoMat

08-127 Scotchbrite (very fine) abrasive pad and repeat
complete procedure above.
NOTE: Maximum time between phosphoric acid anodize

application and adhesive primer application is 24
hours.
D. Adhesive primer application, refer to SRM 54-02-00 REPAIR

006 (VRS2374).
PHOSPHORIC ACID
GAUZE
CAB-O-SIL
MIXED GEL SOLUTION
PLATE
GAUZE
GAUZE
A5S403
Saturating Cheesecloth with Phosphoric Acid

Figure 201
V2500 54-02-00 REPAIR 003

Page 206
Feb 1/09
DC POWER
SOURCE RECTIFIER
A
STAINLESS STEEL SCREEN
(+)
GAUZE
(-)
PLATE
SCREEN (-)
JELLED ACID
GAUZE
JELLED ACID
GAUZE
JELLED ACID
GAUZE
JELLED ACID
PLATE (+)
JELLED ACID
A5S402
Anodizing Repair Part

Figure 202
V2500 54-02-00 REPAIR 003

Page 207
Feb 1/09
POLARIZED FILTER
PHOSPHORIC ACID PLATE

ANODIZED SURFACE
A5S404
Inspecting Phosphoric Acid Anodizing Surface with Polarized Filter

Figure 203
V2500 54-02-00 REPAIR 003

Page 208
Feb 1/09
REPAIR 004
GENERAL - COMPOSITE REPAIRS
VACUUM BAGGING PROCEDURES
(VRS2370)
1. General
A. This procedure provides the instructions for vacuum bagging wet

lay-up and prepreg composite repairs.
2. References
Reference Title
SAE ARP5143 Vacuum Bagging of Thermosetting Composite
Repairs
3. Equipment and material
NOTE: Equivalent equipment and materials can be used.
A. Standard tools
Standard shop tools

Heat blankets
Thermocouples
Vacuum probe
Vacuum pump
V2500 54-02-00 REPAIR 004

Page 201
Feb 1/09
B. Consumable Materials
CoMat 02-097 Lint Free Gloves

CoMat 02-163 Nylon Bagging Film
CoMat 02-166 Breather Cloth
CoMat 02-167 Fiberglass Fabric
CoMat 02-168 Non-porous Parting Film
CoMat 02-265 Tape, Double Layer
CoMat 02-334 Porous Film Release
CoMat 08-061 Perforated Release Film
CoMat 08-132 Bleeder Material
CoMat 12-024 Vacuum Bag Sealant
NOTE: To identify the consumable materials, refer to the PCI.
4. Bagging Instructions (Vertical Bleed Cure) Refer to Figure 201
CAUTION: USE COMAT 02-097 LINT FREE GLOVES TO MOVE OR TOUCH CLEANED
AREAS OR CONTAMINATION WILL OCCUR.
NOTE: When using a heat blanket, check the size of the blanket,
since this will determine the location of the vacuum bag
sealant tape. Ensure that no damage will occur to the part
when applying vacuum pressure. Remove any part or hardware
that can be damaged by this procedure.
A. Apply CoMat 12-024 vacuum bag sealant tape approximately 6 in.

(152 mm) beyond the largest repair ply.
B. Place at least 5 thermocouples space evenly around the repair

area using CoMat 02-265 tape. Refer to Figure 202.
V2500 54-02-00 REPAIR 004

Page 202
Feb 1/09
C. (Optional) Make a low air resistance ventilation channel to

minimize vacuum drop across the vacuum bag. Put one sisal rope
of 0.40 in (10 mm) or two ropes of 0.20 (5 mm) approximately
0.80 in. (20 mm) from the outer edge of the masking tape. Stay
0.50 (13 mm) away from the impregnated peel ply. Use CoMat 02-
265 tape to keep the sisal rope in place. Put a strip of CoMat
02-166 breather cloth 3 in. (76 mm) over the ventilation
channel.
D. If required for better finish, place a layer of porous peel ply

over the repair area. Smooth to avoid wrinkles. Secure using
CoMat 02-265 tape.
E. Put a layer of CoMat 08-061 perforated release film over the

repair area, extending approximately 2 in. (51 mm) around the
edge of the repair. smooth to avoid wrinkles. secure using
CoMat 02-265 tape.
F. Put the Comat 08-132 bleeder material extending approximately 4

in. (101 mm) beyond the edge of the perforated release film. If
using a heat blanket, extend the bleeder approximately 2 in.
(51 mm) beyond the heat blanket edges. Refer to Table 1 for
number of bleeder plies required.
G. Put a layer of CoMat 02-168 non-porous parting film over the

bleeder plies. Cut the film so the edges extend over the
perforated release film and the heat blanket if used.
H. Put a CoMat 02-166 breather cloth or Comat 02-167 fiberglass

fabric over the non-porous parting film. Cut the plies so that
they extend to the edges of the bleeder. Make certain that the
breather cloth makes contact with the bleeder material along
the edges for proper vacuum flow.
I. Put a thin copper or aluminum caul plate over the breather

cloth. (Optional).
J. Put an optional CoMat 02-166 breather cloth over the caul

plate.
V2500 54-02-00 REPAIR 004

Page 203
Feb 1/09
K. If a heat blanket is used as a heat source, refer to Figure 201.
(1) Put the heat blanket over the breather cloth. Make sure it
extends a minimum of 2 in. (51 mm) around the edge of the
material to be cured.
L. Put a thermocouple over the center of the heat blanket. Put

three more thermocouples evenly spaced on the heat blanket 2
in. (51 mm) from the edge. Ensure the thermocouples are secured
to the heat blanket. This allows monitoring of the heat blanket
to prevent overheating.
M. Put four to five layers of CoMat 02-166 breather cloth over the
heat blanket. This will insulate the heat blanket and prevent
damage to the nylon bagging film.
N. Install vacuum ports. do not put ports on or near the repair

area. Put the port on a CoMat 02-166 breather cloth pad (a
minimum of 4 plies thick) and put it on the edge of the
insulation breather cloth. Cover with CoMat 02-163 nylon
bagging film. Make two cuts in the bag diametrically opposite.
One will be used for the vacuum gage and the other will be
connected to the vacuum source. Smooth to minimize wrinkles.
Press the bagging film firmly onto the vacuum bag sealant tape
to get an airtight seal. Put tucks in the bagging film for gap
material stretching and sudden transitional or contour changes.
Refer to Figure 203.
O. When using a heat blanket, insulating material can be placed

over the vacuum bag to prevent heat loss. (Optional)
NOTE: Verify bagging assembly for any bridge area or area

where damage can occur to the part. Rework the bagging
to prevent any damage to the part or risk of punctures
of the bagging assembly.
P. Connect the vacuum source and smooth the bag by hand pressure
as the air is removed. Remove all air from under the vacuum bag.
A minimum vacuum 22 in.Hg (75 kPa) is necessary.
Q. When the bag is completely sealed, draw a light vacuum,

approximately 10 in.Hg (34 kPa). the bag must be drawn into all
contour changes, hollows and ares of overlays.
V2500 54-02-00 REPAIR 004

Page 204
Feb 1/09
R. Check the bag for leaks. Attach an independent gauge to the

repair. Apply a vacuum of 22 in.Hg (75 kPa) and wait for several
minutes after the readings have stabilized. disconnect the
vacuum source and check the rate of vacuum loss. the leak rate
should be less than 5 in.Hg (17kPa) within 5 minutes. If the
leak is more than this rate, seal the area until it is
satisfactory.
NOTE: After the applicable cure cycle, cool the repair to at

least 150° F before the vacuum pressure is removed.
V2500 54-02-00 REPAIR 004

Page 205
Feb 1/09
BLEEDER PLY RATIO
6 LAYERS OR LESS
-2 plies of CoMat 08-132 bleeder cloth.
WET LAY-UP PROCESS OVER 6 PLIES

-Add 1 ply of CoMat 08-132 bleeder cloth
every 3 plies.
3 LAYERS OR LESS
-1 plies of CoMat 08-132 bleeder cloth.
PREPREG MATERIAL AND/OR OVER 3 PLIES

-Add 1 ply of CoMat 08-132 bleeder cloth
ADHESIVE FILM every 3 plies.
Table 1
V2500 54-02-00 REPAIR 004

Page 206
Feb 1/09
Vacuum Bagging Procedure

Figure 201
V2500 54-02-00 REPAIR 004

Page 207
Feb 1/09
Heat Blanket and Thermocouple Installation

Figure 202
V2500 54-02-00 REPAIR 004

Page 208
Feb 1/09
Typical Installation of Thermocouples

at vacuum Bagging Tape Locations
Correct Vacuum Bag Installation
Vacuum Bag Installation Information
Figure 203, Sheet 1
V2500 54-02-00 REPAIR 004

Page 209
Feb 1/09
Typical Vacuum Bagging Film Tuck
Figure 203, Sheet 2
V2500 54-02-00 REPAIR 004

Page 210
Feb 1/09
Typical Installation of Vacuum Probe
Figure 203, Sheet 3
V2500 54-02-00 REPAIR 004

Page 211
Feb 1/09
V2500 54-02-00 REPAIR 004

Page 212
Feb 1/09
REPAIR 005
GENERAL - PASTE AND/OR LIQUID ADHESIVE
MIXING AND CURING
(VRS2373)
1. General
A. This section contains general requirements for adhesive

preparation, handling, and curing of paste and/or liquid
adhesive used for repair.
NOTE: The general procedures listed herein are to be used with

the general repairs and specific repairs included in
this Structural Repair Manual. Refer to the specific
repair section for the repair limits and material of the
component before using these instructions. The
materials covered in this section are all epoxy based
resin systems.
2. References
PCI-V2500-1IA (PCI) Overhaul Processes and Consumable Index
3. Consumable Materials
NOTE: It is possible that some materials in the Consumable Materials

chart cannot be used for some or all of the necessary
applications. Before you use the materials, make sure the
types, quantities, and applications of the materials necessary
are legally permitted in your location. All persons must obey
all applicable federal, state, local, and provincial laws and
regulations when it is necessary to work with these materials.
A. Consumable Materials
Refer to Tables I and II
V2500 54-02-00 REPAIR 005

Page 201
Feb 1/09
4. Instructions
CAUTION: AFTER MIXING THE RESIN AND HARDENER THE POLYMERIZATION

PROCESS STARTS. THIS IS AN EXOTHERMIC REACTION WHICH
GENERATES HEAT. IF THE ENVIRONMENT CAN DISSIPATE THIS HEAT
THEN THE POT-LIFE IS RELATIVELY LONG. THE LACK OF HEAT
DISSIPATION, WHICH RESULTS IN A TEMPERATURE INCREASE OF
THE MIXTURE, CAN CAUSE A VERY SHORT POT-LIFE. BE AWARE OF
THE POT-LIFE IN RELATION TO THE RESIN MASS AND THE WETTED
AREA OF THE MIXTURE. INTRODUCTION OF AN EXCESSIVE AMOUNT
OF AIR INTO THE ADHESIVE MIXTURE WILL RESULT IN EXCESSIVE
POROSITY AND REDUCED STRENGTH.
NOTE: Material preparation shall be performed in a controlled

temperature and humidity environment. Epoxy resin systems
are sensitive to moisture, temperature, and
contamination. To prevent material degradation they must
be properly handled and stored. Epoxy systems used are two
part resin systems and are kept in separate containers.
Part A contains the base resin and part B the curing
agent. They require accurate weighing and thorough mixing
to achieve the required structural properties.
A. Laminating Resin Quantity Determination
(1) Determine the weight of dry fabric material that is

required to be impregnated. This can be done by actually
weighing the piece of fabric or calculating the weight
based on the square area and real weight of the fabric.
V2500 54-02-00 REPAIR 005

Page 202
Feb 1/09
(2) The target Resin content for a typical wet lay-up laminate
is 50% by weight. Therefore, the weight of the mixed resin
should equal the weight of the fabric. It is recommended
that 20% be added to the gross weight of the mixed resin
to account for transfer inefficiencies.
(3) Determine the weight of the resin and the weight of the
hardener.
Example: A piece of fabric 20 in. x 10 in. is to be

impregnated. Since most manufacturers specify
their products in metric units, the area is
converted to metric units. The conversion factor
is 0,000645 m²/in².
The fabric area is:
(20in. x 10in) x 0,000645=m²/in²=0,129m². (Eq.1)
Based on the fabric manufacturer’s data, the real

weight of the fabric is 320 g/m². The weight of
the fabric is:
0,129m² x 320g/m = 41,28g

(Eq.2)
Since the weight of the mixed resin should equal

the weight of the fabric plus 20%, the required
amount of mixed resin is:
41,28g + (0.20 x 41,28g) = 49,5g

(Eq.3)
For this laminating resin the manufacturer

specifies a resin/hardener mixing ratio of 100/
25 parts by weight. The component portion is
determined by multiplying the total weight by the
ratio of the component to the total. The weight
for the component portions are:
Resin: 49,5g x (100/125) = 39,6g

(Eq.4)
Hardener: 49,5g x (25/125) = 9,9g
V2500 54-02-00 REPAIR 005

Page 203
Feb 1/09
B. Adhesive Quantity Determination
(1) Determine the total bond area of the repair. This is the
total area that will be covered with adhesive.
(2) Determine the average bondline thickness for the repair.

If a bondline thickness is not specified, a typical
thickness is 0.005 in. (0,127 mm).
(3) Determine the weight of the adhesive by calculating the

adhesive volume multiplied by the adhesive density. It is
recommended that 20% be added to the gross weight of the
mixed resin to account for transfer inefficiencies. Refer
to TABLE I for the adhesive density.
hardener.
Example: A 5 in. x 10 in. carbon/epoxy pre-cured doubler

is to be bonded to a skin. Since most
manufacturers specify their products in metric
units, the area is converted to metric units. The
conversion factor is 6,45 cm²/in².
The bond area is:
(5in. x 10in) x 6,45cm²/in²=0,129m².

(Eq.5)
A bondlike thickness is not specified therefore a

typical thickness of 0.005 in. is used. The
conversion factor from inches to cm is 2,54 cm/
in. the adhesive volume is then calculated to be:
322,5cm² x (0.005in. x 2,54cm/in.)=4,1cm³

(Eq.6)
The manufacturer specifies that the density of

the adhesive is 1,25g/cm³. The weight of the
mixed adhesive is then calculated and an
additional 20% is added for inefficiencies.
Therefore, the required amount of mixed adhesive
is:
4,1cm³ x 1,25g/cm³ = 5,1g (Eq.7)
V2500 54-02-00 REPAIR 005

Page 204
Feb 1/09
5,1g + (0.20 x 5,1g) = 6,1g
The calculations determined that only 6,1g of

adhesive is needed for this repair. This is below
the recommended minimum of 25g, therefore, 25g
will be mixed for this application.
For the adhesive the manufacturer specifies an

adhesive/hardener mixing ratio of 100/60 parts
by weight. The component portion is determined by
multiplying the total mixed weight by the ratio
of the component to total.
The weight for the component portions are:
Adhesive: 25g x (100/160) = 15,6g (Eq.8)
Hardener: 25g x (60/160) = 9,4g
A general rule of thumb for a quick estimate of

the amount of adhesive (in grams) required to be
mixed for a bondlike application is 0.125 times
the area (in square inches).
C. Additive Quantity Determination
(1) Determine the weight of the mixed resin (part A and B)

that the additives will be added to per paragraph 4B.
(2) Calculate the weight of the additives need to obtain the

syntactic potting compound (refer to TABLE II).
Example: 60 grams of CoMat 08-104 is required as a low

density core filler. The mix ratio to obtain a
syntactic potting compound with hollow
microspheres (micro balloons) is of
approximately 20% by weight.
Mixed CoMat 08-104: = 60g
Micro balloons: = 60 grams x 0.20 = 12g
Syntactic potting compound total weight = 72g
V2500 54-02-00 REPAIR 005

Page 205
Feb 1/09
D. Curing of Adhesives

YOU DO THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND
OBEY ALL INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER
AND GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO
NOT USE PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH
PPE IS NECESSARY.
CAUTION: DO NOT APPLY ADHESIVES TO SURFACE TEMPERATURES BELOW 50ºF

(10” C).
DO NOT ALLOW THE TEMPERATURE TO FALL BELOW 75°F DURING

AMBIENT CURE CYCLE OR STRENGTH WILL BE COMPROMISED.
TO PREVENT BLISTERING, DELAMINATION OR DISBONDING FROM

OCCURRING, DO NOT SET OR ADJUST TEMPERATURE CONTROLLER
HIGHER THAN THE UPPER LIMIT FOR THE CURE TEMPERATURE RANGE
SPECIFIED IN TABLE I.
NOTE: If required, preparation of faying surfaces to be done in

accordance with the applicable SRM. Bonding shall be
within 4 hours after solvent cleaning or priming. If any
abrasion is to be used, perform bonding operation as soon
as possible after abrasion to prevent
re-oxidation of the surface.
(1) Weigh and mix adhesive according to paragraph 4A and TABLE

I.
(2) If required, ensure that pressure is applied to the repair

adhesive pot life is exceeded. Use pressure method as
specified per applicable SRM.
V2500 54-02-00 REPAIR 005

Page 206
Feb 1/09
(3) Room temperature cure: Allow material to set at room

temperature for a minimum of 4 hours. After 4 hours at
room temperature, except for CoMat 08-050 and CoMat 08-131
(no room temperature cure available), pressure maybe
removed even if full cure strength is not achieved yet.
(4) Two part adhesive accelerated cure cycle: cure the repair
area to the temperature specified in TABLE I (accelerated
cure).
Table 1:
Mix
Ambient Ratio
Pot Life
Cure Accelerated by Density
CoMat Minutes/
(min. @ Cure Weight (mixed
material lb. (kg) @
77°F/ (±10°F/±5°C) (resin/ g/ml)
77°F(25°C)
25°C) curing
agent)
08-021 7 days @ 2 hour @ RT 100:33 1.36 40/1

EA934NA 77°F & 2 hours @ (40/.5)
(25°C) 200°F(93°C)
08-104 5 days @ 1 hour @ 100:17 1.36 100/1
EA9321 77°F 160°F (72°C) (100/.5)
(25°C)
08-078 7 days @ 1 hour @ 100:50 1.23 40/1
EA9321 77°F 180°F (82°C) (40/.5)
(25°C)
08-050 No RT 220 minutes 100:56 1.10 120/.5
EA9390 Cure @ 200°F (120/.25
Available (93.3°C)
08-131 No RT 2 hours @ 100:30 __ 480/.25
EA9396 Cure 200°F (480/.1)
Available (93.3°C)
V2500 54-02-00 REPAIR 005

Page 207
Feb 1/09
NOTE:
(1) Heat application methods as per applicable SRM.

(2) The cure condition specified for the individual adhesive
type is the minimum time required at the indicated
temperature to provide adequate adhesive bond strength for
part usage.
(3) Density to be used as reference only. Always refer to
manufacturer data sheet.
(4) Cure cycle defined in applicable SRM take precedence over
Table I and should be referred to for further guidance.
(5) The pot life times are based for 77°F (25°C). At 90°F
(32ºC), these times are reduced by 50%.
(6) RT stands for room temperature.
Table II
CoMat Mix Ratio True Density Density

(additive) (approximate) (approximate) (mixed)
02-164 20% by weight 7.8 to 37.5 40lb/ft³

(Micro balloon) lb./ft³ (640 kg/m³)
(125 to 593
kg/m³)
08-075 10% by weight -- --
(Glass Fibers)
NOTE:
(1) Care should be taken to assure that all additives are

thoroughly dry before adding to the resin mixture.
(2) The base resin and hardener should be mixed first before
adding the additive to have a more homogeneous mix.
V2500 54-02-00 REPAIR 005

Page 208
Feb 1/09
REPAIR 006
GENERAL - ADHESIVE PRIMER APPLICATION
(VRS2374)
1. General
A. This section contains general requirements for adhesive primer

application following a surface preparation process
NOTE: The general procedures listed herein are to be used

with the general repairs and specific repairs included
in this Structural Repair Manual. Refer to the specific
repair section for the repair limits and material of
the component before using these repair instructions.
2. References
PCI-V2500-1IA (PCI) Overhaul Processes and
Consumable Index
NOTE: It is possible that some materials in the Consumable

Materials chart cannot be used for some or all of the
necessary applications. Before you use the materials, make
sure the types, quantities, and applications of the
materials necessary are legally permitted in your location.
All persons must obey all applicable federal, state, local,
and provincial laws and regulations when it is necessary to
work with these materials.
A. Consumable Materials

CoMat 08-137 BR-127
V2500
54-02-00 REPAIR 006
Page 201
Feb 1/09
4. Instructions
A. Adhesive primer application using spray gun method.

SAFELY USED, KEEP, AND DISCARD CHEMICALS. GET

NECESSARY.
CAUTION: USE CLEAN, WHITE GLOVES THAT ARE LINT FREE TO MOVE OR
TOUCH SURFACE THAT HAS BEEN PREPARED BY THIS PROCEDURE
OR CONTAMINATION WILL OCCUR.
NOTE: CoMat 08-137 is to be sprayed using compressed

nitrogen. use only equipment that is non-contaminated
with standard shop air.
Do not use CoMat 08-137 that contains lumps or has any
indication of gelation.
(1) Condition the refrigerated primer to room temperature

(approximately 2 hours) prior to opening the container.
(2) The primer must be agitated before and during

application to prevent the chromate particles from
setting out of solution.
V2500
54-02-00 REPAIR 006
Page 202
Feb 1/09
(3) The following spray procedure is required:

(a) Line pressure - 20 to 35 PSI.
(b) Pot pressure - suction feed
(c) Standoff distance - 6 to 12 inches (152 to 305 mm).
(4) Apply in smooth even strokes on area to be primed to

give a primer thickness of 0.0001 to 0.0004 in. (0,0025
to 0,0101 mm).
(5) Air dry primer at room temperature for 30 minutes.
(6) The primer is to be cured after the air dry cycle using
certified explosion proof heat sources at 240°F to
260°F (115°C to 125°C) for 30 minutes. The repair parts
may be cured in an oven.
(7) The cured thickness of the primer layer must be between

0.0001 to 0.0004 in. (0,0025 to 0,0101 mm). Measurement
of primer thickness may be performed by adequate
measuring equipment or by certified color chips. If
primer thickness is not acceptable, restart surface
preparation process.
NOTE: Prepared parts must be bonded within 4 hours
(8) Part can be wrapped in clean, non-waxed kraft paper and

store in a clean room environment up to 90 days or
until ready to be used to reduce the possibility of
contamination.
B. Adhesive primer application using hand cloth wipe method.

SAFELY USED, KEEP, AND DISCARD CHEMICALS. GET
V2500
54-02-00 REPAIR 006
Page 203
Feb 1/09
CAUTION: USE CLEAN, WHITE GLOVES THAT ARE LINT FREE TO MOVE OR
TOUCH SURFACE THAT HAS BEEN PREPARED BY THIS PROCEDURE
OR CONTAMINATION WILL OCCUR.
NOTE: Do not use CoMat 08-137 that contains lumps or has any
indication of gelation.
(1) Condition the refrigerated primer to room temperature

(approximately 2 hours) prior to opening.
(2) The primer must be agitated before and during

application to prevent the chromate particles from
setting out of solution.
(3) Using a clean Comat 02-099 cloth, make a pad for

applying the primer. Moisten the pad with primer and
wipe surface to be bonded lightly with pad. Apply
primer evenly. Primer should have a light green
appearance on the surface to obtain the correct dry
film thickness of between 0.0001 to 0.0004 in. (0,0025
to 0,0101 mm). A dark green color and/or streaks of
dark green color are unacceptable.
(4) Air dry primer at room temperature for 30 minutes.
(5) The primer is to be cured after the air dry cycle using
certified explosion proof heat sources at 240° to 260°F
(115° to 126°C) for 30 minutes. The repair parts may be
cured in an oven.
(6) The cured thickness of the primer layer must be between

0.0001 to 0.0004 in. (0,0025 to 0,0101 mm). Measurement
of primer thickness may be performed by adequate
measuring equipment or by certified color chips. If
primer thickness is not acceptable, restart surface
preparation process.
NOTE: Prepared parts must be bonded within 4 hours
(7) Part can be wrapped in clean, non-waxed kraft paper and

store in a clean room environment up to 90 days or
until ready to be used to reduce the possibility of
contamination.
V2500
54-02-00 REPAIR 006
Page 204
Feb 1/09
REPAIR 007
GENERAL - WET LAYUP PROCESS
(VRS2375)
1. General
A. This procedure is for resin impregnation of fabric repair

plies.
2. Reference
SAE AMS 2980/1 Wet Layup Process
A. Standard Equipment
Spatula
Roller
Plastic squeegee
Knife or shears
CoMat 02-168 Non-porous parting film

CoMat 02-036 Masking tape polyester film
(mylar)
4. Instructions
NOTE: Figure 201 is for a typical repair ply layup and is for
reference only. Refer to the specific repair for all repair
ply layup information.
A. Perform the repair at the controlled environment with optimal

conditions as shown in Figure 202. The repair is strongly
affected by temperature and moisture.
V2500 54-02-00 REPAIR 007

Page 201
Feb 1/09
B. Determine the amount of fabric material that will be needed for

the repair plies. Refer to the repair for the material type of
each ply. Cut a piece that is large enough for cutting the
required number of plies for the repair. Make each ply slightly
larger than the repair specifies.
C. Cut two pieces of CoMat 02-168 parting film approximately 3.0

in. (72,2 mm) larger than each fabric ply all around. Tape one
piece to a smooth surface.
D. Lay the fabric ply on the CoMat 02-168 parting film.
E. Determine the amount of resin mix required for each fabric ply.
Refer to SRM 54-02-00 General REPAIR 005 (VRS2373) Paste and/or
Liquid Adhesive Mixing and Curing.
F. Spread the resin to adequately cover the fabric evenly.
G. Cover the fabric with the second piece of CoMat 02-168 parting
film.
H. Press the resin through the fabric by working over the parting
film with a squeegee or roller. This impregnates the fabric
with resin and removes entrapped air.
I. Work excess resin to the edges of the fabric such that the
fabric weave is barely visible.
J. Follow steps 4C through 4I for each fabric ply of the repair.
K. Make a template for each ply using CoMat 02-036 mylar. Mark the
ply number and ply orientation on each template. The
orientation should be the same as in the original structure.
Refer to the repair for this information.
L. Using the templates, cut the impregnated fabric to the required

sizes for each individual ply.
(1) Clean the work surface and the cutting tools with CoMat
01-438 solvent. Shears or a knife and a straight edge
should be used for cutting repair material.
V2500 54-02-00 REPAIR 007

Page 202
Feb 1/09
M. Apply a light coat of resin over the repair area. Refer to SRM
54-02-00 General REPAIR 005 (VRS2373) Paste and/or Liquid
Adhesive Mixing and Curing.
N. Remove the CoMat 02-168 parting film from one side of the
smallest ply repair layup. Place the exposed face against the
repair area with the proper orientation and overlap all around.
O. Use a plastic squeegee over the CoMat 02-168 parting film that
covers the repair area to remove wrinkles and entrapped air. Do
not apply excessive pressure because it will produce a ply
deficient in resin.
P. Remove the CoMat 02-168 parting film from the ply and the next
larger ply of the layup. Place the next ply on the repair area
with the proper orientation and overlap all around. Refer to
the specific repair for this information.
Q. Follow steps O and P for all subsequent plies.
R. Place CoMat 02-036 mylar over the layup and use a roller or
spatula to squeeze out air bubbles and excess resin. Push the
roller from the center of the layup to the edges.
V2500 54-02-00 REPAIR 007

Page 203
Feb 1/09
Wet Layup Process

Figure 201
V2500 54-02-00 REPAIR 007

Page 204
Feb 1/09
Wet Layup Process

Figure 202
V2500 54-02-00 REPAIR 007

Page 205
Feb 1/09
V2500 54-02-00 REPAIR 007

Page 206
Feb 1/09
REPAIR 008
GENERAL - FABRICATION AND INSTALLATION OF A BACKUP PLATE
(VRS2377)
1. General
A. This procedure is for the fabrication of a backup plate to be

used for composite repairs.
B. Depending on the repair being performed, wet layup or prepreg

layup, use the available fabric to make the backup plate
A. Drill and drilling tools

Standard workshop tools

CoMat 02-165 Graphite Fabric
CoMat 08-138 Pre-impregnated Graphite Fabric
CoMat 02-119 Lockwire
CoMat 05-020 Abrasive Paper
CoMat 05-021 Abrasive Paper
CoMat 02-099 Lint Free Cloth
V2500 54-02-00 REPAIR 008

Page 201
Feb 1/09
3. Instructions

PPE IS NECESSARY.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH
PREIMPREGNATED FABRICS. THIS PREVENTS CONTAMINATION.
A. Cut the plies for the backup plate. The backup plate must
overlap the damage cutout by 1.0 in. (25,4 mm) all around when
installed.
(1) Cut four plies from CoMat 02-165 graphite fabric.
(2) As an alternative, cut eight plies from CoMat 08-138 pre-

impregnated graphite fabric or eight plies from
CoMat 02-167 fiberglass fabric.
B. Put all the plies into position on a hard surface that has the
same contour as the repair area. Once cured, the backup plate
must fit on the repair area with light finger pressure.
(1) For a pre-impregnated layup, press the plies into position

and remove the wrinkles.
(2) For a wet layup, refer to SRM 54-02-00 REPAIR 007

(VRS2375), Wet Layup Process.
C. Prepare the vacuum bag for the backup plate, refer to

SRM 54-02-00 REPAIR 004 (VRS2370), Vacuum Bagging Procedures.
D. Cure the backup plate.
(1) For a pre-impregnated layup, refer to SRM 54-02-00 REPAIR

010 (VRS2378), Prepreg Handling and Curing.
(2) For a wet layup, refer to SRM 54-02-00 REPAIR 005

(VRS2373), Paste and/or Liquid Adhesive Mixing and Curing.
V2500 54-02-00 REPAIR 008

Page 202
Feb 1/09
E. Install the backup plate.
(1) Drill four 0.098 in. (2,5 mm) diameter holes through the
backup plate. Locate the holes as shown in Figure 201.
(2) Install pieces of the CoMat 02-119 lockwire through the

holes as shown in Figure 201. Twist the wire ends tightly
together.
(3) Bond the backup plate to the backside of the skin around
the cutout. Apply adhesive to the mating surface of the
backup plate and the inner surface of the skin per
SRM 54-02-00 REPAIR 005 (VRS2373), Paste and/or Liquid
Adhesive Mixing and Curing. Put the backup plate through
the cutout and onto the inner surface of the skin. Make
sure the plate has an equal overlap around the cutout. Use
a rod as shown in Figure 201. Twist the lockwire until the
backup plate is firmly in place.
NOTE: Do not apply too much tension to the lockwire. This
can cause the plate to be warped.
(4) Apply more adhesive to fill the lockwire holes. Cure the
backup plate to the inner skin. Refer to
SRM 54-02-00 REPAIR 005 (VRS2373), Paste and/or Liquid
Adhesive Mixing and Curing.
F. Remove the rod and cut the lockwire at the backup plate.
Lightly sand with CoMat 05-020 and CoMat 05-021 abrasive papers
to remove sharp edges.
G. Clean the repair area. Use dry air blast and a CoMat 02-099 lint
free cloth made moist with CoMat 01-438 solvent. Rub the
surfaces clean before the solvent becomes dry.
V2500 54-02-00 REPAIR 008

Page 203
Feb 1/09
Fabrication and Installation of a Backup Plate

Figure 201
V2500 54-02-00 REPAIR 008

Page 204
Feb 1/09
REPAIR 009
GENERAL - HONEYCOMB CORE REPAIR PROCESS
(VRS2372)
1. General
A. This procedure provides the instructions on potting or

honeycomb core for full or partial penetration repairs.
B. Method 1 is used for full or partial penetration repair using a

core plug and a 250°F film adhesive.
C. Method 2 is used for full or partial penetration repair using a

core plug and a paste adhesive system.
D. Method 3 is used for full or partial penetration repair using

adhesive filling process. The damage must not be larger than
1.0 in. (24.4 mm) diameter.
E. Method 4 is used for full or partial penetration repair using a

core plug and a 350°F film adhesive.
F. Determine core density and ribbon direction before removing

damages core.
G. This procedure must be used in conjunction with an approved

Goodrich Engineering repair.
2. References
V2500 54-02-00 REPAIR 009

Page 201
Feb 1/09
A. Standard tools
Standard shop tools

Heat blankets
Thermocouples
Vacuum probe
Vacuum pump

CoMat 01-457 Solvent, alternative for CoMat 01-438
CoMat 02-099 Clean lint free gloves
CoMat 02-265 Tape, double layer
CoMat 08-052 Non-perforated release film
CoMat 08-078 EA9321 adhesive
CoMat 08-085 Adhesive film
CoMat 08-088 Foaming adhesive, FM410-1
CoMat 08-089 Foam adhesive, Alternate for CoMat 08-078
CoMat 08-104 EA9394 epoxy paste adhesive, Alternate for
CoMat 08-078
CoMat 08-136 Adhesive film, FM300-2M or -2K
V2500 54-02-00 REPAIR 009

Page 202
Feb 1/09
4. Core Removal
A. Method A:
NOTE: This type of damaged core removal is used when the core
will be replaced with a new piece of core, method 1, 2 and
4.
(1) Clean the area using a piece of CoMat 01-438 or CoMat 01-
457 solvent and a clean coMat 02-099 cloth. Wipe the area
dry before the solvent evaporates.
(2) Using a core slicer or core knife, carefully slice down

the core cell walls to separate the core in the damage
area from the remaining part core section. Slice along the
part core cell axis. Make sure core slicer cutting edge is
sharp.
(3) If only one skin has been damaged, use the core slicer to
separate the core. Then completely remove separated core
in the damage cleanup hole area down to the opposite skin
inner surface. High-density core can be removed using
needle nose pliers and gently pulling in a twisting
motion. Core can be removed also using a 90° router motor
and an 80 grit abrasive disk. Use care not to damage
adjacent core areas or sand into opposite skin. DO NOT
REMOVE REMAINING ADHESIVE AT THE BOTTOM OF CUTOUT.
(4) Vacuum core and sanding residue from repair area. Wipe
inner skin surface using CoMat 02-099 clean, dry lint free
cloth. Mask area properly to prevent contamination.
B. Method B, Refer to Figure 202:
NOTE: This type of damaged core removal is used when the core
will be replaced with paste adhesive, method 3.
(1) Clean the area using CoMat 01-438 or CoMat 01-457 solvent
and a clean CoMat 02-099 cloth. Wipe the area dry before
solvent evaporates.
V2500 54-02-00 REPAIR 009

Page 203
Feb 1/09
(2) Locate and drill a hole through the panel in the center of
the damaged area. The hole will permit the fit of the
below described Hockey Stick tool in the damaged core
area.
(3) Protect the outer skin of the panel using a guide template
for the hockey Stick tool. Attached the template in place
using adhesive tape or equivalent to prevent damage to the
outer skin.
NOTE: The Hockey Stick tool can be made from a modified

Allan Key tool, stainless steel wire or
equivalent.
(4) Carefully start removing the core up to 1.5 in. (38 mm)
diameter (unless specified in applicable repair). In some
cases different Hockey Stick tools may be required to
achieve proper diameter. DO NOT REMOVE REMAINING ADHESIVE
AT THE BOTTOM OF THE CUTOUT.
(5) Vacuum the core and sanding residues from the area. Wipe
inner skin surface using CoMat 02-099 clean, dry lint free
cloth. Mask the area properly to prevent contamination.
5. Method 1: Core Plug Repair Using 250°F Film Adhesive Process. Refer
to Figure 203
NOTE: Make sure that the repair cavity has been cleaned and that the
surface preparation has been performed in accordance with the
applicable repair.
If you see or suspect the part has liquid contamination,

remove the liquid before you start the repair to prevent
further damage as per SAE ARP4977 or SRM 54-02-00 REPAIR 002
(VRS2371), Moisture Removal Process.
A. Fabricate honeycomb replacement core using same core material,

thickness and density as original part unless specified in the
repair. Core ribbon direction as per parent part. Maximum gap
between plug and existing core equivalent to (1) cell. If
required, core plug shall be wrapped properly and stored in a
clean room environment until ready to use.
V2500 54-02-00 REPAIR 009

Page 204
Feb 1/09

PPE IS NECESSARY.
B. Flush core plug with CoMat 01-438 or 01/457 solvent to remove

any contaminants and allow to dry. Core plug can also be vapor
degreased.
C. For partial penetration repairs, install up to two layers of

Comat 08-136 adhesive film in the bottom of the repair cavity.
Refer to Figure 3.
D. Press one layer of CoMat 08-088 or CoMat 08-089 foaming

adhesive into the part core sidewalls in the repair cavity.
Repeat the process for a second layer.
E. Carefully insert the core plug into the cavity. Make sure that
the core ribbon direction matches existing core and the
adhesive was not wiped off walls during core installation.
F. Cure the adhesive as follows:
(1) Install CoMat 08-052 release film on top of core plug and
repair area approximately 2 in. (50,8 mm) larger than the
heat blanket. Use CoMat 02-265 tape to secure it.
(2) For partial penetration repairs, add dead weight as

required over the core plug to make sure proper contact
with bottom skin.
CAUTION: TO PREVENT BLISTERING, DELAMINATION OR DISBONDS FROM

OCCURRING, DO NOT SET OR ADJUST TEMPERATURE
CONTROLLER HIGHER THAN THE UPPER LIMIT FOR THE CURE
TEMPERATURE RANGE SPECIFIED.
NOTE: Apply additional insulation (CoMat 02-166) over

assembly as required to assist in obtaining the
desired cure temperature.
V2500 54-02-00 REPAIR 009

Page 205
Feb 1/09
NOTE: If the bottom skin is thin or can deflect due to

pressure and heat, install a pressure plate to prevent
permanent deformation.
(3) Cure the repair area using heat blanket, oven and/or other
explosion proof certified equipment as follows. Heat the
repair area at a rate of 1 to 6°F (1 to 4°C) per minute to
bring all thermocouples within the cure temperature range
specified in step 4.
CAUTION: UNDERCURING AND A WEAK BOND WILL RESULT IF THE

COLDEST THERMOCOUPLE DOES NOT REACH THE LOWER LIMIT
FOR THE CURE TEMPERATURE.
(4) Upon the coldest thermocouple reaching the 250°F (121°C) ±

10°F (±5°C) cure temperature range, begin a 60 minutes
soak. Continuously monitor and record all thermocouples to
make sure the cure temperature range is maintained during
soak period.
(5) After the soak at the required temperature is complete,

cool to 150°F (65°C) at a rate not to exceed 5°F (3°C) per
minute. Upon reaching 150°F (65°C), the equipment may be
removed.
G. Inspect the core sidewall bond to make sure the adhesive was
properly expanded and that no gap exists.
H. Remove any residual foaming adhesive and sand core flush to the
repair area as per Figure 3. Vacuum clean the core plug and
repair area. Wipe skin surface clean with a CoMat 02-099 clean
dry lint free cloth.
I. Continue with the applicable repair.
J. Inspect repair per step 9.
V2500 54-02-00 REPAIR 009

Page 206
Feb 1/09
6. Method 2: Core Plug Repair Using Paste Adhesive, Refer to

Figure 204
NOTE: Make sure that the repair cavity has been cleaned and
that a surface preparation has been performed in
accordance with the applicable repair.
NOTE: If you see or suspect the part has liquid

contamination, remove the liquid before you start the
repair to prevent further damage as per SAE ARP 4977 or
SRM 54-02-00 REPAIR 002 (VRS2371), Moisture Removal
Process.

B. Flush core plug with CoMat 01-438 of CoMat 01-457 solvent to

remove any contaminants and allow to dry. Core plug can also be
vapor degreased.
NOTE: For partial penetration repairs. Chop fibers additives are

required for aluminum core to graphite skin to prevent
galvanic corrosion.
V2500 54-02-00 REPAIR 009

Page 207
Feb 1/09
C. For partial penetration repairs, mix CoMat adhesive with chop

fibers (use CoMat 08-104 as alternate adhesive with chop
fibers) as per SRM 54-02-00 REPAIR 005 (VRS2373), Paste and or
Liquid Adhesive Mixing and Curing. Use a plastic spatula or
injection flow gun to form a 0.100 in. (2,54 mm) film on the
bottom skin. Refer to figure 204.
D. Carefully insert the core plug into the cavity. Make sure that
the core ribbon direction matches existing core.
E. Use a plastic spatula or injection flow gun to fill the gap

between the existing core and the core plug replacement. Make
sure that the cavity is properly filled.
(2) For partial penetration repairs, add dead weight over the
core plug to make sure proper contact with bottom skin.

OCCURRING, DO NOT SET OR ADJUST TEMPERATURE CONTROLLER
SPECIFIED.
NOTE: Apply additional insulation (CoMat 02-166 breather

material) over the assembly as required to assist in
obtaining the desired cure temperature.
NOTE: If bottom skin is thin or can deflect due to pressure and

heat, install a pressure plate to prevent permanent
deformation.
(3) Cure the repair area using a heat blanket, oven and/or
other explosion proof certified equipment in accordance
with SRM 54-02-00 REPAIR 005 (VRS2373), Paste and or
Liquid Adhesive Mixing and Curing.
CAUTION: UNDERCURING AND A WEAK BOND WILL RESULT IF THE COLDEST

THERMOCOUPLE DOES NOT REACH THE LOWER LIMIT FOR THE CURE
TEMPERATURE.
V2500 54-02-00 REPAIR 009

Page 208
Feb 1/09
G. Inspect the core sidewall bond to make sure that no gap exists.
H. Remove any residual adhesive and sand core flush to repair area
as per Figure 204. Vacuum clean core plug and repair area. Wipe
skin surface clean with a CoMat 02-099 clean cloth.
7. Method 3: Core Cavity Partial And Complete Filling Using Paste

Adhesive. Refer to Figure 205
NOTE: This method must not be used for damage larger than 1.0 in
(25,4 mm) in diameter.
A. Carefully unbend the damaged core cells and make straight.
B. Verify for core cell and back skin corrosion or damage using a
light source. Report any anomaly to Goodrich Customer Support.
CAUTION: EXCESSIVE PRESSURE CAN DAMAGE CORE CELLS
C. Clean the damaged area using clean light air pressure (dry
line, no oil) and CoMat 01-438 or CoMat 01-457 solvent. Allow
it to dry for 30 minutes.
V2500 54-02-00 REPAIR 009

Page 209
Feb 1/09
D. Mix CoMat 08-078 (CoMat 08-104 can be used as alternate) per

SRM 54-02-00 REPAIR 005 (VRS2373), Paste and or Liquid Adhesive
Mixing and Curing. Use a plastic spatula or injection flow gum
to form a partial or solid fill area. Refer to figure 205. If
possible, apply CoMat 08-052 release film with CoMat 02-265
tape around the repair area and turn part upside down.
E. Cure adhesive per SRM 54-02-00 REPAIR 005 (VRS2373), Paste and
or Liquid Adhesive Mixing and Curing.
F. Continue with applicable repair.
G. Inspect per step 9
8. Method 4: Core Plug Repair Using 350° Film Adhesive Process. Refer to
Figure 206
NOTE: Make sure that the repair cavity has been cleaned and that a
surface preparation has been performed in accordance with
the applicable repair.
NOTE: If you see or suspect the part has liquid contamination,

remove the liquid before you start the repair to prevent
further damage as per SAE ARP 4977 or SRM 54-02-00 REPAIR
002 (VRS2371), Moisture Removal Process.

INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
V2500 54-02-00 REPAIR 009

Page 210
Feb 1/09
B. Flush core plug with CoMat 01-438 of CoMat 01-457 solvent to

remove any contaminants and allow to dry. Core plug can also be
vapor degreased.
C. For partial penetration repairs, install up to two layers of

CoMat 08-085 adhesive film in the bottom of the repair cavity.
D. Press one layer of CoMat 08-088 or CoMat 08-089 foaming

adhesive into the part core sidewalls in the repair cavity.
Repeat the process for a second layer.
E. Carefully insert the core plug into the cavity. Make sure that
the core ribbon direction matches existing core and the
adhesive was not wiped off walls during core installation.
(2) For partial penetration repairs, add dead weight as

required over the core plug to make sure proper contact
with bottom skin.

OCCURRING, DO NOT SET OR ADJUST TEMPERATURE
CONTROLLER HIGHER THAN THE UPPER LIMIT FOR THE CURE
TEMPERATURE RANGE SPECIFIED.
NOTE: Apply additional insulation (CoMat 02-166) over

assembly as required to assist in obtaining the
desired cure temperature.
NOTE: If the bottom skin is thin or can deflect due to

pressure and heat, install a pressure plate to prevent
permanent deformation.
(3) Cure the repair area using heat blanket, oven and/or other
explosion proof certified equipment as follows. Heat the
repair area at a rate of 1 to 6°F (1 to 4°C) per minute to
bring all thermocouples within the cure temperature range
specified in step 4.
V2500 54-02-00 REPAIR 009

Page 211
Feb 1/09
CAUTION: UNDERCURING AND A WEAK BOND WILL RESULT IF THE

COLDEST THERMOCOUPLE DOES NOT REACH THE LOWER LIMIT
FOR THE CURE TEMPERATURE.
(4) Upon the coldest thermocouple reaching the 250°F (121°C) ±

10°f (±5°C) cure temperature range, begin a 60 minutes
soak. Continuously monitor and record all thermocouples to
make sure the cure temperature range is maintained during
soak period.
(5) After the soak at the required temperature is complete,

cool to 150°F (65°C) at a rate not to exceed 5°F (3°C) per
minute. Upon reaching 150°F (65°C), the equipment may be
removed.
G. Inspect the core sidewall bond to make sure the adhesive was
properly expanded and that no gap exists.
H. Remove any residual foaming adhesive and sand core flush to the
repair area as per Figure 3. Vacuum clean the core plug and
repair area. Wipe skin surface clean with a CoMat 02-099 clean
dry lint free cloth.
J. Inspect repair per step 9.
9. Inspect Completed Repair
A. Inspect rework area for heat damage or disbond. Use visual and
tap test methods. Report any discrepancies to Goodrich
Engineering.
V2500 54-02-00 REPAIR 009

Page 212
Feb 1/09
Figure 201
V2500 54-02-00 REPAIR 009

Page 213
Feb 1/09
Figure 202
V2500 54-02-00 REPAIR 009

Page 214
Feb 1/09
Figure 203
V2500 54-02-00 REPAIR 009

Page 215
Feb 1/09
Figure 204
V2500 54-02-00 REPAIR 009

Page 216
Feb 1/09
Figure 205
V2500 54-02-00 REPAIR 009

Page 217
Feb 1/09
Figure 206
V2500 54-02-00 REPAIR 009

Page 218
Feb 1/09
REPAIR 010
GENERAL - PRE-IMPREGNATED MATERIAL HANDLING AND CURING
(VRS2378)
1. General
A. This section contains general requirements for handling and

curing of pre-impregnated material.

in this structural repair manual.
Refer to the specific repair section for the repair

limits and material of the component before using these
instructions.
The materials covered in this section are all epoxy based

resin systems.
2. References

SRM 54-02-00 Structural Adhesive Handling and Curing,
REPAIR 010 (VRS2376)
SRM 54-02-00 Vacuum Bagging Procedures, REPAIR 004
(VRS2370)
SAE ARP 5089 Composite Repair NDT/NDI Handbook
A. Consumable materials
NOTE: It is possible that some materials in the consumable

material chart cannot be used for some or all of the
necessary applications. Before you use the materials,
make sure that types, quantities and applications of
the materials necessary are legally permitted in your
location. All persons must obey all applicable federal,
state, local and provincial laws and regulations when
it is necessary to work with these materials.
V2500 54-02-00 REPAIR 010

Page 201
Feb 1/09
CoMat 02-161 Teflon Tape

CoMat 02-168 Non-Porous Release Film
CoMat 06-131 Marker Pen, (ASTM D-4236)
CoMat 08-136 Adhesive Film, Support (FM300-2M)
CoMat 08-138 M20/40%/G904, Prepreg Fabric- Graphite
CoMat 08-139 M20 Glass, Prepreg Fabric - Fiberglass
B. Special tools - none
C. Expendable parts - none
4. Instructions
V2500 54-02-00 REPAIR 010

Page 202
Feb 1/09
CAUTION: PRE-IMPREGNATED MATERIAL REQUIRE SPECIAL HANDLING AND

REFRIGERATED STORAGE. MANUFACTURER’S INSTRUCTIONS MUST BE
FOLLOWED OR POOR RESULTS WILL OCCUR.
PRE-IMPREGNATED MATERIAL STORED AT 0° (-180°C) MUST BE

ALLOWED TO WARM AT ROOM TEMPERATURE IN THEIR SEALED BAG
BEFORE USE.IF CONDENSATION IS SEEN ON THE PRE-IMPREGNATED
MATERIAL ONLY, DO NOT USE THE MATERIAL.
USE CLEAN, WHITE GLOVES THAT ARE LINT FREE TO MOVE OR

TOUCH PRE-IMPREGNATED MATERIAL OR CONTAMINATION WILL
OCCUR.
TO PREVENT DAMAGE FROM OCCURRING, DO NOT SET OR ADJUST

TEMPERATURE CONTROLLER HIGHER THAN THE UPPER LIMIT FOR THE
CURE TEMPERATURE RANGE SPECIFIED IN TABLE 1.
MATERIAL PREPARATION SHALL BE PERFORMED IN A CONTROLLED

TEMPERATURE AND HUMIDITY ENVIRONMENT. EPOXY RESIN SYSTEMS
ARE SENSITIVE TO MOISTURE, TEMPERATURE AND CONTAMINATION.
TO PREVENT MATERIAL DEGRADATION THEY MUST BE PROPERLY
HANDLED AND STORED.
A. Ply Cutting and Layup Procedures
NOTE: Application defined in applicable SRM take precedence

over this procedure and should be referred to for
further guidance.
Make sure the bonding surfaces are prepared per

applicable process and are clean from any contamination
or poor bond result will occur.
Pre-impregnated adhesive systems used are partially

cured (B stage). Make sure that their shelf life is not
expired.
(1) Determined the number of patch plies, ply orientation and

patch stacking sequence from the part. Determined the
patch periphery based upon the damage cleanup. Determined
the overlap plies requirements.
(2) Identify an mark on part 0 degree and other ply directions

as specified in applicable SRM general and SRM repair.
V2500 54-02-00 REPAIR 010

Page 203
Feb 1/09
(3) Install a non-porous release film CoMat 02-168 over the

repair area. Make sure that the film conforms to contour.
Tape the film in place with teflon tape CoMat 02-161.
(4) Trace periphery of each ply onto release film with a

marker pen CoMat 06-131. Identify each ply direction onto
the film. Remove film from part.
(5) Transfer ply contour from film to the applicable

pre-impregnated material barrier film. Make sure to keep
the ply orientation. Identify each ply in their stacking
sequence and ply orientation.
(6) Cut applicable pre-impregnated material with composite

material scissors. Make sure that each ply is properly
identified
CAUTION: PRE-IMPREGNATED MATERIAL REQUIRES STRUCTURAL

ADHESIVE FILM AT THE INTERFACE WITH PART TO BE
REPAIRED. REFER TO APPLICABLE SRM REPAIR AND SRM
54-02-00 REPAIR 010 (VRS2376), STRUCTURAL ADHESIVE
HANDLING AND CURING.
NOTE: Make sure the ply orientation are kept. Typical

tolerance for patch alignment is +/- 2 degrees.
(7) Ply layup. Plies can be laid up using either the flat ply
collation (all plies properly oriented and stacked on a
flat surface) or by individual ply technique (plies laid
up individually on the part).
(8) If required, debulk patch at room temperature under vacuum

pressure for a minimum of 30 minutes remove excess of
entrapped air and make sure proper location of plies
before cure process. Refer to SRM 54-02-00 REPAIR 004
(VRS2370), Vacuum Bagging Procedure.
NOTE: Vacuum pressure shall be applied as soon as the patch

has been laid up and kept until the cure process is
complete. Refer to SRM 54-02-00 REPAIR 004 (VRS2370),
Vacuum Bagging Procedure.
V2500 54-02-00 REPAIR 010

Page 204
Feb 1/09
B. Curing of pre-impregnated material.
CAUTION: CURE OF PRE-IMPREGNATED MATERIAL MUST BE DONE UNDER VACUUM

OR POSITIVE PRESSURE. IF NOT THE MATERIAL WILL NOT FULLY
CURE RESULTING IN A INCOMPLETE BOND.
(1) Install thermocouples for temperature controller as

follows:
(a) Install at least (1) thermocouple to control heat

source.
(b) Install at least (3) thermocouples to control bondline

temperature.
(c) Install (1) extra thermocouple for each 10 square feet

of heated area.
(d) Thermocouples shall be isolated from part.
(e) Thermocouple shall be placed to represent areas of

highest and lowest heat up rate.
(f) Record location of thermocouples on part ad heat

blanket for inspection purpose.
(2) Cure the repair area with heat blanket, oven and or other
explosive proof certified equipment.
(3) Vacuum bag equipment may be removed after part reaches

150° F (65°C) in the cool down ramp.
(4) Visually inspect cured pre-impregnated material for

defect(s). If dark brown color (overheating), uncured
adhesive, adhesive void, excess wrinkles or other
nondesirable damage are suspected, repeat complete
process.
(5) Inspect patch integrity with the ultrasonic method

(preferred) or tap test method in accordance with SAE ARP
5089 or equivalent.
V2500 54-02-00 REPAIR 010

Page 205
Feb 1/09
TABLE 1
CoMat CoMat SOAK CURE TEMPRATURE

(Pre-impregnated (structure Adhesive TIME (±10°F/±5°C)
Material) film) ± 5 min
08-138 08-136 120 260°F (130°C)
M20/40%/G904
(Graphite)
08-139 08-136 120 260°F (130°C)
M20 Glass
(Fiberglass)
NOTE:
1. All cures use a temperature rise rate of 2° to 6°F (1° to 3°C)/minutes

and a maximum cool down rate of 5° F(3°C)/ minute.
2. Heat area with heat blanket, oven and/or other explosion proof certified
equipment.
3. The cure condition specified for the individual adhesive type is the
minimum time required at the indicated temperature to provide adequate
adhesive bond strength for part use.
4. Cure cycles defined in applicable SRM take precedence over TABLE 1 and
should be referred to for further guidance.
V2500 54-02-00 REPAIR 010

Page 206
Feb 1/09
REPAIR 011
GENERAL - STRUCTURAL ADHESIVE HANDLING AND CURING
(VRS2376)
1. General
A. This section contains general requirements for handling and

curing of structural film and foaming adhesive for repair.

in this structural repair manual.
Refer to the specific repair section for the repair

limits and material of the component before using these
instructions.
The materials covered in this section are all epoxy based

resin systems.
2. References
A. Consumable materials
NOTE: It is possible that some materials in the consumable

material chart cannot be used for some or all of the
necessary applications. Before you use the materials,
make sure that types, quantities and applications of
the materials necessary are legally permitted in your
location. All persons must obey all applicable federal,
state, local and provincial laws and regulations when
it is necessary to work with these materials.
V2500 54-02-00 REPAIR 011

Page 201
Feb 1/09
CoMat 08-084 Bonding Film Adhesive, Unsupported EA9689

CoMat 08-085 Bonding Film Adhesive, Supported EA9689
CoMat 08-086 Bonding Film Adhesive, Unsupported FM350 NA
CoMat 08-087 Bonding Film Adhesive, Supported FM350 NA
CoMat 08-089 Foaming Film Adhesive FM-410-1 Grade 100
CoMat 08-136 Film Adhesive FM300-2M
B. Special tools - none
C. Expendable parts - none
4. Instructions
CAUTION: STRUCTURAL ADHESIVE MATERIAL REQUIRE SPECIAL HANDLING AND

REFRIGERATE STORAGE. MANUFACTURE’S INSTRUCTIONS MUST BE
FOLLOWED.
FILM AND FOAMING ADHESIVE STORED AT 0°F (-18°C) MUST BE

ALLOWED TO WARM AT ROOM TEMPERATURE IN THEIR SEALED BAG
BEFORE USE. IF CONDENSATION IS SEEN ON THE ADHESIVE FILM
ONLY, DO NOT USE THIS MATERIAL.
USE CLEAN, WHITE GLOVES THAT ARE LINT FREE TO MOVE OR

TOUCH STRUCTURAL ADHESIVE MATERIAL OR CONTAMINATION WILL
OCCUR.
V2500 54-02-00 REPAIR 011

Page 202
Feb 1/09
PREPARATION OF FAYING SURFACES TO BE DONE IN ACCORDANCE

WITH THE APPLICABLE SRM. BONDING SHALL BE WITHIN 4 HOURS
AFTER SOLVENT CLEANING OR PRIMING.
TO PREVENT DAMAGE FROM OCCURRING, DO NOT SET OR ADJUST

TEMPERATURE CONTROLLER HIGHER THAN THE UPPER LIMIT FOR THE
CURE TEMPERATURE RANGE SPECIFIED IN TABLE 1.
NOTE: Material preparation shall be performed in a controlled

temperature and humidity environment. Epoxy resins
systems are sensitive to moisture, temperature and
contamination. To prevent material degradation they
must be properly handled and stored.
A. Handling of structural film adhesive

further guidance.
Make sure that the bonding surfaces are prepared per

Film adhesive systems used in this procedure have the

base resin and curing agent pre-mixed and are cast into
a thin film containing a carrier cloth. The adhesive is
partially cured (B stage) during the casting process
resulting in a solid film.
(1) Cut film adhesive as required to perform the repair.
B. Handling of structural foaming adhesive.

further guidance.
Make sure that the bonding surfaces are prepared per

V2500 54-02-00 REPAIR 011

Page 203
Feb 1/09
Foaming adhesive systems used in this procedure are

used as a lightweight splice material for splicing
honeycomb core repair section. They consist of a thin
unsupported epoxy film which contain a blowing agent.
During the initial part of the cure process, an inert
gas is liberated causing an expansion or foaming action
in the film. Following expansion, the adhesive is cured
into a strong structural foam.
Foaming adhesive has a very narrow temperature band for

handling. At subfreezing temperatures the material
breaks into small pieces. At temperatures above 40°F
(5°C) it becomes extremely tacky. The material is most
workable at 40°F (5°C). It may be reinserted into the
freezer momentarily to bring the material into workable
range.
(1) Cut foaming adhesive as required to perform the repair.
C. Curing of film and foaming adhesives.
(1) Cure structural adhesive in accordance with TALBLE 1.

Application defined in applicable SRM takes precedence
over TABLE 1 and should be referred to for further
guidance.
(2) Inspect cured film adhesive. If dark brown color

(overheating) or uncured adhesive is suspected, repeat
complete film adhesive bonding process.
(3) Inspect cured foam adhesive. The expansion shall be 2.5 to

4 times the original film thickness. If the average
expansion is not within these limits or the gap is not
properly filled, repeat complete foaming adhesive
process.
V2500 54-02-00 REPAIR 011

Page 204
Feb 1/09
TABLE 1
FILM ADHESIVE
CoMat SOAK TIME CURE TEMPERATURE
(Material)
±5 min ±10°F(± 6°C)
08-084 65 350°F(177°C)
08-085 65 350°F(177°C)
08-086 65 350°F(177°C)
08-087 65 350°F(177°C)
08-136 120 250°F(121°C)
FOAMING ADHESIVE
CoMat SOAK TIME CURE TEMPERATURE
(Material)
±5 min ±10°F(± 6°C)
08-089 65 250°F(121°C)
08-089 65 350°F(177°C)
NOTE:
1. All cures use a temperature rise rate of 2° to 6°F (1° to 3°C)/minutes

and a maximum cool down rate of 5° F(3°C)/ minute.
2. If adhesive is to be co-cured with other material, cure cycles shall be

defined in applicable SRM.
3. Heat application methods as per applicable SRM.
4. The cure condition specified for the individual adhesive type is the
minimum time required at the indicated temperature to provide adequate
adhesive bond strength for part use.
5. Cure cycles defined in applicable SRM take precedence over TABLE 1 and
should be referred to for further guidance.
V2500 54-02-00 REPAIR 011

Page 205
Feb 1/09
V2500 54-02-00 REPAIR 011

Page 206
Feb 1/09
REPAIR 012
GENERAL DAMAGE BLEND REPAIR FOR METALLIC PARTS
(VRS2548)
1. Applicability
This procedure is for minor blending of dents, scratches, nicks,

gouges, and chafing and edge damage on metallic parts.

CoMat 02-099 Lint-free Cloth
3. Repair Instructions
A. Damage Blend Repair for Steel Alloys, Nickel and Cobalt Alloys
parts.
(1) Use the applicable medium from Figure 1 to remove the damage.
Blend surface damage to 10 to 1 blend ratio, see Figure 2. Make
the area smooth. Blend edge damage to 10 to 1 blend ratio, see
Figure 3 Detail A or B.
(2) Make sure that a 2X diameter is maintained from all bolt holes
and features of the part that is to be repaired.
(3) Use the applicable medium from Figure 1 for finishing. Polish
the damage area smooth.
(4) After the blending the damage area, make sure that the blend is
not larger than the allowable damage limits. See applicable
inspection/repair Task and Figure 3.
V2500 54-02-00 REPAIR 012

Page 201
Feb 1/09
WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU

DO THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY
ALL INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.
(5) Clean the area with a clean CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent.
(6) Perform SPPM Task 70-23-00-230-501 Fluorescent Penetrant

Inspection of suitable strength for surface discontinuities.
(7) Repeat steps 3.A.1 through 3.A.6. if surface discontinuities

exist.
(8) Apply a protective finish to the blended area.
(a) For corrosion resistant steels, nickel, and cobalt alloys,

Passivate the blended area refer to SRM 54-02-00 REPAIR 013
(VRS2330).
(b) For non-corrosive resistant steels, apply protective

finish, refer to SRM 54-02-00 General Repair Procedures,
Protective Treatment of Metals.
B. Damage Blend Repair for Aluminum parts
CAUTION: DO NOT USE STEEL WOOL OR A STEEL WIRE BRUSH TO REMOVE

DAMAGE FROM ALUMINUM. STEEL PARTICLES THAT ARE TOO SMALL
TO SEE CAN BECOME IMBEDDED IN THE ALUMINUM. CORROSION CAN
OCCUR IF THE ALUMINUM BECOMES MOIST.
V2500 54-02-00 REPAIR 012

Page 202
Feb 1/09
Figure 3 Detail A or B.

NECESSARY.

(7) Repeat steps 3.B.1 through 3.B.6 if surface discontinuities

exist.
(8) Apply a protective finish to the blended area per

SRM 54-02-00 Protective Treatment of Metals.
V2500 54-02-00 REPAIR 012

Page 203
Feb 1/09
C. Damage Cleanup for Titanium
CAUTION: SMALL PARTICLES AND FINE SHAVINGS OF TITANIUM IGNITE

EASILY AND MAKE A VERY DANGEROUS FIRE HAZARD. DO NOT USE
FOAM, WATER, CARBON TETRACHLORIDE OR CARBON DIOXIDE ON
TITANIUM FIRES. WATER THAT TOUCHES MOLTEN TITANIUM CAN
CAUSE A STEAM EXPLOSION. EXTINGUISH A TITANIUM FIRE WITH
FULLY DRY TALC, CALCIUM CARBONATE, AND/OR GRAPHITE. APPLY
THE POWDER TO A DEPTH OF 0.5 IN. (12,7 MM) OR MORE ABOVE
THE METAL THAT BURNS.
Figure 3 Detail A or B. The blending strokes must be parallel
with the edge of material until blending ratio is achieved.

NECESSARY.
V2500 54-02-00 REPAIR 012

Page 204
Feb 1/09

(7) Repeat steps 3.C.1 through 3.C.6 if surface discontinuities

exist.
V2500 54-02-00 REPAIR 012

Page 205
Feb 1/09
V2500 54-02-00 REPAIR 012

Page 206
Feb 1/09
Abrasives Used to Sand or Scour

Figure 2
V2500 54-02-00 REPAIR 012

Page 207
Feb 1/09
Typical Rework of Surface Damage

Figure 3
V2500 54-02-00 REPAIR 012

Page 208
Feb 1/09
REPAIR 013
LOCAL PASSIVATION USING PASAJELL 101 METHOD
(VRS2330)
1. Applicability
This procedure is for non-immersion passivation. It applies to

localized areas with minor rework.
CoMat 01-433 Distilled or Deionized Water
CoMat 01-471 Cleaner/Passivator Pasajell 101
CoMat 02-182 Metal Foil Tape
CoMat 02-206 Indicator Paper
CoMat 02-224 Silicone Adhesive Polyester Tape
CoMat 02-331 Stainless Steel Wire Brush
CoMat 05-073 Aluminum Oxide Abrasive Paper

PPE IS NECESSARY.
V2500 54-02-00 REPAIR 013

Page 201
Feb 1/09
A. Damage Blend Repair for Steel Alloys, Nickel and Cobalt Alloys
Parts.
(1) Clean the area with a clean CoMat 02-099 lint free cloth
made moist with CoMat 01-438 solvent.
(2) If required, abrade the area with a CoMat 02-331 brush to

remove any scale or surface damage. Smooth and polish the
area with a CoMat 05-073 aluminum oxide abrasive paper. Do
not increase the depth of the damage.
(3) Clean the area with a clean CoMat 02-099 lint free cloth
made moist with CoMat 01-438 solvent.
(4) Apply CoMat 02-182 metal foil tape or CoMat 02-224

silicone adhesive polyester tape around the area to be
passivated. Mask any other areas that may be affected by
this procedure.
B. Passivate the repaired area.

AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY
INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP AND
DISCARD CHEMICALS.
V2500 54-02-00 REPAIR 013

Page 202
Feb 1/09
CAUTION: DO NOT LET COMAT 01-471 GO ON ADJACENT AREAS. IT

WILL CAUSE DAMAGE TO THE SURFACES.
(1) Using a CoMat 02-099 lint free cloth apply CoMat 01-471
solution to the repair area. Saturate the cloth and dab on
the area. Do not rub.
NOTE: Prevent the area from discoloring or becoming dry

by applying fresh CoMat 01-471 solution to the
area.
(2) Leave the CoMat 01-471 solution on the surface for 5 to 10

minutes.
(3) After 5-10 minutes, remove the gel with a clean CoMat 02-
099 lint free cloth saturated with CoMat 01-433 water. If
possible without contaminating other areas, wipe or flush
the area with CoMat 01-433 water for 2 minutes to remove
the CoMat 01-471, Pasajell 101. Continue to wipe or flush
until no trace of
CoMat 01-471 remains.
NOTE: Make sure no CoMat 01-471 solution is trapped.

Flush properly or damage can occur.
NOTE: Do not allow CoMat 01-471 into other areas.
(4) Remove the tape from the area.
(5) Confirm the removal of acid using a clean CoMat 02-206

paper. Wipe the surface using a clean CoMat 02-099 lint
free cloth saturated with CoMat 01-433 water. Insert a
clean CoMat 02-206 paper into the cloth. If the paper
turns pink, continue flushing and/or wiping the surface
with a clean CoMat 02-099 lint free cloth saturated with
CoMat 01-433 water until all traces of acid have been
removed (no color change on the paper).
(6) Air dry for a minimum of 30 minutes at room temperature or

force air dry in an oven or certified equipment at 140°F
(60°C) to 160°F (71°C). Dry until no water is visible on
the surface.
V2500 54-02-00 REPAIR 013

Page 203
Feb 1/09
DESCRIPTION DESIGNATION MANUFACTURER

Cleaner/ Pasajell 101 Semco Division Product
Passivator Research and Chemical Corp
(CoMat 01-471) 5454 San Fernando Rd.
Glendale, CA 91203
USA
TEL: +1-818-247-7140
TEL: +1-818-247-9207
V2500 54-02-00 REPAIR 013

Page 204
Feb 1/09
INLET COWL - STRUCTURE IDENTIFICATION
1. General
A. The inlet cowl has a leading edge (lip skin), an intake barrel, an
outer barrel, and an aft bulkhead.
B. The lip skin is a C-shaped nose of aluminum alloy sheet attached to

a bulkhead (forward bulkhead).
C. The intake barrel (pre SBN 70-0909) has three acoustic panels and
post SBN 70-0909 has two acoustic panels. The panels form the
inside diameter of the engine air inlet duct and also provide sound
absorption at the engine air inlet area.
D. The outer barrel has LH and RH skin panels of bonded carbon fabric.
The panels are reinforced at stress points, such as door cutouts,
edges, and frames with additional plies of carbon fabric and carbon
tape.
E. The aft bulkhead (pre SBN 70-0908) is a honeycomb carbon composite

and post SBN 70-0908 is titanium and makes a fire seal between the
inlet cowl and the engine fan compartment.
2. Structure Description
A. Aluminum is the primary structural material except where operating

temperatures and/or strength require the use of titanium, inconel,
or corrosion resistant steels (CRES). Aluminum perforated sheet
and honeycomb cell foil are used in the acoustic panels. Carbon
fabric plies form the outer barrel panels.
3. Structure Identification
Structures chosen for field repairs are identified in illustrations

(figures) and tables. The tables list the structural components used in
the inlet cowl except for fasteners. Each component is identified by an
item number in the table. The same item number also appears in the
figure. The tables give the component's description, guage (thickness),
and material.
The purpose of the tables is to help you to easily locate and identify
components which may be damaged. This is then used to help you to:
A. Determine those parts which an operator should or should not

attempt to fabricate.
B. Select a suitable repair from those given in this manual.
V2500 54-10-00 Page 1

Feb 1/09
Inlet Cowl Assembly

Figure 1 (Sheet 1)
V2500 54-10-00 Page 1.01

Feb 1/09
Inlet Cowl Assembly

Figure 1 (Sheet 2)
V2500 54-10-00 Page 1.02

Feb 1/09
Inlet Cowl Assembly

Figure 1 (Sheet 3)
V2500 54-10-00 Page 1.03

Feb 1/09
Inlet Cowl Assembly

Figure 1 (Sheet 4)
V2500 54-10-00 Page 1.04

Feb 1/09
Inlet Cowl Assembly

Figure 1 (Sheet 5)
V2500 54-10-00 Page 1.05

Feb 1/09
Inlet Cowl Assembly

Figure 1 (Sheet 6)
V2500 54-10-00 Page 1.06

Feb 1/09
Inlet Cowl Assembly

Figure 1 (Sheet 7)
V2500 54-10-00 Page 1.07

Feb 1/09
Inlet Cowl Assembly

Figure 1 (Sheet 8)
V2500 54-10-00 Page 1.08

Feb 1/09
ITEM DESCRIPTION GAUGE MATERIAL

(INCH)
1 INLET COWL ASSEMBLY
2 Interphone Access Panel Refer to Figure 2
3 Probe Access Panel Refer to Figure 3
4 Outer Skin Segment (LH) Refer to Figure 4

A1 (Pre SBN 70-0626)
4A Outer Skin Segment (LH) Refer to Figure 4A

A1 Hybrid (Post SBN
70-0626) & A5
5 Outer Skin Segment (RH) Refer to Figure 5

A1 (Pre SBN 70-0626)
5A Outer Skin Segment (RH) Refer to Figure 5A

A1 Hybrid (Post SBN
70-0626) & A5
6 Rear Bulkhead (Lower) Refer to Figure 6

A1 (Pre SBN 70-0626)
6A Rear Bulkhead (Lower) Refer to Figure 6A

A1 Hybrid (Post SBN
70-0626) & A5 (Pre SBN
70-0908)
7 Rear Bulkhead (Upper) Refer to Figure 7

A1 (Pre SBN 70-0626)
7A Rear Bulkhead (Upper) Refer to Figure 7A

A1 Hybrid (Post SBN
70-0626) & A5 (Pre SBN
70-0908)
8 Intake Barrel Refer to Figure 8

(Rad 305.075 - 54.925)
A1 (Pre SBN 70-0626)
8A Intake Barrel Refer to Figure 8A

(Rad 305.075 - 54.925)
A1 Hybrid (Post SBN
70-0626)
Inlet Cowl Assembly

Table 1
V2500 54-10-00 Page 1.09

Feb 1/09

(INCH)
8B Intake Barrel Refer to Figure 8B

(Rad 305.075 - 54.925)
A5 (Pre SBN 70-0909)
8C Intake Barrel Upper Refer to Figure 8C

(Rad 270 - 90)
A5 (Post SBN 70-0909)

(Rad 54.925 - 176.012)
A1 (Pre SBN 70-0626)

(Rad 54.925 - 176.012)
A1 Hybrid (Post SBN
70-0626)

(Rad 54.925 - 176.012)
A5 (Pre SBN 70-0909)
9C Intake Barrel Lower Refer to Figure 9C

(Rad 90 - 270)
A5 (Post SBN 70-0909)

(Rad 176.012 - 305.075)
A1 (Pre SBN 70-0626)

(Rad 176.012 - 305.075)
A1 Hybrid (Post SBN
70-0626)

(Rad 176.012 - 305.075)
A5 Pre SBN 70-0909
11 Lip Skin 0.064- 2219-0 Bare Aluminium Sheet,

0.090 Chemically Profiled, Solution
Heat Treated and Artificially
Aged
12 Engine Ring L77 Machine Forging
Inlet Cowl Assembly

Table 1
V2500 54-10-00 Page 1.10

Feb 1/09

(INCH)
13 Titanium Bulkhead 0.040 Titanium Plate, AMS 4901

A5 (Post SBN 70-0908)
14 Anti-Ice Access Panel 0.092 Aluminium Alloy Sheet, DTD 5070

(Pre SBN 71-0257)
14A Anti-Ice Access Panel 0.063 Stainless Steel, AMS 5510

(Post SBN 71-0184,
Post SBN 71-0257
& Post SBN 71-0266)
15 Outlet Grille Aluminium Alloy Casting, L99

(Pre SBN 71-0266)
15A Outlet Grille Stainless Steel, AMS5510

(Post SBN 71-0184,
Post SBN 71-0257
& Post SBN 71-0266)
16 Half Locating Plate 0.019 Titanium Plate, TA57

A1, A1 Hybrid & A5
(Pre SBN 70-0908)
16A Half Locating Plate 0.019 Titanium Plate, AMS 4965

A5 (Post SBN 70-0908)
17 Half Locating Plate 0.019 Titanium Plate, TA57

A1, A1 Hybrid & A5
(Pre SBN 70-0908)
17A Half Locating Plate 0.019 Titanium Plate, AMS 4965

A5 (Post SBN 70-0908)
18 Guide Bar 0.30 Cres Bar, S80
19 Locator 0.76 Cres Bar, S80
20 Shim Shim (Attewell) to BS 1449
21 Bracket Stainless Stee, S524

A1 (Pre SBN 70-0626)
21A Bracket 0.104 Stainless Steel, S524

A1 Hybrid (Post SBN
70-0626) & A5 (Pre SBN
70-0908)
Inlet Cowl Assembly

Table 1
V2500 54-10-00 Page 1.11

Feb 1/09

(INCH)
21B Bracket Stainless Steel, S524

A5 (Post SBN 70-0259,
Post SBN 70-0908)
22 Guide Angle 0.182 QQS-766-302 Grade A, Stainless

(Post SBN 71-0259) Steel
23 Pin CRES 17-4 PH AMS 5643

(Post SBN 71-0259)
24 Blocker Bar Assembly CRES 17-4 PH AMS 5643

(Post SBN 71-0259)
25 Plunger Assembly QCRES 17-4 PH AMS 5643

(Post SBN 71-0259)
26 Guide CRES 17-4 PH AMS 5643

(Post SBN 71-0259)
Inlet Cowl Assembly

Table 1
V2500 54-10-00 Page 1.12

Feb 1/09
Interphone Access Panel

Figure 2
V2500 54-10-00 Page 2.01

Feb 1/09

(INCH)
1 INTERPHONE ACCESS PANEL
C1 Access panel ply 0.0138 - Epoxy Resin Impregnated Carbon

0.0164 Fibre, Type III, Class 2,
Style 3K-135-8H at ±45 degrees

Style 3K-135-8H at 0 - 90
degrees



Style 3K-135-8H at 0 - 90
degrees

Interphone Access Panel

Table 2
V2500 54-10-00 Page 2.02

Feb 1/09
Probe Access Panel

Figure 3
V2500 54-10-00 Page 3.01

Feb 1/09

(INCH)
1 PROBE ACCESS PANEL


Style 3K-135-8H at 0-90 degrees





Probe Access Panel

Table 3
V2500 54-10-00 Page 3.02

Feb 1/09
Outer Skin Segment (LH) - A1 (Pre SBN 70-0626)

Figure 4 (Sheet 1)
V2500 54-10-00 Page 4.01

Feb 1/09

Figure 4 (Sheet 2)
V2500 54-10-00 Page 4.02

Feb 1/09

Figure 4 (Sheet 3)
V2500 54-10-00 Page 4.03

Feb 1/09

Figure 4 (Sheet 4)
V2500 54-10-00 Page 4.04

Feb 1/09

Figure 4 (Sheet 5)
V2500 54-10-00 Page 4.05

Feb 1/09

Figure 4 (Sheet 6)
V2500 54-10-00 Page 4.06

Feb 1/09

Figure 4 (Sheet 7)
V2500 54-10-00 Page 4.07

Feb 1/09

Figure 4 (Sheet 8)
V2500 54-10-00 Page 4.08

Feb 1/09

(INCH)
1 OUTER SKIN SEGMENT (LH)
C3A- Outer Skin Ply 0.0138 - Epoxy Resin Impregnated Carbon

C3C 0.0164 Fibre, Type III, Class 2,
C4- Outer Skin Ply 0.0138 - Epoxy Resin Impregnated Carbon

C5 0.0164 Fibre, Type III, Class 2,




C9B 0.0164 Fibre, Type III, Class 2,


C13 Outer Skin Ply 0.0138 - Epoxy Resin Impregnated Carbon


Outer Skin Segment (LH) - A1 (Pre SBN 70-0626

Table 4
V2500 54-10-00 Page 4.09

Feb 1/09

(INCH)




0.0091 Fibre, Type IV, Class 2,
Style 3K-70-PW at 0-90 degrees


Style 3K-70-PW at ±45 degrees
G9C Outer Skin Ply 0.0035 - Epoxy Resin Impregnated Glass

0.0055 Cloth Fabric, Type 120, Class I
at 0-90 degrees
G12A- Outer Skin Ply 0.0138 - Epoxy Resin Impregnated Carbon

G12B 0.0164 Fibre, Type III, Class 2,
G19A- Outer Skin Ply 0.0035 - Epoxy Resin Impregnated Glass

G19F 0.0055 Cloth Fabric, Type 120, Class I
at 0-90 degrees
Outer Skin Segment (LH) - A1 (Pre SBN 70-0626

Table 4
V2500 54-10-00 Page 4.10

Feb 1/09
Outer Skin Segment (LH) - A1 Hybrid (Post SBN 70-0626) & A5

Figure 4A (Sheet 1)
V2500 54-10-00 Page 5.01

Feb 1/09

Figure 4A (Sheet 2)
V2500 54-10-00 Page 5.02

Feb 1/09
Outer Skin Segment (LH) - A1 Hybrid (post SBN 70-0626) & A5

Figure 4A (Sheet 3)
V2500 54-10-00 Page 5.03

Feb 1/09

Figure 4A (Sheet 4)
V2500 54-10-00 Page 5.04

Feb 1/09

Figure 4A (Sheet 5)
V2500 54-10-00 Page 5.05

Feb 1/09

Figure 4A (Sheet 6)
V2500 54-10-00 Page 5.06

Feb 1/09

Figure 4A (Sheet 7)
V2500 54-10-00 Page 5.07

Feb 1/09

Figure 4A (Sheet 8)
V2500 54-10-00 Page 5.08

Feb 1/09

Figure 4A (Sheet 9)
V2500 54-10-00 Page 5.09

Feb 1/09

Figure 4A (Sheet 10)
V2500 54-10-00 Page 5.10

Feb 1/09

(INCH)
1 OUTER SKIN SEGMENT (LH)




C4B 0.0091 Fibre, Type IV, Class 2,





C10B Outer Skin Ply 0.0138 - Epoxy Resin Impregnated Carbon


Table 4A
V2500 54-10-00 Page 5.11

Feb 1/09

(INCH)




G10A Outer Skin Ply 0.0035 - Epoxy Resin Impregnated Glass

at 0-90 degrees

G15B 0.0120 Cloth Fabric, Type 1581,
Class I at 0-90 degrees

G16E 0.0055 Cloth Fabric, Type 120, Class I
at 0-90 degrees

Table 4A
V2500 54-10-00 Page 5.12

Feb 1/09
Outer Skin Segment (RH) - A1 (Pre SBN 70-0626)

Figure 5 (Sheet 1)
V2500 54-10-00 Page 6.01

Feb 1/09

Figure 5 (Sheet 2)
V2500 54-10-00 Page 6.02

Feb 1/09

Figure 5 (Sheet 3)
V2500 54-10-00 Page 6.03

Feb 1/09

Figure 5 (Sheet 4)
V2500 54-10-00 Page 6.04

Feb 1/09

Figure 5 (Sheet 5)
V2500 54-10-00 Page 6.05

Feb 1/09

Figure 5 (Sheet 6)
V2500 54-10-00 Page 6.06

Feb 1/09

Figure 5 (Sheet 7)
V2500 54-10-00 Page 6.07

Feb 1/09

Figure 5 (Sheet 8)
V2500 54-10-00 Page 6.08

Feb 1/09

Figure 5 (Sheet 9)
V2500 54-10-00 Page 6.09

Feb 1/09

Figure 5 (Sheet 10)
V2500 54-10-00 Page 6.10

Feb 1/09

Figure 5 (Sheet 11)
V2500 54-10-00 Page 6.11

Feb 1/09

Figure 5 (Sheet 12)
V2500 54-10-00 Page 6.12

Feb 1/09

Figure 5 (Sheet 13)
V2500 54-10-00 Page 6.13

Feb 1/09

(INCH)
1 OUTER SKIN SEGMENT (RH)
A19C Adhesive Adhesive Film, Type II, Class

I, Grade 03, Weight 0.146 kg/m2
(0.03 lb/ft2)
A34 Adhesive Adhesive Film, Type II, Class

(0.03 lb/ft2)





C7G 0.0164 Fibre, Type III, Class 2,

C8G 0.0164 Fibre, Type III, Class 2,

C9F 0.0164 Fibre, Type III, Class 2,
C9H Outer Skin Ply 0.0138 - Epoxy Resin Impregnated Carbon


Table 5
V2500 54-10-00 Page 6.14

Feb 1/09

(INCH)

C10E 0.0164 Fibre, Type III, Class 2,

C12A Outer Skin Ply 0.0138 - Epoxy Resin Impregnated Carbon

C12B- Outer Skin Ply 0.0138 - Epoxy Resin Impregnated Carbon









Table 5
V2500 54-10-00 Page 6.15

Feb 1/09

(INCH)

G9G Outer Skin Ply 0.0035 - Epoxy Resin Impregnated Glass

at 0-90 degrees

G19B 0.0055 Cloth Fabric, Type 120, Class I
at 0-90 degrees
C20- Stiffener Ply 0.0075 - Epoxy Resin Impregnated Carbon

C20F 0.0091 Fibre, Type IV, Class 2,
C21A- Stiffener Ply 0.0075 - Epoxy Resin Impregnated Carbon



C23G 0.0091 Fibre, Type IV, Class 2,





Table 5
V2500 54-10-00 Page 6.16

Feb 1/09

(INCH)

C28C Stiffener Ply 0.0075 - Epoxy Resin Impregnated Carbon


G30A- Stiffener Ply 0.0035 - Epoxy Resin Impregnated Glass

at 0-90 degrees

Table 5
V2500 54-10-00 Page 6.17

Feb 1/09
Outer Skin Segment (RH) - A1 Hybrid (Post SBN 70-0626) & A5

Figure 5A (Sheet 1)
V2500 54-10-00 Page 7.01

Feb 1/09
Outer Skin Segment (RH) - A1 Hybrid (Post SBN 70-0626) & A5.
Figure 5A (Sheet 2)
V2500 54-10-00 Page 7.02

Feb 1/09

Figure 5A (Sheet 3)
V2500 54-10-00 Page 7.03

Feb 1/09

Figure 5A (Sheet 4)
V2500 54-10-00 Page 7.04

Feb 1/09

Figure 5A (Sheet 5)
V2500 54-10-00 Page 7.05

Feb 1/09

Figure 5A (Sheet 6)
V2500 54-10-00 Page 7.06

Feb 1/09

Figure 5A (Sheet 7)
V2500 54-10-00 Page 7.07

Feb 1/09

Figure 5A (Sheet 8)
V2500 54-10-00 Page 7.08

Feb 1/09
Outer Skin Segment (RH) - A1 Hybrid (Post SBN 70-0626) & A5.
Figure 5A (Sheet 9)
V2500 54-10-00 Page 7.09

Feb 1/09

V2500 54-10-00 Page 7.10

Feb 1/09

V2500 54-10-00 Page 7.11

Feb 1/09
Outer Skin Segment (RH) - A1 (Post SBN 70-0626) & A5

V2500 54-10-00 Page 7.12

Feb 1/09

V2500 54-10-00 Page 7.13

Feb 1/09

V2500 54-10-00 Page 7.14

Feb 1/09

V2500 54-10-00 Page 7.15

Feb 1/09

V2500 54-10-00 Page 7.16

Feb 1/09

(INCH)
1 OUTER SKIN SEGMENT (RH)
A16- Adhesive Adhesive Film, Type II, Class

A17 I, Grade 03, Weight 0.146 kg/m2
(0.03 lb/ft2)










Table 5A
V2500 54-10-00 Page 7.17

Feb 1/09

(INCH)





G10F Outer Skin Ply 0.0035 - Epoxy Resin Impregnated Glass

at 0-90 degrees

G15B 0.0120 Cloth Fabric, Type 1581,
Class I at 0-90 degrees

at 0-90 degrees




Table 5A
V2500 54-10-00 Page 7.18

Feb 1/09

(INCH)






C28C Stiffener Ply 0.0075 - Epoxy Resin Impregnated Carbon


G30A- Stiffener Ply 0.0035 - Epoxy Resin Impregnated Glass

at 0-90 degrees

Table 5A
V2500 54-10-00 Page 7.19

Feb 1/09
Rear Bulkhead (Lower) - A1 (Pre SBN 70-0626)

Figure 6 (Sheet 1)
V2500 54-10-00 Page 8.01

Feb 1/09
Rear Bulkhead (Lower) - A1 (OPre SBN 70-0626)

Figure 6 (Sheet 2)
V2500 54-10-00 Page 8.02

Feb 1/09

Figure 6 (Sheet 3)
V2500 54-10-00 Page 8.03

Feb 1/09

Figure 6 (Sheet 4)
V2500 54-10-00 Page 8.04

Feb 1/09

Figure 6 (Sheet 5)
V2500 54-10-00 Page 8.05

Feb 1/09

(INCH)
1 REAR BULKHEAD (Lower)
2 BACKING SHEET (See Below)
3 FACING SHEET (See Below)
4 HONEYCOMB CORE 0.001 - Aluminium Alloy Honeycomb Core,

0.500 3/16 (5 mm), Class 2, Type III,
Grade II, Density 3.1 lb/ft3
(50 kg/m3)
A1- Adhesive Adhesive Film, Type II,

A2 Grade 03, Weight 0.146 kg/m2
(0.03 lb/ft2), 3 layers minimum
A3 Adhesive Foaming Adhesive Film,

Grade 50, Weight 1.93 kg/m2
(0.395 lb/ft2)
C1A- Facing Sheet Ply 0.0075 - Epoxy Resin Impregnated Carbon


C2 Backing Sheet Ply 0.0075 - Epoxy Resin Impregnated Carbon

C2A- Backing Sheet Ply 0.0075 - Epoxy Resin Impregnated Carbon




Table 6
V2500 54-10-00 Page 8.06

Feb 1/09

(INCH)








G13 Backing Sheet Ply 0.0035 - Epoxy Resin Impregnated Glass

at 0-90 degrees

Table 6
V2500 54-10-00 Page 8.07

Feb 1/09
Rear Bulkhead (Lower) - A1 Hybrid (Post SBN 70-0626) & A5 (Pre SBN 70-0908)
Figure 6A (Sheet 1)
V2500 54-10-00 Page 9.01

Feb 1/09
Figure 6A (Sheet 2)
V2500 54-10-00 Page 9.02

Feb 1/09
Figure 6A (Sheet 3)
V2500 54-10-00 Page 9.03

Feb 1/09
Figure 6A (Sheet 4)
V2500 54-10-00 Page 9.04

Feb 1/09
Figure 6A (Sheet 5)
V2500 54-10-00 Page 9.05

Feb 1/09

(INCH)
1 REAR BULKHEAD (Lower)
4 HONEYCOMB CORE 0.500 Aluminium Alloy Honeycomb Core,

3/16 (5 mm), Class 2, Type III,
(50 kg/m3)

(50 kg/m3)

(0.03 lb/ft2)



C6K 0.0091 Fibre, Type IV, Class 2,

S1A- Facing Sheet Ply 0.026 Siltemp, Pre-shrunk white

S1B fabric, width 33 inch, weight
18.5 oz/yd (alternative
material Tygasil Y0551/037) at
0-90 degrees
Table 6A
V2500 54-10-00 Page 9.06

Feb 1/09

(INCH)


C6D 0.0091 Fibre, Type IV, Class 2,







G14A- Backing Sheet Ply 0.0035 - Epoxy Resin Impregnated Glass

Table 6A
V2500 54-10-00 Page 9.07

Feb 1/09
Rear Bulkhead (Upper) - A1 (Pre SBN 70-0626)

Figure 7 (Sheet 1)
V2500 54-10-00 Page 10.01

Feb 1/09

Figure 7 (Sheet 2)
V2500 54-10-00 Page 10.02

Feb 1/09

Figure 7 (Sheet 3)
V2500 54-10-00 Page 10.03

Feb 1/09

Figure 7 (Sheet 4)
V2500 54-10-00 Page 10.04

Feb 1/09

Figure 7 (Sheet 5)
V2500 54-10-00 Page 10.05

Feb 1/09

(INCH)
1 REAR BULKHEAD (Upper)
3 HONEYCOMB CORE 0.001 - Aluminium Alloy Honeycomb Core,

0.500 3/16 (5 mm), Class 2, Type III,
(50 kg/m3)
A1- Adhesive Adhesive Film, Type I,

A2 Grade 3, Weight 0.146 kg/m2
(0.03 lb/ft2), 3 layers minimum

(0.395 lb/ft2)







Table 7
V2500 54-10-00 Page 10.06

Feb 1/09

(INCH)







at 0-90 degrees



Table 7
V2500 54-10-00 Page 10.07

Feb 1/09
Rear Bulkhead (Upper) - A1 Hybrid (Post SBN 70-0626) & A5 (Pre SBN 70-0908)
Figure 7A (Sheet 1)
V2500 54-10-00 Page 11.01

Feb 1/09
Figure 7A (Sheet 2)
V2500 54-10-00 Page 11.02

Feb 1/09
Figure 7A (Sheet 3)
V2500 54-10-00 Page 11.03

Feb 1/09
Figure 7A (Sheet 4)
V2500 54-10-00 Page 11.04

Feb 1/09

(INCH)
1 REAR BULKHEAD (Upper)
2 FACING SHEET

(50 kg/m3)

(50 kg/m3)

(0.03 lb/ft2)
C4A- Rear Bulkhead Ply 0.0075 - Epoxy Resin Impregnated Carbon


C6 Rear Bulkhead Ply 0.0075 - Epoxy Resin Impregnated Carbon


C6C 0.0091 Fibre, Type IV, Class 2,


Table 7A
V2500 54-10-00 Page 11.05

Feb 1/09

(INCH)






G14 Rear Bulkhead Ply 0.0035 - Epoxy Resin Impregnated Glass

at 0-90 degrees
S1 Rear Bulkhead Ply 0.026 Siltemp, Pre-shrunk white

fabric, width 33 inch, weight
18.5 oz/yd (alternative
material Tygasil Y0551/037) at
0-90 degrees
Table 7A
V2500 54-10-00 Page 11.06

Feb 1/09
Intake Barrel (Rad 305.075 - 54.925) - A1 (Pre SBN 70-0626)

Figure 8 (Sheet 1)
V2500 54-10-00 Page 12.01

Feb 1/09

Figure 8 (Sheet 2)
V2500 54-10-00 Page 12.02

Feb 1/09

Figure 8 (Sheet 3)
V2500 54-10-00 Page 12.03

Feb 1/09

Figure 8 (Sheet 4)
V2500 54-10-00 Page 12.04

Feb 1/09

Figure 8 (Sheet 5)
V2500 54-10-00 Page 12.05

Feb 1/09

Figure 8 (Sheet 6)
V2500 54-10-00 Page 12.06

Feb 1/09

(INCH)
1 INTAKE BARREL
(Rad 305.075 - 54.925)
3 HONEYCOMB PANEL Nomex Honeycomb Core,

1/2 (19 mm), Class I, Type 6,
Density 1.45 lbs/ft3 (23 kg/m3)
4 SEPTUM LAYER Stainless Steel Wire Mesh, Type

I, 720 Warp Wires/147 Weft
Wires per inch

7 HONEYCOMB CORE INSERT Nomex Honeycomb Core,

A1 Adhesive 0.005 Adhesive Film, Type II, Grade

II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
A2- Adhesive 0.005 Adhesive Film, Type II, Grade
A2F II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
A4A- Adhesive Adhesive Film, Type II, Class
A4C I, Grade 03, Weight 0.146 kg/m2
(0.03 lb/ft2)

Table 8
V2500 54-10-00 Page 12.07

Feb 1/09

(INCH)

A5B I, Grade 03, Weight 0.146 kg/m2
(0.03 lb/ft2)

A6E I, Grade 03, Weight 0.146 kg/m2
(0.03 lb/ft2)
A7A Adhesive Adhesive Film, Type II, Class

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)
A16C Adhesive Adhesive Film, Type II, Class

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

Table 8
V2500 54-10-00 Page 12.08

Feb 1/09

(INCH)











A17B 0.0164 Fibre, Type III, Class 2,

Table 8
V2500 54-10-00 Page 12.09

Feb 1/09

(INCH)





G14A- Backing SheetSheet Ply 0.0035 - Epoxy Resin Impregnated Glass

G14C 0.0055 Cloth Fabric, Type 120, Class I
at 0-90 degrees

at 0-90 degrees
M5A- Backing Sheet Ply Stainless Steel Wire Mesh, Type

M5B III, 720 Warp Wires/154 Weft
Wires per inch

Wires per inch
C3 Facing Sheet Ply 0.033 - Epoxy Resin Impregnated Open

0.045 Weave Carbon Fibre, Type 31,
Class 1000 at 0-90 degrees
C4A- Facing Sheet Ply 0.0092 Epoxy Resin Impregnated Carbon

C4C Fibre, Type I, Class 2,

Table 8
V2500 54-10-00 Page 12.10

Feb 1/09

(INCH)






C10B Fibre, Type I, Class 2,


C13- Facing Sheet Ply 0.0092 Epoxy Resin Impregnated Carbon


G9C Facing Sheet Ply 0.0035 - Epoxy Resin Impregnated Glass

at 0-90 degrees

Table 8
V2500 54-10-00 Page 12.11

Feb 1/09

(INCH)
G16 Facing Sheet Ply 0.0035 - Epoxy Resin Impregnated Glass

at 0-90 degrees
M1 Facing Sheet Ply Stainless Steel Wire Mesh, Type

II, 720 Warp Wires/150 Weft
Wires per inch at 0-90 degrees

Table 8
V2500 54-10-00 Page 12.12

Feb 1/09
Intake Barrel (Rad 305.075 - 54.925) - A1 Hybrid (Post SBN 70-0626)

Figure 8A (Sheet 1)
V2500 54-10-00 Page 13.01

Feb 1/09

Figure 8A (Sheet 2)
V2500 54-10-00 Page 13.02

Feb 1/09

Figure 8A (Sheet 3)
V2500 54-10-00 Page 13.03

Feb 1/09

Figure 8A (Sheet 4)
V2500 54-10-00 Page 13.04

Feb 1/09

Figure 8A (Sheet 5)
V2500 54-10-00 Page 13.05

Feb 1/09

Figure 8A (Sheet 6)
V2500 54-10-00 Page 13.06

Feb 1/09

(INCH)
1 INTAKE BARREL
(Rad 305.075 - 54.925)


Wires per inch



M6 Wire Mesh Stainless Steel Wire Mesh, Type

V, 720 Warp Wires/154 Weft
Wires per inch
A1-A4 Adhesive Adhesive Film, Type II, Grade

II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
(0.03 lb/ft2)

Table 8A
V2500 54-10-00 Page 13.07

Feb 1/09

(INCH)

(0.03 lb/ft2)
A8 Adhesive Adhesive Film, Type II, Grade

II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
(0.03 lb/ft2)

II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
(0.03 lb/ft2)

A11D I, Grade 03, Weight 0.146 kg/m2
(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

Table 8A
V2500 54-10-00 Page 13.08

Feb 1/09

(INCH)
A14A- Adhesive Foaming Adhesive Film,

A14H Grade 50, Weight 1.93 kg/m2
(0.395 lb/ft2),
(0.755 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)






Table 8A
V2500 54-10-00 Page 13.09

Feb 1/09

(INCH)









at 0-90 degrees

at 0-90 degrees

at 0-90 degrees

Table 8A
V2500 54-10-00 Page 13.10

Feb 1/09

(INCH)
M12 Backing Sheet Ply Stainless Steel Wire Mesh, Type

III, 720 Warp Wires/147 Weft
Wires per inch and Adhesive
Film, Type II, Class I, Grade
03, Weight 0.146 kg/m2 (0.03
lb/ft2) at ±45 degrees

03, Weight 0.146 kg/m2 (0.03

03, Weight 0.146 kg/m2 (0.03

03, Weight 0.146 kg/m2 (0.03




Table 8A
V2500 54-10-00 Page 13.11

Feb 1/09

(INCH)







C13- Facing Sheet Ply 0.0092 Epoxy Resin Impregnated Carbon


G9C Facing Sheet Ply 0.0035 - Epoxy Resin Impregnated Glass

at 0-90 degrees

at 0-90 degrees

Table 8A
V2500 54-10-00 Page 13.12

Feb 1/09

(INCH)


Table 8A
V2500 54-10-00 Page 13.13

Feb 1/09

Figure 8B (Sheet 1)
V2500 54-10-00 Page 14.01

Feb 1/09

Figure 8B (Sheet 2)
V2500 54-10-00 Page 14.02

Feb 1/09

Figure 8B (Sheet 3)
V2500 54-10-00 Page 14.03

Feb 1/09

Figure 8B (Sheet 4)
V2500 54-10-00 Page 14.04

Feb 1/09

Figure 8B (Sheet 5)
V2500 54-10-00 Page 14.05

Feb 1/09

Figure 8B (Sheet 6)
V2500 54-10-00 Page 14.06

Feb 1/09

Figure 8B (Sheet 7)
V2500 54-10-00 Page 14.07

Feb 1/09

Figure 8B (Sheet 8)
V2500 54-10-00 Page 14.08

Feb 1/09

Figure 8B (Sheet 9)
V2500 54-10-00 Page 14.09

Feb 1/09

Figure 8B (Sheet 10)
V2500 54-10-00 Page 14.10

Feb 1/09

V2500 54-10-00 Page 14.11

Feb 1/09

V2500 54-10-00 Page 14.12

Feb 1/09
V2500 54-10-00 Page 14.13

Feb 1/09

(INCH)
1 INTAKE BARREL
(Rad 305.075 - 54.925)

1/2 (12.7 mm), Class I, Type 5,

3/8 (9.5 mm), Class I, Type 4,

1/2 (12.7 mm), Class I, Type 5,

M3A Septum Layer Stainless Steel Wire Mesh, Type

Wires per inch
M3B Septum Layer Stainless Steel Wire Mesh, Type

VII, 325 Warp Wires/325 Weft
Wires per inch

A2 II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
A2A- Adhesive 0.005 Adhesive Film, Type II, Grade
A2E II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)

Table 8B
V2500 54-10-00 Page 14.14

Feb 1/09

(INCH)
A3 Adhesive One Part Liquid Epoxy Adhesive,

spray ont brochier before
bonding with facing sheet

II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

A8H Grade 50, Weight 1.93 kg/m2
(0.395 lb/ft2),
(0.755 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

Table 8B
V2500 54-10-00 Page 14.15

Feb 1/09

(INCH)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)
A20 Adhesive Film, Type II, Class

(0.03 lb/ft2)

Style 3K-70-PWH at ±45 degrees

Table 8B
V2500 54-10-00 Page 14.16

Feb 1/09

(INCH)












Table 8B
V2500 54-10-00 Page 14.17

Feb 1/09

(INCH)


at 0-90 degrees

at 0-90 degrees

at 0-90 degrees

03, Weight 0.146 kg/m2 (0.03
lb/ft2) at -45 degrees

03, Weight 0.146 kg/m2 (0.03

03, Weight 0.146 kg/m2 (0.03

Table 8B
V2500 54-10-00 Page 14.18

Feb 1/09

(INCH)

03, Weight 0.146 kg/m2 (0.03










Table 8B
V2500 54-10-00 Page 14.19

Feb 1/09

(INCH)





at 0-90 degrees

at 0-90 degrees

VI, 720 Warp Wires/147 Weft
Wires per inch

Table 8B
V2500 54-10-00 Page 14.20

Feb 1/09
Intake Barrel Upper (Rad 270 - 90) - A5 (Post SBN 70-0909)

Figure 8C(Sheet 1)
V2500 54-10-00 Page 15.01

Feb 1/09

Figure 8C (Sheet 2)
V2500 54-10-00 Page 15.02

Feb 1/09

Figure 8C (Sheet 3)
V2500 54-10-00 Page 15.03

Feb 1/09

Figure 8C (Sheet 4)
V2500 54-10-00 Page 15.04

Feb 1/09

Figure 8C (Sheet 5)
V2500 54-10-00 Page 15.05

Feb 1/09

Figure 8C (Sheet 6)
V2500 54-10-00 Page 15.06

Feb 1/09

Figure 8C (Sheet 7)
V2500 54-10-00 Page 15.07

Feb 1/09

Figure 8C (Sheet 8)
V2500 54-10-00 Page 15.08

Feb 1/09

Figure 8C (Sheet 9)
V2500 54-10-00 Page 15.09

Feb 1/09

Figure 8C (Sheet 10)
V2500 54-10-00 Page 15.10

Feb 1/09
Intake Barrel Upper (Rad 270 - 90) - A5 (Post SBN 70-0909).

V2500 54-10-00 Page 15.11

Feb 1/09

V2500 54-10-00 Page 15.12

Feb 1/09

V2500 54-10-00 Page 15.13

Feb 1/09

V2500 54-10-00 Page 16.01

Feb 1/09

(INCH)
1 INTAKE BARREL UPPER

(Rad 270 - 90)
3 HONEYCOMB CORE Nomex Honeycomb,

1/2 inch (12.7 mm), Class 1,
Type 5, Density 2.0 lbs/ft3
(32 kg/m3)

3/8 inch (9.53 mm), Class 1,
(32 kg/m3)

1/2 inch (12.7 mm), Class 1,
(32 kg/m3)
6 HI-DENSITY CORE Nomex Honeycomb,

1/8 inch (3.18 mm), Class 1,
(352 kg/m3)

1/8 inch (3.18 mm), Class 1,
(352 kg/m3)

1/8 inch (3.18 mm), Class 1,
(352 kg/m3)
10 AERODYNAMIC FILLER Siloset 152

Table 8C
V2500 54-10-00 Page 16.02

Feb 1/09

(INCH)

Wires per inch

V1I, 325 Warp Wires/325 Weft
Wires per inch

A1B 1, Grade III, Weight 0.146
kg/m2 (0.03 lb/ft2)
A2A- Adhesive (Panel Assy) Adhesive Film, Type II, Class

kg/m2 (0.03 lb/ft2)
A2A- Adhesive (Facing Sheet) 0.005 Adhesive Film, Type II, Grade
A2E II, Weight 0.18 +0.018 kg/m2
(0.037 +0.004 lb/ft2)
A3 Adhesive One part Liquid Epoxy Adhesive,

spray onto brochier before

kg/m2 (0.03 lb/ft2)

1, Grade III, Weight 0.146
kg/m2 (0.03 lb/ft2)

kg/m2 (0.03 lb/ft2)

kg/m2 (0.03 lb/ft2)

Table 8C
V2500 54-10-00 Page 16.03

Feb 1/09

(INCH)

(0.395 lb/ft2),
(0.755 lb/ft2)

A7C II, Weight 0.18 +0.018 kg/m2
(0.037 +0.004 lb/ft2)

A8E Grade 50, Weight 1.93 kg/m2
(0.395 lb/ft2)
(0.755 lb/ft2)

II, Weight 0.18 +0.018 kg/m2
(0.037 +0.004 lb/ft2)

II, Weight 0.18 +0.018 kg/m2
(0.037 +0.004 lb/ft2)

II, Weight 0.18 +0.018 kg/m2
(0.037 +0.004 lb/ft2)

A13C 1, Grade III, Weight 0.146
kg/m2 (0.03 lb/ft2)

kg/m2 (0.03 lb/ft2)

kg/m2 (0.03 lb/ft2)

Table 8C
V2500 54-10-00 Page 16.04

Feb 1/09

(INCH)

kg/m2 (0.03 lb/ft2)

(0.395 lb/ft2),
(0.755 lb/ft2)

kg/m2 (0.03 lb/ft2)

kg/m2 (0.03 lb/ft2)

kg/m2 (0.03 lb/ft2)

kg/m2 (0.03 lb/ft2)

kg/m2 (0.03 lb/ft2)

C2E 0.0091 Fibre, Type IV, Class 2,
Style 3K-70-PW at +45 degrees
C3A- Backing Sheet Ply 0.0075- Epoxy Resin Impregnated Carbon


Style 3K-135-8H at +45 degrees

Table 8C
V2500 54-10-00 Page 16.05

Feb 1/09

(INCH)

C5L 0.0164 Fibre, Type III, Class 2,








C14 Backing Sheet Ply 0.0138- Epoxy Resin Impregnated Carbon



Table 8C
V2500 54-10-00 Page 16.06

Feb 1/09

(INCH)

G1A- Backing Sheet Ply 0.0035- Epoxy Resin Impregnated Glass

at 0-90 degrees

G26F 0.0055 Cloth Fabric, Type 120, Class I
at 0-90 degrees

Film, Type II, Class 1, Grade
III, Weight 0.146 kg/m2 (0.03




Table 8C
V2500 54-10-00 Page 16.07

Feb 1/09

(INCH)
C4A- Facing Sheet Ply 0.0083 Epoxy Resin Impragnated Carbon

C4D Fibre, Type I, Class II,

C5C Fibre, Type I, Class II,

C6D 0.045 Fibre, Type 1, Class 1I



C11 Facing Sheet Ply 0.0083 Epoxy Resin Impragnated Carbon

Fibre, Type I, Class II,




C15B Fibre, Type I, Class II,

Table 8C
V2500 54-10-00 Page 16.08

Feb 1/09

(INCH)




C20A- Facing Sheet ply 0.0083 Epoxy Resin Impragnated Carbon








Table 8C
V2500 54-10-00 Page 16.09

Feb 1/09

(INCH)




G32A- Facing Sheet Ply 0.0035- Epoxy Resin Impregnated Glass

G32D 0.0055 Cloth Fabric, Type 120, Class I
at 0-90 degrees

Wires per inch

Table 8C
V2500 54-10-00 Page 16.10

Feb 1/09

Figure 9 (Sheet 1)
V2500 54-10-00 Page 17.01

Feb 1/09

Figure 9 (Sheet 2)
V2500 54-10-00 Page 17.02

Feb 1/09

Figure 9 (Sheet 3)
V2500 54-10-00 Page 17.03

Feb 1/09

Figure 9 (Sheet 4)
V2500 54-10-00 Page 17.04

Feb 1/09

Figure 9 (Sheet 5)
V2500 54-10-00 Page 17.05

Feb 1/09

(INCH)
1 INTAKE BARREL
(Rad 54.925 - 176.012)


Wires per inch


II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
(0.037 ±0.004 lb/ft2)
II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
(0.03 lb/ft2)

(0.03 lb/ft2)

Table 9
V2500 54-10-00 Page 17.06

Feb 1/09

(INCH)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)




Table 9
V2500 54-10-00 Page 17.07

Feb 1/09

(INCH)











at 0-90 degrees

Table 9
V2500 54-10-00 Page 17.08

Feb 1/09

(INCH)

Wires per inch

Wires per inch




C7A Facing Skin Ply 0.0092 Epoxy Resin Impregnated Carbon

Fibre, Type I, Class 2,
C8A Facing Sheet Ply 0.0092 Epoxy Resin Impregnated Carbon


at 0-90 degrees


Table 9
V2500 54-10-00 Page 17.09

Feb 1/09

Figure 9A (Sheet 1)
V2500 54-10-00 Page 18.01

Feb 1/09

Figure 9A (Sheet 2)
V2500 54-10-00 Page 18.02

Feb 1/09

Figure 9A (Sheet 3)
V2500 54-10-00 Page 18.03

Feb 1/09

Figure 9A (Sheet 4)
V2500 54-10-00 Page 18.04

Feb 1/09

Figure 9A (Sheet 5)
V2500 54-10-00 Page 18.05

Feb 1/09

Figure 9A (Sheet 6)
V2500 54-10-00 Page 18.06

Feb 1/09

(INCH)
1 INTAKE BARREL
(Rad 54.925 - 176.012)


Wires per inch


M6 Wire Mesh Stainless Steel Wire Mesh, Type

V, 720 Warp Wires/154 Weft
Wires per inch

II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
A2A- Adhesive Adhesive Film, Type II, Grade
(0.037 ±0.004 lb/ft2)
II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)

Table 9A
V2500 54-10-00 Page 18.07

Feb 1/09

(INCH)

(0.03 lb/ft2)

(0.03 lb/ft2)

II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
(0.03 lb/ft2)

II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

Table 9A
V2500 54-10-00 Page 18.08

Feb 1/09

(INCH)

(0.03 lb/ft2)

A14F Grade 50, Weight 1.93 kg/m2
(0.395 lb/ft2),
(0.755 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)





Table 9A
V2500 54-10-00 Page 18.09

Feb 1/09

(INCH)









at 0-90 degrees

03, Weight 0.146 kg/m2 (0.03

Table 9A
V2500 54-10-00 Page 18.10

Feb 1/09

(INCH)

03, Weight 0.146 kg/m2 (0.03

03, Weight 0.146 kg/m2 (0.03

03, Weight 0.146 kg/m2 (0.03




C7 Facing Skin Ply 0.0092 Epoxy Resin Impregnated Carbon


Table 9A
V2500 54-10-00 Page 18.11

Feb 1/09

(INCH)
C8 Facing Sheet Ply 0.0092 Epoxy Resin Impregnated Carbon


at 0-90 degrees


Table 9A
V2500 54-10-00 Page 18.12

Feb 1/09

Figure 9B (Sheet 1)
V2500 54-10-00 Page 19.01

Feb 1/09

Figure 9B (Sheet 2)
V2500 54-10-00 Page 19.02

Feb 1/09

Figure 9B (Sheet 3)
V2500 54-10-00 Page 19.03

Feb 1/09

Figure 9B (Sheet 4)
V2500 54-10-00 Page 19.04

Feb 1/09

Figure 9B (Sheet 5)
V2500 54-10-00 Page 19.05

Feb 1/09

Figure 9B (Sheet 6)
V2500 54-10-00 Page 19.06

Feb 1/09

(INCH)
1 INTAKE BARREL
(Rad 54.925 - 176.012)

1/2 (12.7 mm), Class I, Type 5,

1/2 (12.7 mm), Class I, Type 5,

1/2 (12.7 mm), Class I, Type 5,

Wires per inch

VII, 325 Warp Wires/325 Weft
Wires per inch

A2 II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
A2D II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
spray ont brochier before

Table 9B
V2500 54-10-00 Page 19.07

Feb 1/09

(INCH)

II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

A8G Grade 50, Weight 1.93 kg/m2
(0.395 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

Table 9B
V2500 54-10-00 Page 19.08

Feb 1/09

(INCH)












Table 9B
V2500 54-10-00 Page 19.09

Feb 1/09

(INCH)


at 0-90 degrees

03, Weight 0.146 kg/m2 (0.03

03, Weight 0.146 kg/m2 (0.03

03, Weight 0.146 kg/m2 (0.03

03, Weight 0.146 kg/m2 (0.03


Table 9B
V2500 54-10-00 Page 19.10

Feb 1/09

(INCH)






at 0-90 degrees

Wires per inch

Table 9B
V2500 54-10-00 Page 19.11

Feb 1/09
Intake Barrel Lower (Rad 90 - 270) - A5 (Post SBN 70-0909)

Figure 9C(Sheet 1)
V2500 54-10-00 Page 20.01

Feb 1/09

Figure 9C (Sheet 2)
V2500 54-10-00 Page 20.02

Feb 1/09

Figure 9C (Sheet 3)
V2500 54-10-00 Page 20.03

Feb 1/09

Figure 9C (Sheet 4)
V2500 54-10-00 Page 20.04

Feb 1/09

Figure 9C (Sheet 5)
V2500 54-10-00 Page 20.05

Feb 1/09

Figure 8C (Sheet 6)
V2500 54-10-00 Page 20.06

Feb 1/09

Figure 8C (Sheet 7)
V2500 54-10-00 Page 20.07

Feb 1/09

Figure 9C (Sheet 8)
V2500 54-10-00 Page 20.08

Feb 1/09
Intake Barrel Lower (Rad 90 - 270) - A5 (Post SBN 70-0909).

Figure 9C (Sheet 9)
V2500 54-10-00 Page 20.09

Feb 1/09

V2500 54-10-00 Page 20.10

Feb 1/09

V2500 54-10-00 Page 20.11

Feb 1/09

V2500 54-10-00 Page 20.12

Feb 1/09

V2500 54-10-00 Page 20.13

Feb 1/09

V2500 54-10-00 Page 20.14

Feb 1/09

V2500 54-10-00 Page 21.01

Feb 1/09

V2500 54-10-00 Page 21.02

Feb 1/09

(INCH)
1 INTAKE BARREL LOWER

(Rad 90 - 270)

1/2 inch (12.7 mm), Class 1,
(32 kg/m3)

3/8 inch (9.53 mm), Class 1,
(32 kg/m3)

1/2 inch (12.7 mm), Class 1,
(32 kg/m3)

1/2 inch (12.7 mm), Class 1,
(32 kg/m3)

1/8 inch (3.18 mm), Class 1,
(352 kg/m3)

1/8 inch (3.18 mm), Class 1,
(352 kg/m3)
10 AERODYNAMIC FILLER Siloset 152

Wires per inch

Table 9C
V2500 54-10-00 Page 21.03

Feb 1/09

(INCH)
M10B- Septum Layer Stainless Steel Wire Mesh, Type

M10C V1I, 325 Warp Wires/325 Weft
Wires per inch

kg/m2 (0.03 lb/ft2)
A2A- Adhesive (Panel Assy) Adhesive Film, Type II, Class

kg/m2 (0.03 lb/ft2)
A2D II, Weight 0.18 +0.018 kg/m2
(0.037 +0.004 lb/ft2)
A3 Adhesive One part Liquid Epoxy Adhesive,

spray onto brochier before

kg/m2 (0.03 lb/ft2)

kg/m2 (0.03 lb/ft2)

kg/m2 (0.03 lb/ft2)

kg/m2 (0.03 lb/ft2)

Table 9C
V2500 54-10-00 Page 21.04

Feb 1/09

(INCH)
A7A- Adhesive (Panel Assy) Foaming Adhesive Film,

A7B Grade 50, Weight 1.93 kg/m2
(0.395 lb/ft2),
(0.755 lb/ft2)
A7C II, Weight 0.18 +0.018 kg/m2
(0.037 +0.004 lb/ft2)

A8C Grade 50, Weight 1.93 kg/m2
(0.395 lb/ft2)
(0.755 lb/ft2)

II, Weight 0.18 +0.018 kg/m2
(0.037 +0.004 lb/ft2)

II, Weight 0.18 +0.018 kg/m2
(0.037 +0.004 lb/ft2)

II, Weight 0.18 +0.018 kg/m2
(0.037 +0.004 lb/ft2)

kg/m2 (0.03 lb/ft2)

kg/m2 (0.03 lb/ft2)

kg/m2 (0.03 lb/ft2)

Table 9C
V2500 54-10-00 Page 21.05

Feb 1/09

(INCH)

kg/m2 (0.03 lb/ft2)

(0.395 lb/ft2),
(0.755 lb/ft2)

kg/m2 (0.03 lb/ft2)

kg/m2 (0.03 lb/ft2)

kg/m2 (0.03 lb/ft2)


C3H 0.0091 Fibre, Type IV, Class 2,

C4I 0.0164 Fibre, Type III, Class 2,

C5K 0.0164 Fibre, Type III, Class 2,


Table 9C
V2500 54-10-00 Page 21.06

Feb 1/09

(INCH)



C9K 0.0164 Fibre, Type III, Class 2,







at 0-90 degrees

G25E 0.0055 Cloth Fabric, Type 120, Class I
at 0-90 degrees

Table 9C
V2500 54-10-00 Page 21.07

Feb 1/09

(INCH)






C5C Fibre, Type 1, Class 1I


Table 9C
V2500 54-10-00 Page 21.08

Feb 1/09

(INCH)
C8 Facing Sheet Ply 0.033- Epoxy Resin Impragnated Open












Table 9C
V2500 54-10-00 Page 21.09

Feb 1/09

(INCH)

C20A- Facing Sheet ply 0.0083 Epoxy Resin Impragnated Carbon











Table 9C
V2500 54-10-00 Page 21.10

Feb 1/09

(INCH)

G31A- Facing Sheet Ply 0.0035- Epoxy Resin Impregnated Glass

at 0-90 degrees

Wires per inch

Table 9C
V2500 54-10-00 Page 21.11

Feb 1/09

Figure 10 (Sheet 1)
V2500 54-10-00 Page 22.01

Feb 1/09

Figure 10 (Sheet 2)
V2500 54-10-00 Page 22.02

Feb 1/09

Figure 10 (Sheet 3)
V2500 54-10-00 Page 22.03

Feb 1/09

Figure 10 (Sheet 4)
V2500 54-10-00 Page 22.04

Feb 1/09

Figure 10 (Sheet 5)
V2500 54-10-00 Page 22.05

Feb 1/09

(INCH)
1 INTAKE BARREL
(Rad 176.012 - 305.075)


Wires per inch


II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
(0.037 ±0.004 lb/ft2)
II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
(0.03 lb/ft2)

(0.03 lb/ft2)

Table 10
V2500 54-10-00 Page 22.06

Feb 1/09

(INCH)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)
A16B Adhesive Adhesive Film, Type II, Class

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)


Table 10
V2500 54-10-00 Page 22.07

Feb 1/09

(INCH)












Table 10
V2500 54-10-00 Page 22.08

Feb 1/09

(INCH)


at 0-90 degrees

Wires per inch at -45 degrees

Wires per inch at +45 degrees

C4A- Facing Skin Ply 0.0092 Epoxy Resin Impregnated Carbon







Table 10
V2500 54-10-00 Page 22.09

Feb 1/09

(INCH)





G9B Facing Sheet Ply 0.0035 - Epoxy Resin Impregnated Glass

at 0-90 degrees


Table 10
V2500 54-10-00 Page 22.10

Feb 1/09

V2500 54-10-00 Page 23.01

Feb 1/09

V2500 54-10-00 Page 23.02

Feb 1/09

V2500 54-10-00 Page 23.03

Feb 1/09

V2500 54-10-00 Page 23.04

Feb 1/09

V2500 54-10-00 Page 23.05

Feb 1/09

V2500 54-10-00 Page 23.06

Feb 1/09

V2500 54-10-00 Page 23.07

Feb 1/09

(INCH)
1 INTAKE BARREL
(Rad 176.012 - 305.075)


Wires per inch



M6A- Wire Mesh Stainless Steel Wire Mesh, Type

M6B V, 720 Warp Wires/154 Weft
Wires per inch

A3 II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
A4B II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
Table 10A
V2500 54-10-00 Page 23.08

Feb 1/09

(INCH)

(0.03 lb/ft2)

(0.03 lb/ft2)

A8B II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
(0.03 lb/ft2)

A10B II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

Table 10A
V2500 54-10-00 Page 23.09

Feb 1/09

(INCH)

A14L Grade 50, Weight 1.93 kg/m2
(0.395 lb/ft2),
(0.755 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)






Table 10A
V2500 54-10-00 Page 23.10

Feb 1/09

(INCH)








at 0-90 degrees
M12- Backing Sheet Ply Stainless Steel Wire Mesh, Type

03, Weight 0.146 kg/m2 (0.03

Table 10A
V2500 54-10-00 Page 23.11

Feb 1/09

(INCH)

03, Weight 0.146 kg/m2 (0.03

N16B III, 720 Warp Wires/147 Weft
03, Weight 0.146 kg/m2 (0.03

03, Weight 0.146 kg/m2 (0.03

C4A- Facing Skin Ply 0.0092 Epoxy Resin Impregnated Carbon





Table 10A
V2500 54-10-00 Page 23.12

Feb 1/09

(INCH)







G9B Facing Sheet Ply 0.0035 - Epoxy Resin Impregnated Glass

at 0-90 degrees


Table 10A
V2500 54-10-00 Page 23.13

Feb 1/09

V2500 54-10-00 Page 24.01

Feb 1/09

V2500 54-10-00 Page 24.02

Feb 1/09

V2500 54-10-00 Page 24.03

Feb 1/09

V2500 54-10-00 Page 24.04

Feb 1/09

V2500 54-10-00 Page 24.05

Feb 1/09

V2500 54-10-00 Page 24.06

Feb 1/09

V2500 54-10-00 Page 24.07

Feb 1/09

V2500 54-10-00 Page 24.08

Feb 1/09

(INCH)
1 INTAKE BARREL
(Rad 176.012 - 305.075)

1/2 (12.7 mm), Class I, Type 5,

3/8 (9.5 mm), Class I, Type 4,



Wires per inch
M3B- Septum Layer Stainless Steel Wire Mesh, Type

M3C VII, 325 Warp Wires/325 Weft
Wires per inch

A2 II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
A2A- Adhesive Adhesive Film, Type II, Grade
A2D II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)

Table 10B
V2500 54-10-00 Page 24.09

Feb 1/09

(INCH)

spray on to brochier before

II, Weight 0.18 ±0.018 kg/m2
(0.037 ±0.004 lb/ft2)
A5F I, Grade 03, Weight 0.146 kg/m2
(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

A8L Grade 50, Weight 1.93 kg/m2
(0.395 lb/ft2),
(0.755 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

(0.03 lb/ft2)

Table 10B
V2500 54-10-00 Page 24.10

Feb 1/09

(INCH)

(0.03 lb/ft2)

(0.03 lb/ft2)










Table 10B
V2500 54-10-00 Page 24.11

Feb 1/09

(INCH)




at 0-90 degrees

03, Weight 0.146 kg/m2 (0.03

03, Weight 0.146 kg/m2 (0.03

03, Weight 0.146 kg/m2 (0.03

Table 10B
V2500 54-10-00 Page 24.12

Feb 1/09

(INCH)

03, Weight 0.146 kg/m2 (0.03










Table 10B
V2500 54-10-00 Page 24.13

Feb 1/09

(INCH)





at 0-90 degrees

Wires per inch

Table 10B
V2500 54-10-00 Page 24.14

Feb 1/09
INLET COWL - ALLOWABLE DAMAGE
1. Introduction
This section contains the allowable damage limits for both sheet metal
and bonded panel structural components of the V2500 inlet cowl. Any
damage which is found to be more than the allowable damage limits should
be repaired in accordance with the procedures found in 54-10-00, Repairs,
Page Block 201.
2. Zones
Each of the individual components is divided into zones. The zones which
are affected by the different types of allowable damage are identified in
the figures and tables which follow.
3. Section Organization
The information in this section is given in six paragraphs. Paragraph A

gives general information about allowable damage, structure material,
and damage types. Paragraph B gives the allowable damage limits for the
Inlet Cowl Lip Skins. Paragraph C gives the allowable damage limits for
the Inlet Cowl Outer Barrel structure. Paragraph D gives the allowable
damage limits for the Inlet Cowl Acoustic Inner Barrel structure.
Paragraph E gives the allowable limits for the Inlet Cowl Anti-Ice
Exhaust Panel Grille. Paragraph F gives the allowable limits for the
Inlet Cowl Aerodynamic Sealant.
A. General
(1) General - Allowable damage data are intended to permit an

operator to determine whether a damaged nacelle component
may be returned to service without repair. Damage permitted
by these data will have no significant effect on the strength
or fatigue life of the structure, which will still be able to
fulfill its design function. The types of allowable damage
permitted are defined and brief descriptions are given of
the cleanup procedures needed to either prevent damage
propagation or improve the aerodynamic smoothness of the
damaged part.
(2) Material Types - The materials used in the construction of

the inlet cowl are aluminum alloys, corrosion resistant
steels (CRES), titanium and graphite fabric of various
weaves and forms. These forms include honeycomb (NOMEX),
closed-weave fabric, open-weave fabric, and tape. CRES is
used for tubes, ducts, fittings and accessories. The main
V2500 54-10-00 Page 101

Feb 1/09
aluminum alloy component in the inlet cowl is the one-piece

pressed
inlet lip skin. On A1 and A5 (serial no. V001 to V999 and
N0001 to N7353) aluminum alloy honeycomb is used in the core
of the composite sandwich which makes up the rear bulkhead.
On A5 (serial no. N7354 and sub) the rear bulkhead is made of
three titanium web segments.
(3) Damage - All damage limits assume that exposed edges do not
extend above the skin contour. Any such damage should be
reworked to remove or feather the extensions. Holes and
cracks in the pressure boundaries must be sealed with
applicable tape material. Allowable damage is classified as
either unlimited usage or time limited.
(a) Unlimited usage damage is defined as minor damage which

does not affect the structural integrity or functional
capability of the component and which needs no repairs
over the aircraft design life.
(b) Time limited damage is defines as minor damage which

does not affect the structural integrity of the
component in normal operation, but could reduce the
design life of the component. Therefore, damage must be
permanently repaired no later than the next 6000 FH,
4500 FC or 20 Months. The location and size of the
damage is to be noted and checked at each subsequent
600 FH, 750 FC or 100 Days to make sure that the damage
has not grown beyond the time limited damage
allowances.
(4) Damage Types - The types of allowable damage permitted on the

inlet cowl components are defined below. They apply only to
the parent material and do not include damage to surface
finishes such as paint.
(a) Abrasion - An abrasion is a damage area which results

in a cross sectional area change because the area was
scuffed, rubbed, scraped or had other surface erosion.
An abrasion usually appears rough and irregular.
(b) Gouge - A gouge is a damage area of any size which

results in a cross sectional area change. It is usually
caused by contact with a relatively sharp object which
produces a continuous, sharp or smooth channel-like
groove in the material.
(c) Nick - A nick is a local gouge with sharp edges.

Consider a series of nicks in a line to be a gouge.
V2500 54-10-00 Page 102

Feb 1/09
(d) Scratch - A scratch is a line of damage in the material

and results in a cross sectional area change. It is
usually caused by contact with a very sharp object.
(e) Crack - A crack is a partial fracture or complete break

in the material and produces a most significant cross
sectional area change. It usually appears as an
irregular line.
(f) Dent - A dent is damage area which is depressed with

respect to its normal contour. There is no change in
the cross sectional area. Area boundaries are smooth.
Its form is usually the result of contact with a
smoothly contoured object.
(g) Rip/Tear (Woven Wire) - A rip or a tear in the woven

wire of an acoustic bonded panel is a sharp continuous
separation of of the wire fibers.
(h) Hole - A hole is a complete penetration of the

material.
(i) Disbond - A disbond is a separation of the face sheet

from the honeycomb core of a bonded panel.
(j) Delamination - A delamination is the separation of two

laminate plies or faying surfaces.
(k) Void - Separation of the face sheet from honeycomb

core or faying surfaces.
V2500 54-10-00 Page 103

Feb 1/09
B. Inlet Cowl Lip Skin Structure - Allowable Damage (See Figure 101
and Table 101).
The allowable damage zones for the inlet cowl lip skin structures
are:
K1 - Lip skin, inner intake surface (between 135 and 225 degreess).
H - Lip skin, inner intake surface (all other areas).
K2 - Lip skin, outer intake surface (between 315 and 45 degrees).
J - Lip skin, outer intake surface (all other areas).
V2500 54-10-00 Page 104

Feb 1/09
Inlet Cowl Lip Skin Zones

Figure 101
V2500 54-10-00 Page 105

Feb 1/09
ALLOWABLE INSPECTION
DAMAGE ZONE REQUIREMENT LIMITS INTERVALS
Abrasion H Across all areas Max. depth of 6000 FH

J 0.015 in. (0.381 4500 FC
K1 mm). 20 Months
K2 Unlimited use.
Dent K1 No nearer than 1.00 in. Max. depth of 6000 FH

(25.4 mm) to any rivet. 0.10 in. (2.54 4500 FC
Rounded contour. mm) by max. 20 Months
Minimum 10 in. (254 mm) length of 1.00
to any other damage. in. (25.4 mm) in
Maximum 2 dents in this any direction.
region. Depth must not be
more than 10% of
length.
Unlimited use.
H No nearer than 1.00 in. Max. depth of 6000 FH

any direction.
Depth must not be
more than 10% of
length.
Unlimited use.
K2 No nearer than 1.00 in. Max. depth of 6000 FH

Maximum 2 dents in this any direction.
region. Depth must not be
more than 10% of
length.
Unlimited use.
Inlet Cowl Lip Skin Structure Allowable Damage Limits

Table 101 (Sheet 1 of 4)
V2500 54-10-00 Page 106

Feb 1/09
Dent J No nearer than 1.00 in. Max. depth of 6000 FH

any direction.
Depth must not be
more than 10% of
length.
Unlimited use.
Gouge H Across rivet heads. Max. depth of 6000 FH

J No nearer than 10.00 in. 0.005 in. (0.127 4500 FC
K1 (254.0 mm) to other mm) by max. 20 Months
K2 damage. length of 4.00
in. (101.6 mm) in
any direction.
Unlimited use.
H All other areas, no Max. depth of 6000 FH

J nearer than 10.00 in. 0.015 in. (0.396 4500 FC
K1 (254.0 mm) to other mm) by max. 20 Months
K2 damage. length of 4.00
in. (101.6 mm) in
any direction.
Unlimited use.
Scratch H No nearer than 10.00 in. Max. depth of 6000 FH

J (254.0 mm) to other 0.015 in. (0.396 4500 FC
K1 damage. If depth exceeds mm) by max. 20 Months
K2 limit then consider as a length of 6.00
crack. in. (152.4 mm) in
any direction.
Unlimited use.

V2500 54-10-00 Page 107

Feb 1/09
Nick H No nearer than 10.00 in. Max. depth of 6000 FH

J (254.0 mm) to other 0.015 in. (0.396 4500 FC
K1 damage. If depth exceeds mm) by max. 20 Months
K2 limit then consider as a length of 1.00
crack. in. (25.4 mm) in
any direction.
Unlimited use.
Crack H No nearer than 12.00 in. Max. length of Fly on limit

J (305.00 mm) to other 2.00 in. (51.00 only. Must
K1 damage. Stop drill crack mm) in any be repaired
K2 (refer to SRM 54-02-00). direction. no later
Time limited. than next
600 FH
750 FC
100 Days.
Examine
crack for
propagation
after every
flight.
NOTE: Cracks
must be
repaired
before next
flight if
longer than
2.00 in.
(50.8 mm).
Hole H Not acceptable.

J
K1
K2

V2500 54-10-00 Page 108

Feb 1/09
Fastener H Maximum of 10 Fly-on limit

loss K1 fasteners. only. Must
(Attach- Time limited. be repaired
ment to no later
forward than next
bulk- 600 FH
head) 750 FC
100 Days.
J Maximum of 7 Examine for
K2 fasteners. increase in
Time limited. fastener
loss after
every
flight.
NOTE: If
number of
failed
fasteners is
more than
the stated
limits,
repair
before next
flight.

V2500 54-10-00 Page 109

Feb 1/09
C. Inlet Cowl Outer Barrel Structure - Allowable Damage (See Figure

102 and Table 102).
The Allowable damage zones for the inlet cowl outer barrel
structure are:
G - Capping strap - A1 hybrid (serial no. V299 to V999) and A5

only.
R - Panel frame, power plant radial (PPR) 230.
S - Panel frame - PPR 240.
T - Access panel frame - PPR 340.
U - Circumferential stiffeners, power plant station (PPS) 35.32

(TOP)
V - Splice lands - barrel panels - PPR 237 and PPR 57.
W - Panel lands, front and rear.
X - Outer Barrel panel - PPR 223 to PPR 57 (LH).
Y - Outer Barrel panel - PPR 57 to PPR 237 (RH).
Z - Composite Rear Bulkhead (serial no. V001 to V999 and N0001 to

N7353).
NOTE: For Titanium Rear Bulkhead refer to para. D.
V2500 54-10-00 Page 110

Feb 1/09
Inlet Cowl Outer Barrel Structure Zones

Figure 102 (Sheet 1)
V2500 54-10-00 Page 111

Feb 1/09
Inlet Cowl Outer Barrel Structure Zones

V2500 54-10-00 Page 112

Feb 1/09
DAMAGE ZONE REQUIREMENTS LIMITS INTERVALS
Abrasion R S Confined to surface Local resin max. Aircraft “A”

T U resin over unlimited depth. check.
V W area. Protect with
X Y sealing tape (CoMat
Z 02-006).
G Damaged capping straps 0.040 inches Aircraft “A”

on the aft door landing. (1.016 mm) max. check.
depth. Do CMM repair
Time Limited. No. 20
(VRS2788) or
SRM repair
No. 30
(VRS2792) at
next “C”
check.
more than 0.040 Do CMM repair

inches (1.016 mm) No. 20
deep and less (VRS2788) or
than the limits SRM repair
(zones 1 and 2) No. 30
shown in Fig 102 (VRS2792)
(Sheet 2).
more than 0.040 Do CMM repair

inches (1.016 mm) No. 20
deep and more (VRS2788).
than the limits
(zones 1 and 2)
shown in Fig 102
(Sheet 2).
Inlet Cowl Outer Barrel Allowable Damage Limits

Table 102 (Sheet 1)
V2500 54-10-00 Page 113

Feb 1/09
Gouge/ R S No nearer than 8.00 0.010 inch Aircraft “A”

Scratch T U inches (203.2 mm) to (0.254 mm) max. check.
V W other unrepaired damage. depth. 6.00
X Y No more than 6 gouges/ inches (152.4 mm)
scratches per barrel max. length.
half. Protect with 0.010 inch
sealing tape (CoMat (0.254 mm) max.
02-006). width.
Z Depth: Within
surface resin only.
6.00 inches
(152.4 mm) max.
length in circum-
ferential direction.
2.00 inches
(50.8 mm) max. in
radial direction.
0.10 inch (2.54 mm)
max. width.
Nick R S No nearer than 4.00 0.010 inch Aircraft “A”

T U inches (101.6 mm) to (0.254 mm) max. check.
V W other unrepaired damage. depth. 6.00
X Y Protect with sealing inches
tape (CoMat 02-006). If (152.4 mm) max.
length exceeds length. 0.010
1.00 inch (25.4 mm) inch (0.254 mm)
consider as a gouge. max. width.
Delami- X Y No nearer than 8.00 2.00 inch Aircraft “A”

nations inches (203.2 mm) to (50.8 mm) max. check.
other damage. No surface across in any
cracking. Repair no direction.
later than next “C”
check.

Table 102 (Sheet 2)
V2500 54-10-00 Page 114

Feb 1/09
Crack X Y No nearer than 10.00 3.00 inch Fly on limit

inches (254.0 mm). Stop (76.0 mm) max. only. Must be
drill (refer to SPM). length. repaired at
Protect with sealing earliest
tape (CoMat 02-006). opportunity.
Examine for
propagation
after every
flight.
Hole X Y No nearer than 10.00 Fly on limit

inch (254.0 mm) to other only. Must be
damage. Protect with repaired at
sealing tape (CoMat earliest
02-006). opportunity.
Check tape to
ensure that
no peel
occurs after
every flight.

Table 102 (Sheet 3)
V2500 54-10-00 Page 115

Feb 1/09
D. A5 (serial no. N7354 and sub) - Inlet Cowl Titanium Rear Bulkhead
Structure - Allowable Damage (See Figure 103 and Table 103).
The Allowable damage zones for the inlet cowl aluminium outer
barrel structure are:
Z - Titanium Rear bulkhead
ZA - Titanium Rear bulkhead web (PPR 330o - PPR 0o - PPR 30o)
ZB - Titanium Rear bulkhead web (PPR 30o - PPR 111o and

PPR 249o - PPR 330o)
ZC - Titanium Rear bulkhead web (PPR 111o - PPR 180o - PPR 249o)
Z1 - Titanium Rear bulkhead Aluminium Alloy zed stiffeners.
Z2 - Titanium Rear bulkhead titanium web joint channels (PPR 43o,

198o & 317o).
V2500 54-10-00 Page 116

Feb 1/09
A5 (serial no. N7354 and sub) - Inlet Cowl Titanium

Rear Bulkhead Structure Zones
Figure 103
V2500 54-10-00 Page 117

Feb 1/09
Abrasion ZA Max. depth of 6000 FH

ZB 0.005 in. (0.127 4500 FC
mm). 20 Months
Unlimited use.
ZC Max. depth of 6000 FH

0.003 in. (0.076 4500 FC
mm) by max. 20 Months
lenght of 2.25
in. (57.15 mm) in
any direction.
Unlimited use.
Z1 Not acceptable.
Z2 Max. depth of 6000 FH

0.010 in. (0.254 4500 FC
mm). 20 Months
Unlimited use.
Gouge/ ZA Bulkhead web. Max. depth of 6000 FH

Scratch ZB Only one scratch/gouge 0.005 in. (0.127 4500 FC
per web. No nearer than mm) by max. width 20 Months
1.00 in. (25.4 mm) to of 0.010
any fastener. in.(0.254 mm).
Unlimited use.
A5 (serial no N7354 and sub) - Inlet Cowl Titanium

Rear Bulkhead Allowable Damage Limits
Table 103 (Sheet 1)
V2500 54-10-00 Page 118

Feb 1/09
Gouge/ ZC Bulkhead web. Max. depth of 6000 FH

Scratch Only one scratch/gouge 0.003 in. (0.076 4500 FC
per web. No nearer than mm) by max length 20 Months
1.00 in. (25.4 mm) to of 2.25 in.
any fastener. (57.15 mm) by
max. width of
0.010 in.(0.254
mm).
Unlimited use.
Z1 Not acceptable.
Z2 Joint channels. Max. depth of 6000 FH

Only one scratch/gouge 0.010 in. (0.254 4500 FC
per channel. mm) by max. 20 Months
length of 6.00
in. (152.4 mm) by
max. width of
0.010 in. (0.254
mm).
Unlimited use.
Nick ZA Bulkhead web. Max. depth of 6000 FH

ZB No nearer than 4.00 in. 0.005 in. (0.127 4500 FC
(101.6 mm) to other mm) by max. 20 Months
unrepaired damage. If length of 1.00
length exceeds 1.00 in. in. (25.4 mm) by
(25.4 mm) consider as a max. width of
gouge. 0.010 in. (0.254
No more than 2 nicks for mm).
each web Unlimited use.

Table 103 (Sheet 2)
V2500 54-10-00 Page 119

Feb 1/09
Nick ZC Bulkhead web. Max. depth of 6000 FH

No nearer than 6.50 in. 0.003 in. (0.076 4500 FC
length exceeds 1.00 in. in. (25.4 mm) by
(25.4 mm) consider as a max. width of
gouge. 0.010 in. (0.254
each web Unlimited use.
Z1 Not acceptable.
Z2 Joint channels. Max. depth of 6000 FH

No nearer than 4.00 in. 0.010 in. (0.254 4500 FC
length is more than 1.00 in. (25.4 mm) by
in. (25.4 mm) consider max. width of
as a gouge. 0.010 in. (0.254
each channel. Unlimited use.
Dent ZA No nearer than 1.00 in. Max. depth of

ZB (25.4 mm) to any rivet. 0.040 in. (1.00
Rounded contour. mm) by max.
length in any
direction of
0.50 in. (12.7
mm).
Unlimited use.
ZC No nearer than 3.00 in. Max. depth of

(76.2 mm) to any rivet. 0.040 in. (1.00
Rounded contour. mm) by max.
length in any
direction of
0.50 in. (12.7
mm).
Unlimited use.
Z1, Z2 Not acceptable.

Table 103 (Sheet 3)
V2500 54-10-00 Page 120

Feb 1/09
Crack ZA ZB Not acceptable.

ZC Z1
Z2
Hole ZA ZB Not acceptable.

ZC Z1
Z2

Table 103 (Sheet 4)
V2500 54-10-00 Page 121

Feb 1/09
E. Inlet Cowl Acoustic Inner Barrel Structure - Allowable Damage (See

Figure 103 and Table 103).
The Allowable damage zones for the inlet cowl acoustic inner
barrel structure are:
N1, P1, Q1 - Woven wire air-wetted surface overlay.
N2, P2, Q2 - Woven fibre inner face sheet.
N3, P3, Q3 - Honeycomb core.
K, L, M - Splice joints.
V2500 54-10-00 Page 122

Feb 1/09
Inlet Cowl Acoustic Inner Barrel Structure Zones

Figure 103
V2500 54-10-00 Page 123

Feb 1/09
Scratch N1 No nearer than 3.00 Depth: To full Aircraft “A”

P1 inches (76.2 mm) to thickness of check.
Q1 similar damage. No mesh. 2.50
nearer than 1.50 inches inches
(38.1 mm) to core edge. (63.5 mm) max.
length.
K No nearer than 3.00 0.020 inch Aircraft “A”

L inches (76.2 mm) to (0.51 mm) max. check.
M similar damage. depth. 5.00
inches
(127.0 mm) max.
length.
Gouge N1 No nearer than 6.00 0.020 inch Aircraft “A”

P1 inches (152.4 mm) to (0.51 mm) max. check.
Q1 similar damage. Smooth depth. 1.50
N2 bottomed Stabilize wire inch (38.1 mm)
P2 mesh damage. max. length.
Q2 0.10 inch
(2.54 mm) max.
width.

L inches (76.2 mm) to (0.254 mm) max. check.
M similar damage. Repair depth. 5.00
no later than next “C” inches
check. (127.0 m) max.
length. 0.10
inch (2.54 mm)
max. width.
Inlet Cowl Acoustic Inner Barrel Allowable Damage Limits

Table 103 (Sheet 1)
V2500 54-10-00 Page 124

Feb 1/09
Nick N1 No nearer than 2.00 0.010 inch Aircraft “A”

P1 inches (50.8 mm) to (0.254 mm) check.
Q1 similar damage. No max. depth
nearer than 1.50 inches 0.25 inch
(38.1 mm) to core edge. (6.35 mm) max.
Nicks longer than 0.25 Length. 0.10
inches (6.35 mm) inch (2.54 mm)
consider as a gouge. max width.

L inches (50.8 mm) to (0.254 mm) check.
M similar damage. Repair max. depth.
no later than next “C” 0.25 inch
check (6.35 mm) max.
length. 0.10
inch (2.54 mm)
max width.
Dent N1,N2 No nearer than 3.00 0.10 inch Aircraft “A”

N3,P1 inches (76.2 mm) to (2.54 mm) max. check.
P2,P3 similar damage. No depth. 1.50
Q1,Q2 nearer than 1.50 inch inch (38.1 mm)
Q3 (38.1 mm) to core edge. max. length in
Repair any damage to any direction
wire mesh layer.

L inches (50.8 mm) to (0.254 mm) check.
M similar damage. Repair max. depth
no later than next “C” 0.25 inch
check. (6.35 mm) max.
Length. 0.10
inch (2.54 mm)
max width.

Table 103 (Sheet 2)
V2500 54-10-00 Page 125

Feb 1/09
Rip/Tear N1 No delamination from Depth: To full Aircraft “A”

P1 face sheet. No nearer thickness of Check
Q1 than 1.50 inch (38.1 face mesh.
mm) to core edge. No 1.50 inch
nearer than 3.00 inches (38.1 mm) max.
(76.2 mm) to similar Length in any
damage. Stabilize wire direction.
mesh if separated.
Delami- N1,N2 No nearer than 6.00 1.50 inch Aircraft “A”

nations N3,P1 inches (152.4 mm) to (38.1 mm) max. Check
P2,P3 other delaminations or width in any
Q1,Q2 voids. No nearer than direction.
Q3 1.50 inch (38.1 mm) to
core edge.
K Damage extends no more Aircraft “A”

L than 15% of the joint Check
M length and no more than
0.20 inch (5.1 mm) to
edge of joint strip.
Void N1,N2 No nearer than 6.00 1.50 inch Aircraft “A”

N3,P1 inches (152.4 mm) to (38.1 mm) max. Check
P2,P3 other delaminations or width in any
voids. No nearer than direction.
1.50 inch (38.1 mm) to
core edge.
Hole Not acceptable. See Repair 29

VRS2780

Table 103 (Sheet 3)
V2500 54-10-00 Page 126

Feb 1/09
F. Inlet Cowl Anti-Ice Exhaust Panel Grille - Allowable Damage (See

Figure 104 and Table 104).
The Allowable damage zones for the inlet cowl anti-ice exhaust
panel grille are:
C - Grille
V2500 54-10-00 Page 127

Feb 1/09
Inlet Cowl Anti-Ice Exhaust Panel Grille Structure Zones

Figure 104
V2500 54-10-00 Page 128

Feb 1/09
Crack C 0.5 inch Aircraft “A”

(12.7 mm) max. Check
length.
Inlet Cowl Anti-Ice Exhaust Panel Grille Allowable Damage Limits

Table 104
V2500 54-10-00 Page 129

Feb 1/09
G. Inlet Cowl Aerodynamic Sealant - Allowable Damage (See Figure 105

and Table 105).
The Allowable damage zones for the inlet cowl aerodynamic sealant
are:
E - Aerodynamic Sealant, outer intake joint
F - Aerodynamic Sealant, inner intake joint
V2500 54-10-00 Page 130

Feb 1/09
Inlet Cowl Aerodynamic Sealant Zones

Figure 105
V2500 54-10-00 Page 131

Feb 1/09
Loose or E 50% or more of the Do Repair

missing F circumference No. 21
sealant (54-10-00) -
Aerodynamic
Sealant
Replacement
Inlet Cowl Aerodynamic Sealant Allowable Damage Limits

Table 105
V2500 54-10-00 Page 132

Feb 1/09
GENERAL REPAIR
1. General
The repairs given in this section are for structural damage which
goes beyond the limits shown in the Allowable Damage section. The
repairs are show you how to restore a part to it’s original strength
and configuration. Procedures to refinish a repaired area are also
given.
2. Adhesive Preparation
Some repairs call for the use of certain adhesives. The following are
the procedures to use in the preparation of the adhesives.
A. EA956/L3 Adhesive

INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND
DISCARD CHEMICALS.
CAUTION: DO NOT SUBSTITUTE EA956 PART A FOR EA956/L3 PART A.

THIS WILL WEAKEN THE ADHESIVE MIXTURE.
(1) Mix 100 parts-by-weight of EA956/L3 base A with 28 parts-

by-weight of L3 catalyst in a metal or plastic container.
Use a metal spatula and mix by hand to avoid heat rise in
adhesive mixture.

Page 201
Feb 1/09
(2) Cover container to prevent contamination of mixture and

store in a cool place until you are ready to use it.
NOTE: The useful life of a one-pound mixture is about

seven hours. Heat makes both the gel time and the
cure time of the adhesive mixture faster.
B. EA956 Adhesive

DISCARD CHEMICALS.
(1) Mix 100 parts-by-weight of EA956 Part A with 58 parts-by-

weight of Part B in a metal or plastic container. Use a
metal spatula and mix by hand to avoid heat rise in
adhesive mixture.

store in cool place until you are ready to use it.
NOTE: The useful life on a one-pound mixture is about

seven hours. Heat makes both the gel time and the
cure time of the adhesive mixture faster.

Page 202
Feb 1/09
C. EA934NA Adhesive

DISCARD CHEMICALS.
(1) Mix 100 parts-by-weight of EA934NA Part A with 33 parts-

by-weight of Part B in a metal or plastic container. Use a
adhesive mixture.
(2) Cover container to prevent contamination of the mixture

and store in cool place until you are ready to use it.
NOTE: The useful life of a one-pound mixture is about 40

minutes at 77ºF (25ºC). Heat makes both the gel
time and the cure time of the adhesive mixture
faster.
3. Carbon/Epoxy Bonded Structures
The inlet cowl outer barrel is made of carbon/epoxy bonded structure.
This type of material is repaired with “wet-layup hot-bonded”

procedures. In these procedures, carbon fabric is soaked with epoxy
and put on the damaged area. Repair equipment (parting film, bleeder
and breather cloth, heat blanket, silicone rubber sheet, and vacuum
bag) are installed over the carbon fabric. The repair is cured at
high temperatures for a specified time, after which the repair
equipment is removed. The repair may then be smoothed as necessary
for an aerodynamic finish.
The number of carbon fabric repair plies used is equal to the number
of damaged plies. See the Structural Identification section to find
the number of plies in the damaged area. You cannot examine the

Page 203
Feb 1/09
damaged skin to count the plies. Cured carbon plies are very
difficult to separate at ply interfaces.
A single ply of fiberglass is used on top of repairs exposed to the

free airstream. This is to permit the repair to be made smooth for an
aerodynamic finish.
Both the original skin and the repair material must be clean and dry
before the repair can be started. Water on the surface or in the
materials will make the repair weak. All water must be removed before
the repair can be done. Use heat lamps at 230ºF-250ºF (115ºC-127ºC)
for one hour.
Drain holes are in the lower part of the inlet cowl outer barrel to
permit moisture to be vented. If these holes are closed during
repair, they must be reopened.
4. Titanium Structures
The forward and aft bulkheads are made of titanium. The bulkhead is
made up of sections of sheet titanium spliced together to form the
bulkhead. Formed titanium inner and outer cap angles are attached to
the edges of the web and to the outer barrel and inlet lip.
Repairs to the forward and aft bulkheads must be sealed to keep the
pressure (approximately 2 psi maximum) between the inner and outer
barrels.
5. Bonded Acoustic Panel Structure
The acoustic panels form the inner barrel of the inlet cowl. Their
main purpose is to reduce the noise that comes from the engine inlet
area. The panels are also the main load-bearing structure for the
inlet cowl.
The panels are made up of a bonded assembly of solid outer skins

(back sheet), perforated inner skins (face sheet), and aluminum core.
Woven wire cloth is bonded to the perforated inner skin of the panel.
It contributes to the noise reducing ability of the panel.

Page 204
Feb 1/09

Adhesive System, Epoxy EA934NA Dexter Hysol Aerospace, Inc.
Base Part A The Dexter Corporation
Catalyst Part B 2850 Willow Pass Rd.
P.O. Box 312
Adhesive System, Epoxy EA956/L3 Dexter Hysol Aerospace, Inc.
Base Part A
Catalyst L3
Cloth, Wiper Cotton Commercially Available
Clothing, Protective Commercially Available
Container Metal or Plastic Commercially Available
Cover, Container Metal or Plastic Commercially Available
Gloves Neoprene or Commercially Available
Polyvinyl
Chloride
Solvent Methyl Ethyl Commercially Available
Ketone
Spatula Metal or Plastic Commercially Available
NOTE: Alternate sources for these materials may be found in
54-00-00, “Bulk Materials Supplier’s List”.
Repair Materials and Equipment

Table 201

Page 205
Feb 1/09

Page 206
Feb 1/09
AIR INTAKE COWL - LIST OF APPROVED REPAIRS
NOTE: You must refer to 54-01-00 Acoustic Treatment Blockage Area

Limits before you do repairs to acoustic areas of the Intake Cowl.
001 AIR INTAKE COWL AFT BULKHEAD SURFACE DAMAGE ON THE

(VRS2803) COMPOSITE REPAIR
(REF 71-11-00)
002 AIR INTAKE COWL DELAMINATION REPAIR
(VRS2816) (REF 71-11-00)
003 AIR INTAKE COWL EDGE DELAMINATION REPAIR

(VRS2817) (REF 71-11-00)
004 AIR INTAKE COWL AFT BULKHEAD HONEYCOMB REPAIR

(VRS2802) (REF 71-11-00)
005 AIR INTAKE COWL OUTER BARREL SURFACE DAMAGE REPAIR

(VRS2805) (REF 71-11-00)
006
(VRS2814) CANCELLED
007 AIR INTAKE COWL INNER BARREL CRACK AND DELAMINATION

(VRS2996) REPAIR
(REF 71-11-00)
008
(VRS2819) CANCELLED
009 AIR INTAKE COWL T2P2 PROBE ACESS PANEL OPENING

(VRS2844) INTERFACE LAND REPAIR
(REF 71-11-00)
010 AIR INTAKE COWL PROBE ACCESS PANEL INTERFACE LAND
(VRS2808) REPAIR
(REF 71-11-00)
011
(VRS2809) CANCELLED
012 AIR INTAKE COWL STIFFENER AREA REPAIR

(VRS2810) (REF 71-11-00)

Page 201
Feb 1/09

013 AIR INTAKE COWL ACCESS PANELS SURFACE DAMAGE REPAIR
(VRS2845) (REF 71-11-00)
014 AIR INTAKE COWL ACCESS PANELS HOLE REPAIR

(VRS2846) (REF 71-11-00)
015 AIR INTAKE COWL ACOUSTIC STRUTURE SURFACE DAMAGE
(VRS2815) REPAIR
(REF 71-11-00)
016 AIR INTAKE COWL HAND BLEND AND POLISH PROCEDURE REPAIR
(VRS2867) (REF 71-11-00)
021 AIR INTAKE COWL OR P2T2 SENSOR AERODYNAMIC SEALANT

(VRS2725) REPLACEMENT (REF 71-11-00)
022 AIR INTAKE COWL PIN RECEPTACLE REPLACEMENT REPAIR
(VRS2739) (REF 71-11-00)
023 AIR INTAKE COWL COOLANT DUCT REPLACEMENT REPAIR
(VRS2933) (REF 71-11-00)
025 AIR INTAKE COWL LIP SKIN SURFACE RIVET REPLACEMENT
(VRS2746) REPAIR
(REF 71-11-00)
026 AIR INTAKE COWL LIP SKIN OUTER SURFACE RIVET
(VRS2770) REPLACEMENT REPAIR
(REF 71-11-00)
027 AIR INTAKE COWL ACOUSTIC LINER WIRE MESH/FACING SHEET
(VRS2779) DELAMINATION REPAIR
(REF 71-11-00)
029 AIR INTAKE COWL ACOUSTIC LINER FACING SHEET HOLE
(VRS2780) DAMAGE
(REF 71-11-00)
030 AIR INTAKE COWL WORN CAPPING STRAP REPAIR
(VRS2792) (REF 71-11-00)
031 AIR INTAKE COWL-SURFACE DAMAGE BLEND REPAIR ON THE

(VRS2501) TITANIUM AFT BULKHEAD
(REF 71-11-00)

Page 202
Feb 1/09

032 AIR INTAKE COWL-TITANIUM AFT BULKHEAD WEB-HOLE REPAIR
(VRS2793) (REF 71-11-00)
033 AIR INTAKE COWL-TITANIUM AFT BULKHEAD DAMAGED WEB
(VRS2794) REPAIR SECTION REPLACEMENT
(REF 71-11-00)
034 AIR INTAKE COWL INNER BARREL ACOUSTIC STRUCTURE HOLE
(VRS7504) REPAIR
(REF 71-11-00)

Page 203
Feb 1/09

Page 204
Feb 1/09
REPAIR NO. 001

AIR INTAKE COWL - REPAIR SURFACE DAMAGE ON THE COMPOSITE AFT BULKHEAD
VRS2803
1. General.
A. This repair is applicable to A1, A1 Hybrid and A5 composite aft

bulkheads only (serial no. N5001 to N7353). For A5 titanium aft
bulkheads (serial no. N7354 and sub) refer to VRS2501 or VRS2794.
B. Use of this repair is restricted to the following types of damage

(Ref. SPM TASK 70-02-02-350-501).
Gouge
Cracked/split
Impact
C. The damage must be more than (4 repair plies + 1 sanding ply)

4.75 in. (120,7 mm) from the edge of the fittings, the brackets,
the flanges and the tapered sections of the bulkhead. The damage
can be nearer to the edge if less than four plies are damaged.
There must be enough distance to install all the repair plies and
sanding ply. Refer to Para. 5A and Fig. 202. There must be a
minimum of 10.0 in. (254,0 mm) between damaged areas. The damage
must not go through all the composite plies and into the honeycomb
core.
NOTE: On the A1 hybrid (serial no. V299 and sub) and A5 Air Intake
Cowl (serial no. N5001 to N7353) do not use this repair on
the titanium plate. Refer to Fig. 201.
D. The repair plies must be at 90 degrees to each other.
E. This repair must be done in a room with a controlled temperature of

between 68o - 77oF (20o - 25oC). The humidity must be keep at 50
percent or less.
F. When damage is beyond the scope of this repair refer to the

Goodrich.
V2500 54-10-00 REPAIR No. 001

Page 201
Feb 1/09
2. Referenced Information.
54-10-00, REPAIR No. 031 Structural Repair Manual (SRM)

(VRS2501)
54-10-00, REPAIR No.033 Structural Repair Manual (SRM)
(VRS2794)
TASK 70-02-02-350-501 Standard Practices/Processes Manual
(SPPM)
(SPPM)
(SPPM)
3. Equipment and Material.
Equivalent materials and equipment may be used.
A. Standard equipment
Heat blanket, range 32o - 248oF (0o - 120oC)

Heat lamp, range 176o - 194oF (80o - 90oC)
Vacuum suction pump, range 0 - 30 in. (0 - 762 mm) of mercury
Temperature probes, range 32o - 248oF (0o - 120oC)
Steel roller 2.0 in. (50,8 mm) diameter, 2.0 in. (50,8 mm) long
Suction cleaner
Standard workshop tools and equipment
B. Special Tools
IAE 1N20403 Sling, inlet Cowl

IAE 1N20444 Tapping Tool
V2500 54-10-00 REPAIR No. 001

Page 202
Feb 1/09
C. Consumable materials (Ref. Overhaul Processes and Consumables

Index).
CoMat 01-076 Methylethylketone

CoMat 02-007 Teflon tape
CoMat 02-087 Tymex nylon brush
CoMat 02-164 Phenolic microballoons (135 micron)
CoMat 02-167 Fiberglass fabric
CoMat 02-168 Nonporous parting film
CoMat 02-169 Porous parting film
CoMat 02-170 Silicone rubber sheet
CoMat 05-021 Waterproof abrasive paper, 240-grit
CoMat 08-050 Epoxy paste adhesive, EA9390
CoMat 08-051 Sealant tape
CoMat 08-057 Breather fabric
CoMat 08-059 Dry carbon fibre fabric
CoMat 12-012 Cushioning felt
D. Repair parts
None.
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Aft bulkhead Carbon fiber composite
honeycomb core sandwich
4. Position the air intake cowl ready for repair.
WARNING: USE THE CORRECT PROCEDURE AND EQUIPMENT WHEN YOU MOVE THE
COWL. MAKE SURE THE COWL IS HELD CORRECTLY DURING THE REPAIR
PROCEDURE.
CAUTION: BE CAREFUL WHEN YOU MOVE THE COWL. DO NOT POSITION THE COWL
DIRECTLY ON TO A HARD SURFACE.
A. Put a layer of the felt, (CoMat 12-012), approximately 1.5 in.

(38,1 mm) thick, on to a smooth surface. Make sure there is no
unwanted material on or below the felt which will cause damage to
the cowl. Using a 1N20403 sling, put the cowl on to the felt. The
damaged area must be positioned horizontally.
V2500 54-10-00 REPAIR No. 001

Page 203
Feb 1/09
5. Examine the damaged area (Ref Fig 202).
A. Referring to Fig 202 examine the repair area to assess the amount
of damage and, using the standard workshop tools, measure the depth
of the damage. Do this in several places where the extent of the
damage permits. From this information the number of repair plies
should be calculated as follows:
DEPTH OF DAMAGE NO.OF REPAIR PLIES
Up to 0.008in. (0,20 mm) 1 + fiberglass ply (Sanding)

0.009 to 0.016in. (0,23 to 0,41 mm) 2 + fiberglass ply (Sanding)
More than 0.025 (0,64 mm) 4 + fiberglass ply (Sanding)
Where doubt can arise over the exact magnitude of the damage
penetration, i.e. deciding between 0.024in. (0,61 mm) and 0.025in.
(0,64 mm), assume the larger figure as the criteria for selecting
the number of repair plies to use. That is, 4 plies rather than 3,
for this example. If on examination it is found that the damage has
fully penetrated the carbon plies and the honeycomb core, repair is
beyond the scope of this document. In this event do SRM 54-10-00
REPAIR No. 004 (VRS 2802).
6. Clean the Repair Area.
MUST SAFELY USE, KEEP AND DISCARD CHEMICALS.
A. Clean the damage and repair area of the bulkhead with the
methylethylketone (CoMat 01-076) and lint free cloth
(CoMat 02-099). Wipe the area with a clean piece of lint free cloth
before the fluid dries.
V2500 54-10-00 REPAIR No. 001

Page 204
Feb 1/09
7. Prepare the Repair Area (Ref Fig 202).

DO THIS TASK. READ, UNDERSTAND AND OBEY ALL INSTRUCTIONS FOR
ITS USE. THESE INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, YOUR EMPLOYER AND GOVERNMENT REGULATIONS. YOU
CAN GET INJURED IF YOU DO NOT USE PPE. GET INSTRUCTIONS FROM
YOUR EMPLOYER ON WHICH PPE IS NECESSARY.
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL.
A. Apply the teflon tape to the repair area. Fig 202 shows the
dimensions of the area to be covered with the tape (Repair of 2 ply
damage shown).
B. Make the surface of the repair area rough and remove the sharp
edges from the damage with the abrasive paper (CoMat 05-021). Do
not damage the carbon plies of the bulkhead.
8. Cut the repair plies (Ref Fig 202).

A. Cut the first repair ply so that it has a 2.0in. (50,8 mm) overlap
around the damage. Use carbon fabric (CoMat 08-059) and lint free
gloves (CoMat 02-097). To prevent fraying, the plies may be cut to
the finished dimensions after soaking in adhesive (Ref. step
10.C).
V2500 54-10-00 REPAIR No. 001

Page 205
Feb 1/09
B. Cut the remaining repair plies if they are required using the
carbon fabric and lint free gloves. Cut each subsequent repair ply
2.0in. (50,8 mm) longer and 2.0in. (50,8 mm) wider. There must be a
repair ply for each ply of the bulkhead which is damaged and these
must be covered by a single fiberglass ply (CoMat 02-167). To
prevent fraying, the plies may be cut to the finished dimensions
after soaking in adhesive (Ref. step 10.C).
9. Dry the repair area.
A. Dry the repair area. Use the heat lamp to keep the repair area of
the bulkhead at 176oF (80oC) for six hours. The repair materials
must be applied at the end of the six hours.
10. Prepare the repair materials (Ref Fig 202).
A. Mix the EA9390 adhesive (CoMat 08-050) in accordance with

manufacturer’s instructions.
NOTE: The weight of the adhesive needed will be approximately the

same as the weight of the carbon fabric (CoMat 08-059). After
the plies are soaked, the remaining adhesive is used on the
repair area (Ref. step 13.).
B. Put each ply on a sheet of non-porous parting film (CoMat 02-168).

Use the brush (CoMat 02-087) to apply the adhesive to the two sides
of each ply. Put another layer of parting film on the plies and
roll the adhesive into the carbon plies and the fiberglass ply so
that they are fully soaked. Do not remove the parting film until
the installation procedure.
V2500 54-10-00 REPAIR No. 001

Page 206
Feb 1/09
C. Cut approximately 1.0 in. (25,4 mm) off each edge of the plies.
Make sure the first ply has a 1.0 in. (25,4 mm) overlap around the
damage. The overlap for each subsequent ply must be 1.0 in.
(25,4 mm). Cut the corners of the repair plies to an angle of
approximately 45 degrees with a length of approximately 0.5 in.
(12,7 mm). Cut the last (fiberglass) ply to the shape defined by
the teflon tape (CoMat 02-007).
11. Clean the repair area.
A. The repair area must be cool after the drying procedure. Clean the
repair area with methylethylketone (CoMat 01-076) using lint free
cloth (CoMat 02-099). Wipe the area with a piece of clean lint free
cloth before the fluid dries.
12. Fill the damaged area.

manufacturer’s instructions. When fully mixed, add the phenolic
microballoons (CoMat 02-164) to the mixture: 5 parts (by weight) of
the microballoons to 100 parts (by weight) of the mixture
B. Fill the damage with the mixture using a clean metal spatula. The
filled damage must be level with the existing carbon plies of the
repair area.
V2500 54-10-00 REPAIR No. 001

Page 207
Feb 1/09
13. Install the repair plies (Ref Fig 202).
A. Apply an even layer of EA9390 adhesive (Ref step 10.A.) to the

repair area using the brush (CoMat 02-087).
B. Remove the parting film from one side of the first repair ply and
position the ply over the damage with the adhesive side down. Make
sure the damage is located in the center of the ply. Use the roller
to remove air caught in the adhesive. Remove the remaining parting
film.
NOTE: Make sure that the ply fibres are at 90 degrees to the first
damaged ply.
C. Remove the parting film from one side of the second repair ply (if
it is required) and position it over the repair area with the
adhesive side down. Make sure it has an equal overlap around the
first ply. Use the roller to remove the air caught in the adhesive.
Remove the remaining parting film.
NOTE: Make sure that the ply fibres are at 90 degrees to each
other.
D. Repeat step C. for remaining repair plies, if any.
NOTE: The last repair (sanding) ply must touch the teflon tape
(CoMat 02-007) all around.
E. Remove unwanted adhesive from the teflon tape with a clean metal
spatula.
14. Prepare to cure the adhesive (Ref. Fig 203).
A. Get a heat blanket which is larger than the repair area.
B. Cut the porous parting film (CoMat 02-169). Make sure that the film
is larger than the heat blanket and overlaps the last (fiberglass)
repair ply by at least 3.0 in. (76,2 mm) all around.
V2500 54-10-00 REPAIR No. 001

Page 208
Feb 1/09
C. Cut the breather fabric (CoMat 08-057) into pieces the same size as
the porous parting film (Ref step B. above). The number of pieces
must equal the number of plies used in the repair.
D. Put the porous parting film on to the repair area so that it has an
equal overlap. Put the breather fabric on top of the porous parting
film. Use one layer of breather fabric for each repair ply used.
E. Cut a piece of non-porous parting film (CoMat 02-168) and a piece

of silicone rubber sheet (CoMat 02-170). The two pieces must be
2.0in. (50,8 mm) larger than the breather fabric installed in step
D. above.
F. Put four fiberglass tows onto the repair area using one strand of
the fiberglass fabric (CoMat 02-167) in each of four positions
around the repair. Each of the strands must connect the breather
fabric with the area around the silicone rubber sheet.
NOTE: With the fiberglass tows installed, gasses can not collect
below the silicone rubber sheet when the adhesive cures.
G. Put the non-porous parting film (Ref step E. above) onto the repair
area first. Make sure that it has an equal overlap around the
repair area. Put the silicone rubber sheet on top of the non-porous
parting film.
H. Cut two pieces of breather cloth (CoMat 02-166), at least 2.0 in.
(50,8 mm) larger on each side than the silicone rubber sheet. Put
the two pieces of the breather cloth on to the repair area. Put the
heat blanket on top of the breather cloth. The heat blanket must
have an overlap all around the repair area.
I. Put at least two temperature probes on to the teflon tape adjacent

to the repair area.
J. Put the nylon bagging film (CoMat 02-163) over the repair area so
that the bag overlaps the breather cloth by 2.0 in. (50,8 mm) all
around. Install the vacuum hose from the suction pump so that it
goes directly on to the breather cloth. Attach and seal the film to
the bulkhead with the sealant tape (CoMat 08-051).
15. Cure the adhesive.
A. Decrease the pressure in the repair area with the vacuum suction
pump. During the cure, the reading must show at least 25.0 in.
(635,0 mm) of mercury.
V2500 54-10-00 REPAIR No. 001

Page 209
Feb 1/09
B. Increase the temperature and keep at 190o - 210oF (88o - 99oC) for
220 minutes. The rate of increase and subsequent decrease must not
be faster than 5.4oF (3oC) in each minute. Start to measure the time
for the adhesive to cure when the temperature gets to 190oF (88oC).
16. Remove the repair equipment.
A. Remove the following parts from the repair area:
the nylon bagging film with its seal and the vacuum hose;
the temperature probes; the heat blanket; the breather cloth;
the silicone rubber sheet; the non-porous parting film;
the breather fabric; the fiberglass tows; the porous parting film
and the teflon tape.
17. Prepare the repair surface.

CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE BULKHEAD. BE

CAREFUL AND ONLY REMOVE MATERIAL FROM THE TOP FIBERGLASS PLY
OF THE REPAIR. DO NOT USE A LIQUID WITH THE ABRASIVE PAPER.
A. Make the repair area smooth. The contours of the repair area must
be smooth and there must not be an edge or step, between the repair
area and the outer skin of the bulkhead. Use the abrasive paper
(CoMat 05-021).
V2500 54-10-00 REPAIR No. 001

Page 210
Feb 1/09
A. Remove unwanted material with a suction cleaner.
B. Clean the repair area with methylethylketone (CoMat 01-076) and

lint free cloth (CoMat 02-099). Wipe the area with a clean piece of
lint free cloth before the fluid dries.
19. Make an inspection of the repair.
A. Do a visual inspection to make sure that the repair has been done
in accordance with these procedures.
B. Inspect the repaired area using IAE 1N20444 tapping tool and the
tap test method, SRM 54-01-00 Composite Structure Tap Test, to
confirm that the repair is correctly bonded.
20. Apply the surface protection.
A. Apply the surface protection to the repair area

(Ref. SPPM TASK 70-38-07-380-501).
21. Identify the repair.
A. Ident the component/log book with the repair no. VRS2803)

(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-10-00 REPAIR No. 001

Page 211
Feb 1/09
Location of Repair Area

Fig. 201
V2500 54-10-00 REPAIR No. 001

Page 212
Feb 1/09
Surface Damage Buildup Repair (Typical)

Fig. 202
V2500 54-10-00 REPAIR No. 001

Page 213
Feb 1/09
Repair Equipment Installation

Fig. 203
V2500 54-10-00 REPAIR No. 001

Page 214
Feb 1/09
REPAIR NO. 002

AIR INTAKE COWL DELAMINATION REPAIR
VRS2816
1. General.
A. This repair may be used to contain the early stages of local

delamination in the plies of the outer barrel. It applies only
where no actual rupture (discontinuity) of the plies is found.
B. The damage must not be more than 3.0 in. (76,2 mm) long or wide. If
the damage is less than 1.5 in. (38,1 mm) from the edge do
REPAIR No.003 (VRS2817). There must be a minimum of 10.0 in.
(254,0 mm) between damaged areas.
C. This repair must be done in a room with a controlled temperature of

percent or less.
D. Damage which is not in the limits of this repair must be referred

to Goodrich.
54-01-00 Structural Repair Manual (SRM)

(VRS2817)
(SPPM)

B. Consumable materials (Ref. Overhaul Processes and Consumables

Index).

CoMat 02-099 Lint-free cloth
CoMat 02-122 Temporary marker
CoMat 02-162 Syringe, injection
V2500 54-10-00 REPAIR No. 002

Page 201
Feb 1/09
C. Special Tools

IAE 1N20406 Rotatable Dolly - Inlet Cowl
D. Repair parts
None.
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Aft Intake Cowl Composite structure
4. Handling and positioning of the cowl.
PROCEDURE.
CAUTION: BE CAREFUL NOT TO DAMAGE THE EDGES AND CORNERS OF THE COWL.
A. Attach the lifting sling (1N20403) to the cowl and position it so

the repair area is lying horizontally.
A. Clean the damaged area with the methylethylketone (CoMat 01-076)

and lint free cloth (CoMat 02-099). Wipe the area with a clean
piece of lint free cloth before the fluid dries.
V2500 54-10-00 REPAIR No. 002

Page 202
Feb 1/09
6. Examine the outer barrel (Ref. Fig. 201 and 202).
A. Determine the extent of the delamination using the sonic test

equipment (1N20444) and the tap test method, SRM 54-01-00 Composite
Structure Tap Test, and mark the approximate outline of the area
using a soft pencil. If the length or width is more than 3.0 in.
(76,2 mm) refer to IAE.
B. At the two farthest points make a mark for drilling. Use a

temporary marker (CoMat 01-122).
7. Prepare the outer barrel for repair (Ref. Fig. 202).

DO THIS TASK. BEFORE YOU USE PPE, READ UNDERSTAND AND OBEY
NECESSARY.
A. With a hand drill, drill a 0.062 in. (1,58 mm) diameter hole at
each of the marked positions. Drill the hole to the depth of the
delamination.
B. Remove all of unwanted material using a suction cleaner.
the outer skin at 176oF (80oC) for six hours. The repair materials

V2500 54-10-00 REPAIR No. 002

Page 203
Feb 1/09
B. After removing the heatlamps used previously for drying the repair
area, fill a suitable disposable syringe (CoMat 02-162) with the
adhesive.
C. Put the syringe into one of the drilled holes and slowly inject the
adhesive until it starts to come through the other drilled hole.
A. Remove all unwanted material with a suction cleaner.

lint-free cloth (CoMat 02-099). Wipe the area with a clean piece of
lint-free cloth before the fluid dries.
A. Using a heatlamp, increase the temperature and keep at 190o - 210oF

(88o - 99oC) for 220 minutes. The rate of increase and subsequent
decrease must not be faster than 5.4oF (3oC) in each minute. Start
to measure the time for the adhesive to cure when the temperature
gets to 190oF (88oC).
B. Using the sonic test equipment (1N20444) and the tap test method,
SRM 54-01-00 Composite Structure Tap Test, examine the repair for
any signs of incomplete filling/delamination.
C. If the filling is found to be incomplete or delamination is found,

repeat steps 7. through 11.
V2500 54-10-00 REPAIR No. 002

Page 204
Feb 1/09
A. Ident the component/log book with the repair no. VRS2816

(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-10-00 REPAIR No. 002

Page 205
Feb 1/09

Fig. 201
V2500 54-10-00 REPAIR No. 002

Page 206
Feb 1/09
Repair a Delamination (Typical)

Fig. 202
V2500 54-10-00 REPAIR No. 002

Page 207
Feb 1/09
V2500 54-10-00 REPAIR No. 002

Page 208
Feb 1/09
REPAIR NO. 003

AIR INTAKE COWL EDGE DELAMINATION REPAIR
VRS2817
1. General.

delamination in the plies of the outer barrel edge landings. It
applies only where no actual rupture (discontinuity) of the plies
is evident.
B. The damage can be along the full length of the aft edge, but must
not be more than 0.38 in. (9,7 mm) from the outer skin aft edge and
1.50 in. (38,1 mm) long by 0.50 in. (12,7 mm) from the access panel
recess edges. Only one repair for each access panel recess edge is
permitted. Refer to Fig. 201.

percent or less.

to Goodrich.

(VRS2816)
(SPPM)

V2500 54-10-00 REPAIR No. 003

Page 201
Feb 1/09

Index).

C. Special Tools

D. Repair parts
None.
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Aft Intake Cowl Composite structure
PROCEDURE.

V2500 54-10-00 REPAIR No. 003

Page 202
Feb 1/09

6. Examine the intake cowl edges (Ref. Fig. 202).

equipment (1N20444) and the tap test method, SRM 54-01-00
Composite Structure Tap Test, and mark the approximate outline of
the area using a soft pencil.

adhesive.
V2500 54-10-00 REPAIR No. 003

Page 203
Feb 1/09
C. Slowly inject the adhesive with the syringe into the delaminated
area until the adhesive begins to flow out from the edges of the
plies.
A. Clean the repair area with methylethylketone (CoMat 01-076) and


any signs of incomplete filling and or delamination.
C. In the event filling is found to be incomplete or delamination is

found, repeat steps 7. through 11.
V2500 54-10-00 REPAIR No. 003

Page 204
Feb 1/09
A. Ident the component/log book with the REPAIR no. VRS2817

(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-10-00 REPAIR No. 003

Page 205
Feb 1/09

Fig. 201
V2500 54-10-00 REPAIR No. 003

Page 206
Feb 1/09
Repair a Delamination (Typical)

Fig. 202
V2500 54-10-00 REPAIR No. 003

Page 207
Feb 1/09
V2500 54-10-00 REPAIR No. 003

Page 208
Feb 1/09
REPAIR NO. 004

AIR INTAKE COWL AFT BULKHEAD HONEYCOMB REPAIR
VRS2802
1. General.
A. This repair is applicable to A1, A1 Hybrid and A5 (serial no. N5001

to N7353) composite aft bulkheads only.
B. This repair applies to damage through the composite plies and into
the honeycomb core of the aft bulkhead.
C. The damage (which includes cracks) must be more than (2 repair

plies + 1 sanding ply + fire protection plate + 0.05 in. (1,3 mm)
edge clearance) 3.8 in. (96,5 mm) from the edge of the fittings,
the brackets, the flanges and the tapered sections of the bulkhead.
It must be confined to an area of 2.0 in. (50,8 mm) diameter or
less. There must be a minimum of 10.0 in. (254,0 mm) between
damaged areas.
NOTE: A fire protection plate is not necessary on the A1 aft

bulkhead installation, but is necessary A1 Hybrid (serial
no. V299 and sub) and A5 installations. Thus, the minimum
edge distance on A1 can be 2.75 in. (69,9 mm).
NOTE: On the A1 hybrid (serial no. V299 and sub) and A5 Air Intake
Cowl (serial no. N5001 to N7353), do not use this repair on
the titanium plate. Refer to Fig. 201.
D. The carbon fibre repair plies must be at 90 degrees to each other.

percent or less.
F. Damage which is not in the limits of this repair must be referred

to Goodrich.

(SPPM)
(SPPM)
V2500 54-10-00 REPAIR No. 004

Page 201
Feb 1/09

Vacuum suction pump, range 0-30 in. (0-762 mm) of mercury
Suction cleaner
B. Special Tools


Index).

CoMat 08-021 Epoxy paste adhesive, EA934NA
CoMat 08-063 Aluminium honeycomb core
CoMat 08-072 Potting compound
CoMat 12-012 Cushioning felt
V2500 54-10-00 REPAIR No. 004

Page 202
Feb 1/09
D. Repair parts
--------------------------------------------
PART NO. PART IDENT
--------------------------------------------
AMS 5516 CRES, Stainless steel
0.006 in. (0,15 mm)
MBF2110S(5) Composi-Lok
NAS-1587-A3C Washer
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Aft bulkhead Carbon fiber composite
honeycomb core sandwich
4. Position the air intake cowl ready for repair.
PROCEDURE.
CAUTION: BE CAREFUL WHEN YOU MOVE THE COWL. DO NOT POSITION THE COWL
DIRECTLY ON TO A HARD SURFACE.
A. Put a layer of the felt, (CoMat 12-012), approximately 1.5 in.

(38,1 mm) thick, on to a smooth surface. Make sure there is no
unwanted material on or below the felt which will cause damage to
the cowl. Using a 1N20403 sling, put the cowl on to the felt. The
damaged area must be positioned horizontally.
5. Examine the damaged area (Ref. Fig. 201 and 202).
A. Examine the damaged area to assess the amount of damage. The damage
must not be more than the limits.
V2500 54-10-00 REPAIR No. 004

Page 203
Feb 1/09
6. Remove the outer plies, the honeycomb, and the inner plies from the
damaged area (Ref. Fig. 202 and 205).

CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE BULKHAED. ONLY
REMOVE MATERIAL FROM THE EDGE OF THE OUTER PLY. DO NOT USE A
LIQUID WITH THE WATERPROOF SILICON CARBIDE ABRASIVE PAPER.
A. Use a marking pen (CoMat 06-131) to make a mark around all of the
damage including cracks and areas of delamination. Make sure that
the cut-out is a regular shape and has a radius of at least 0.5 in.
(12,7 mm).
B. Calculate the distance that a strip of teflon tape must be

positioned from the damage area identified in step A as follows:
Measure 1.0 in. (25,4 mm) from the edge of the area for each of the
outer plies (the bulkhead has two outer plies) and add 0.75 in.
(19,05 mm) for an outer layer of fiberglass cloth (CoMat 02-167).
Apply the teflon tape (CoMat 02-007) so that it goes around the
repair area. Make the corners of the strip of tape have a radius at
least 0.5 in. (12,7 mm).
C. Make the surface of the repair area rough. Do not cause damage to
the carbon plies of the bulkhead. Use the abrasive paper
(CoMat 05-021).
D. Use a high speed rotary cutter to remove the outer plies, the
honeycomb and the inner plies from the area identified in step A.
Carefully remove the resin which holds the honeycomb to the inner
plies. Make sure you do not cause delamination.
V2500 54-10-00 REPAIR No. 004

Page 204
Feb 1/09
A. Use a suction cleaner to remove the unwanted material from the

repair area and from between the forward and aft bulkheads of the
cowl.
B. Clean the damage and repair area of the bulkhead. Use

methylethylketone (CoMat 01-076) and lint-free cloth
(CoMat 02-099). Wipe the area with a clean piece of lint-free cloth
before the fluid dries.
8. Prepare the repair materials (Ref. Fig. 202).

A. Wear lint-free gloves (CoMat 02-097) and cut three plies of carbon
fabric (CoMat 08-059) so that it has 1.5 in. (38,1 mm) overlap all
around the cut-out.
NOTE: To prevent fraying, cut the plies to their finished

dimensions after they are soaked with adhesive.
V2500 54-10-00 REPAIR No. 004

Page 205
Feb 1/09
B. Mix the EA9390 adhesive (CoMat 08-050) in accordance with the


same as the weight of the carbon fabric (CoMat 08-059).
C. Prepare the support plate plies.
(1) Put each ply on a sheet of non-porous parting film

(CoMat 02-168).
(2) Apply the adhesive to each ply with the brush (CoMat 02-087)
and cover each ply with another sheet of non-porous parting
film.
(3) Use the roller to force the adhesive into each ply
thoroughly.
(4) Cut each ply so that it has an overlap of approximately

1.0 in. (25,4 mm) around the cut-out in the inner plies.
NOTE: Make sure that the width of the carbon ply is not more
than the length of the cut-out. This is to allow the
support plate to be inserted through the cut-out in the
lower plies.
D. Put the plies together to make the support plate.
(1) Remove the non-porous parting film from one side of two of
the carbon plies.
(2) Remove the non-porous parting film from each side of the
third carbon ply.
(3) Align the three carbon plies and put them with their adhesive
sides together onto a hard, flat surface.
(4) Use the roller to remove unwanted adhesive and air from the
three carbon plies.
V2500 54-10-00 REPAIR No. 004

Page 206
Feb 1/09
9. Prepare to cure the adhesive (Ref. Fig. 203).
A. Get a heat blanket which must be larger all around than the support
plate.
B. Cut a sheet of porous parting film (CoMat 02-169) making sure that
it is larger than the heat blanket and has an overlap of at least
3.0 in. (76,2 mm) around the support plate.
C. Cut one sheet of breather fabric (CoMat 08-057) for each carbon ply
on the support plate. Make sure that the breather fabric has the
same dimensions as the porous parting film.
D. Remove the top layer of the non-porous parting film (CoMat 02-168)
from the support plate.
E. Put the porous parting film (CoMat 02-169) onto the support plate,
making sure that it has an equal overlap around the support plate.
Put the layers of breather fabric on top of the porous parting
film.
F. Cut the non-porous parting film (CoMat 02-168) and silicon rubber
sheet (CoMat 02-170), making sure that the two pieces of material
have an overlap of 2.0 in. (50,8 mm) around the breather fabric
installed in step E above.
G. Put four fiberglass tows onto the repair area using one strand of
H. Put the non-porous parting film (Ref. step F) onto the support
plate. Make sure that it has an equal overlap around the support
plate. Put the silicone rubber sheet on top of the non-porous
parting film.
I. Put the heat blanket and breather cloth onto the support plate.
(1) Cut two sheets of breather cloth (CoMat 02-166), at least

2.0 in. (50,8 mm) larger on each side than the silicone
rubber sheet.
(2) Put the two sheets of breather cloth on top of the silicone
rubber sheet.
V2500 54-10-00 REPAIR No. 004

Page 207
Feb 1/09
(3) Put the heat blanket on top of the breather cloth, making
sure that the heat blanket has an overlap all around the
support plate.
J. Put at least two temperature probes on the teflon tape adjacent to

the support plate.
K. Install the vacuum bag.
(1) Use nylon bagging film (CoMat 02-163) and sealant tape
(CoMat 08-051).
(2) Make sure that sure the vacuum bag has an overlap of
approximately 2.0 in. (50,8 mm) around the breather cloth.
(3) Install the vacuum hose, from the suction pump, so that it
goes directly onto the breather cloth.
(4) Attach and seal the vacuum bag to the cowl with the sealant
tape.
10. Cure the adhesive (Ref. Fig. 203).
A. Use the vacuum suction pump to decrease the pressure in the repair
area. Make sure it gives an indication of at least 25.0 in.
(635,0 mm) of mercury while the adhesive cures.
B. Use the heat blanket to keep the temperature of the repair area at
190o - 210oF (88o - 99oC) for 220 minutes.
C. The rate of temperature increase and subsequent decrease must not

be greater than 5.4oF (3oC) in each minute.
D. Start to measure the cure time when the temperature reaches 190oF
(88oC).
A. When the cure process is completed, remove the lay-up materials

from the support plate.
12. Drill the lockwire holes (Ref. Fig. 204).
A. Drill two pairs of holes 0.050 in. (1,27 mm) diameter, a sufficient
distance apart to attach the support plate to a clamp bar with
lockwire.
V2500 54-10-00 REPAIR No. 004

Page 208
Feb 1/09
the bulkhead at 176oF (80oC) for six hours. The repair materials
14. Install the support plate (Ref. Fig. 204).
A. Attach the lockwire (CoMat 02-127) to the support plate. Make sure
there is sufficient lockwire to hold during the installation and
that the assembly can not fall into the cowl.
B. Mix the EA934NA adhesive (CoMat 08-021) in accordance with the

C. Apply an equal layer of adhesive to the support plate and the

bulkhead interface using the brush (CoMat 02-087).
D. Put the support plate through the cut-out and onto the inner
surface of the bulkhead. Make sure the plate has an equal overlap
around the cut-out. Put a bar across the repair area and attach the
lockwire to the bar. Tighten the lockwire to hold the support plate
in the correct position.
E. Cure the adhesive as follows:
Gradually increase the temperature with the heat lamp; the rate of
the increase mist not exceed 5.4oF (3oC) in each minute. Keep the
temperature at 190o - 210oF (88o - 99oC) for 1 hour. Start to
measure the curing time when the temperature gets to 190oF (88oC).
F. Remove the lockwire and the bar.
V2500 54-10-00 REPAIR No. 004

Page 209
Feb 1/09
15. Prepare the filler plies, the repair plies, and the honeycomb
(Ref. Fig. 204 and 205).

A. Wear lint-free gloves (CoMat 02-097) and cut the lower filler
plies:
Two plies of carbon fabric (CoMat 08-059) and one ply of fiberglass
fabric (CoMat 02-167). The lower filler plies must overlap the cut-
out in the bulkhead inner skin by 1.0 in. (25,4 mm) all around.
Wear lint free gloves (CoMat 02-097) and cut the upper filler
plies:
fabric (CoMat 02-167). The upper filler plies must overlap the cut-
out in the bulkhead outer skin by 1.0 in. (25,4 mm) all around.
Wear lint free gloves (CoMat 02-097) and cut the repair plies:
fabric (CoMat 02-167). Cut the first repair ply so that it has a
2.0 in. (50,8 mm) overlap around the cut-out in the bulkhead outer
plies. Cut each subsequent repair ply 2.0 in. (50,8 mm) longer and
2.0 in. (50,8 mm) wider.
NOTE: To prevent fraying, the plies may be cut to the finished

dimensions after soaking in resin.
B. Cut the repair plug from the honeycomb (CoMat 08-063, 08-065,
08-066) to be a good fit in the repair hole. Use lint-free gloves
(CoMat 02-097).
V2500 54-10-00 REPAIR No. 004

Page 210
Feb 1/09
16. Install the lower filler plies (Ref. Fig. 204 and 205).
A. Mix the EA9390 adhesive (CoMat 80-050) in accordance with the

manufacturer’s instructions. Make sufficient adhesive to soak and
install the lower filler plies.
B. Put each filler ply onto a sheet of non-porous parting film (CoMat
02-168). Use the brush (CoMat 02-087) to apply the adhesive to the
two sides of each ply. Put another layer of parting film on these
plies and roll the adhesive into the plies so that they are fully
soaked. Do not remove the parting film until the installation
procedure.
C. Cut each lower filler ply to be a good fit in the cut-out. They
must be flat on the support plate and have the same shape as the
cut-out. The edges of the plies must not overlap on the sides of
the cut-out.
D. Remove the non-porous parting film from one side of the first
carbon filler ply. Put the ply into the cut-out, adhesive side
down. The ply must be located correctly and flat against the
support plate. Remove the remaining non-porous parting film and
use a clean metal spatula to keep the ply flat on the support
plate. Repeat this step for the second carbon filler ply and
fiberglass filler ply. Make sure that the plies are flat and
located correctly.
increase must not exceed 5.4oF (3oC) in each minute. Keep the
temperature at 190o - 210oF (88o - 99oC) for 220 minutes. Start to
When the adhesive has cured, remove the non-porous parting film.
V2500 54-10-00 REPAIR No. 004

Page 211
Feb 1/09
17. Install the honeycomb plug (Ref. Fig. 204).
A. Mix the potting compound (CoMat 08-072) in accordance with the

manufacturer’s instructions
B. Fill the open cells of the honeycomb in the aft bulkhead and the
repair plug with potting compound. Use a clean metal spatula and
make sure all of the cells are filled.
C. Install the honeycomb plug into the hole and make sure it is flat
against the inner plies. Use a clean metal spatula to remove
unwanted potting compound and make the surface smooth.
D. Cure the potting compound as follows:
temperature at 113o - 131oF (45o - 55oC) for between one and two
hours. Start to measure the curing time when the temperature gets
to 113oF (45oC).

lint free cloth (CoMat 02-099). Wipe the area with a piece of clean
V2500 54-10-00 REPAIR No. 004

Page 212
Feb 1/09
19. Install the upper filler plies and the repair plies (Ref. Fig. 205).

install the upper filler plies.

same weight of the carbon and the fiberglass plies. After the
plies are soaked, the remaining adhesive is used on the
repair area.
B. Put each filler ply onto a sheet of non-porous parting film

(CoMat 02-168). Use the brush (CoMat 02-087) to apply the adhesive
to the two sides of each ply. Put another layer of parting film on
the plies and roll the adhesive into the carbon plies so that they
are fully soaked. Do not remove the parting film until the
installation procedure.
C. Cut each upper filler ply to be a good fit in the cut-out of the
outer skin. They must be flat on the honeycomb plug and have the
same shape as the cut-out. The edges of the plies must not overlap
on the edges of the cut-out.
D. Cut the first carbon repair ply to its finished dimensions so that
it overlaps the cut-out in the outer skin by 1.0 in. (25,4 mm) all
around. Cut the second carbon ply to overlap the first by 1.0 in
(25,4 mm). Cut the fiberglass repair ply so that it has the same
shape as the area defined by the teflon tape.
E. Apply an equal layer of adhesive to the top of the honeycomb plug

using the brush (CoMat 02-087).
F. Remove the non-porous parting film from one side of the fiberglass
filler ply. Put the ply into the cut-out resin side down. The ply
must be located correctly and flat against the honeycomb plug.
Remove the remaining non-porous parting film and use a clean metal
spatula to keep the ply flat on the plug. Repeat this step for the
first and second carbon filler plies. Make sure that the plies are
flat and located correctly.
V2500 54-10-00 REPAIR No. 004

Page 213
Feb 1/09
G. Remove the parting film from one side of the first carbon repair
ply and position it over the damage with the adhesive side down.
Make sure that the damage is located in the centre of the ply. Use
the roller to remove air caught in the adhesive. Remove the
remaining parting film.
NOTE: Make sure that the ply fibres are at 90 degrees to the first
damaged ply.
H. Remove the parting film from one side of the second carbon repair
ply and position it over the repair area with the resin side down.
Make sure it has an equal overlap around the first ply. Use the
roller to remove air caught in the resin. Remove the remaining
parting film.
other.
I. Remove the parting film from one side of the fiberglass repair ply
and position it over the repair area with the adhesive side down.
Make sure it has an equal overlap around the last ply.
NOTE: The fiberglass repair ply must touch the teflon tape.
J. Use the roller to remove air caught in the adhesive. Remove the
remaining parting film. Remove unwanted adhesive from the teflon
tape with a clean metal spatula.
A. Get a heat blanket, which must be larger all around than the repair
area.
is larger than the heat blanket and has an overlap of at least
3.0 in. (76,2 mm) all around.
C. Cut one sheet of breather fabric (CoMat 08-057) for each carbon and
fiberglass ply on the repair area, excluding the filler plies. Make
sure that the breather fabric has the same dimensions as the porous
parting film.
D. Put the porous parting film on to the repair area, making sure it
has an equal overlap around the repair area. Put the layers of
breather fabric on top of the porous parting film.
V2500 54-10-00 REPAIR No. 004

Page 214
Feb 1/09
E. Cut the non-porous parting film (CoMat 02-168) and silicone rubber
sheet (CoMat 02-170). The two pieces must be 2.0 in. (50,8 mm)
larger than the breather fabric installed in step D. above.
G. Put the non-porous parting film (Ref. step E) onto the repair area
making sure that it has an equal overlap around the repair area.
Put the silicone rubber sheet on top of the non-porous parting
film.
H. Put the heat blanket and breather cloth onto the repair area.

rubber sheet.
(2) Put the two sheets of breather cloth onto the repair area.
repair area.
I. Put at least two temperature probes on to teflon tape adjacent to

the repair area.
J. Install the vacuum bag onto the repair area.
(CoMat 08-051).
(2) Make sure that the vacuum bag has an overlap of approximately
2.0 in. (50,8 mm) around the breather cloth.
goes directly on to the breather cloth.
(4) Attach and seal the film to the cowl with the sealant tape.
V2500 54-10-00 REPAIR No. 004

Page 215
Feb 1/09
area making sure it gives an indication of at least 25.0 in.

D. Start to measure the cure time when the temperature gets to 190oF
(88oC).
A. When the cure is completed, remove the lay-up materials from the
repair.

CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. BE

be smooth and there must not be an edge or step between the repair
(CoMat 05-021)
V2500 54-10-00 REPAIR No. 004

Page 216
Feb 1/09
A. Remove unwanted materials from the repair area with a suction

cleaner.

lint free cloth before the solvent evaporates.
tap test method, (Ref. SRM 54-01-00) Composite Structure Tap
Test, to confirm that the repair is correctly bonded.
26. Make the fire protection plate (A1 hybrid (serial no. V299 and sub) and
A5 aft bulkheads only).

A. Make the fire protection plate from CRES, stainless steel

(AMS 5516). Cut the fire protection plate so that it has a 1.0 in.
(25,4 mm) overlap around the last repair ply.
B. Make the fire protection plate align with the contour of the
structure in the repair area. The plate must fit the contour with
light finger pressure. Make sure a minimum distance of 0.050 in.
(1,3 mm) between fire protection plate and all edges.
V2500 54-10-00 REPAIR No. 004

Page 217
Feb 1/09
C. Make a mark of the holes on the fire protection plate. The edge
distance must be a 0.5 in. (12,7 mm) minimum and the pitch must be
2.80 in. (71,1 mm) maximum. Refer to Fig. 207.
D. Using drills and drilling tools, drill the pilot holes at the
marked locations. Remove the burrs.
E. Temporarily install the fire protection plate. Use temporary

fasteners to hold the plate in position. Make sure all the holes
are aligned.
F. Drill the holes to their final size, using drills and drilling
tools. Remove all burrs.
G. Remove the fire protection plate from the repair area.
H. Remove the sharp edges using the abrasive paper (CoMat 05-021).
27. Prepare the adhesive.
A. Mix the EA934NA (CoMat 08-021) in accordance with manufacturer’s

instructions.
28. Install the fire protection plate (A1 hybrid (serial no. V299 and sub)
and A5 aft bulkheads only).
A. Apply and even layer of EA934NA (CoMat 08-021) to the repair area
V2500 54-10-00 REPAIR No. 004

Page 218
Feb 1/09
B. Put the fire protection plate into position. Make sure the holes
are aligned.
C. Attach fire protection plate with Composi-Loks (MBF2110S(5)) and

washers (NAS-1587-AC).
D. Make sure a bead of EA934NA (CoMat 08-021) is applied around the

fire protection plate.
E. Clean the repair area with methylethylketone (CoMat 01-076) and

A. Apply the surface protection to the repair area in accordance with

standard painting procedures (Ref. SPPM TASK 70-38-07-380-501).
Where fitted, do not apply surface protection to the fire
protection plate
A. Ident the component/log book with the repair no.VRS2802

(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-10-00 REPAIR No. 004

Page 219
Feb 1/09

Fig. 201
V2500 54-10-00 REPAIR No. 004

Page 220
Feb 1/09
Damage Cut-Out Dimensions

Fig. 202
V2500 54-10-00 REPAIR No. 004

Page 221
Feb 1/09
Support Plate Repair Equipment Installation

Fig. 203
V2500 54-10-00 REPAIR No. 004

Page 222
Feb 1/09
Support Plate, Filler Ply and Honeycomb Installation

Fig. 204
V2500 54-10-00 REPAIR No. 004

Page 223
Feb 1/09
Repair Ply Installation

Fig. 205
V2500 54-10-00 REPAIR No. 004

Page 224
Feb 1/09

Fig. 206
V2500 54-10-00 REPAIR No. 004

Page 225
Feb 1/09
Fire Protection Plate Installation

Fig. 207
V2500 54-10-00 REPAIR No. 004

Page 226
Feb 1/09
REPAIR NO. 005

AIR INTAKE COWL OUTER BARREL SURFACE DAMAGE REPAIR
VRS2805
1. General.
A. This repair may be used to repair damage to the outer composite

layers of the intake cowl outer barrel where rupture
(discontinuity) of the plies has occurred.
B. The damage must be more than (4 repair plies + 1 sanding ply)

4.75 in. (120,7 mm) from the edge of the panel and no more than
24.5 in. (622,3 mm) around the circumference. The damage can be
nearer to the edge if less than four plies are damaged. There must
be enough distance to install all the repair plies and sanding ply
and a minimum distance of 1.0 in. (25,4 mm) from the edge of the
damage to any outer skin attachment fastener. Refer to Para. 5A and
7A and Fig. 201 and 202. There must be a minimum of 10 in. (254,0
mm) between damaged areas. The damage must not go through all the
composite plies.
C. The carbon fibre repair plies must be at 45 degrees to each other.
D. Repairs must be carried out in a controlled environment where

temperature can be maintained between 68o - 77oF (20o - 25oC) and
humidity can be kept to 50 percent or less.
E. Where damage is beyond the scope of this repair refer to Goodrich.

(SPPM)
(SPPM)
V2500 54-10-00 REPAIR No. 005

Page 201
Feb 1/09
Heat blanket, 32o - 248oF (0o - 120oC)

Heat lamp, 176o - 194oF (80o - 90oC)
Vacuum suction pump, 0 - 30 in. (0 - 762 mm) of mercury
Temperature probes, 32o - 248oF (0o - 120oC)
Steel roller, 2.0 in. (50,8 mm) diameter, 2.0 in. (50,8 mm) long
Suction cleaner
B. Special Tools

C. Consumable materials (Ref Overhaul Processes and Consumables Index

(PCI)).

CoMat 02-170 Silicon rubber sheet
D. Repair parts
None.
V2500 54-10-00 REPAIR No. 005

Page 202
Feb 1/09
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Air intake cowl Carbon fiber composite
PROCEDURE.
CAUTION: BE CAREFUL NOT TO CAUSE DAMAGE TO THE EDGES AND THE CORNERS
OF THE COWL.
A. Attach the lifting sling to the cowl and with the aid of the
rotatable dolly position the cowl so that it is lying horizontally.
A. Referring to Fig. 201 and 202 examine the repair area to assess the
amount of damage and, using the standard workshop tools, measure
the depth of the damage. Do this in several places where the extent
of the damage permits. From this information the number of repair
plies should be calculated as follows:

More than 0.46in. (1,17 mm) 4 + fiberglass ply (Sanding)
fully penetrated the panel, repair is beyond the scope of this
document. In this event reference must be made to alternative
repair procedures.
V2500 54-10-00 REPAIR No. 005

Page 203
Feb 1/09
A. Using the methylethylketone (CoMat 01-076) applied with the lint

free cloth (CoMat 02-099), wipe the repair area clean. Dry the
area, while it is still wet, with a fresh piece of the lint free
cloth.
7. Prepare the Repair Area (Ref. Fig. 201 and 202).
A. With reference to Fig. 201 and 202 calculate the distance for
positioning the strip of teflon tape (CoMat 02-007) from the edge
of the damage as follows (repair of 2 ply shown): from the edge of
the damaged area measure 1.0 in. (25,4 mm) from each damaged ply of
the cowl, i.e., if 4 plies damaged then measure 4.0 in. (101,6 mm)
from the edge of the damaged area. Add 0.75 in. (19,05 mm) for an
outer layer of fiberglass fabric (CoMat 02-167). Apply the teflon
tape so that it goes around the repair area in a 2.0 in. (50,8 mm)
wide strip. Make the corners at an angle of approximately 45
degrees and approximately 1.0 in. (25,4 mm) length of side.
B. Remove the sharp edges of the damage using the abrasive paper
(CoMat 05-021) and, with a fresh piece of the abrasive paper, make
the surface of the repair area rough.
8. Cut the repair plies (Ref. Fig. 201).

A. Cut the first repair ply so that it has a 2.0 in. (50,8 mm) overlap
the finished dimensions after soaking in adhesive (Ref. step 10.C).
V2500 54-10-00 REPAIR No. 005

Page 204
Feb 1/09
B. Cut the remaining repair plies if they are required. Use the carbon
fabric and lint free gloves. Cut each subsequent repair ply 2.0in.
(50,8 mm) longer and 2.0in. (50,8 mm) wider. Cut the last ply
(sanding ply) from fiberglass fabric to give a 1.0in. (25,4 mm)
overlap beyond the teflon tape. There must be a repair ply for each
ply of the panel which is damaged and these must be covered by a
single fiberglass ply. To prevent fraying, the plies may be cut to
the finished dimensions after soaking in adhesive (Ref step 10.C).
the panel at 176oF (80oC) for six hours. The repair materials must
be applied at the end of the six hours.
10. Prepare the repair materials (Ref. Fig. 201 and 202).


repair area (Ref step 13.).

roll the adhesive into the carbon plies so that they are fully
procedure.
V2500 54-10-00 REPAIR No. 005

Page 205
Feb 1/09
(12,7 mm). Cut the last ply (fiberglass) to the shape defined by
A. Mix the EA9390 (CoMat 08-050) in accordance with manufacturer’s

instructions.
B. Fill the damage with the adhesive using a clean metal spatula. The
filled damage must be level with the outermost existing carbon ply
of the repair area.
V2500 54-10-00 REPAIR No. 005

Page 206
Feb 1/09
13. Install the repair plies (Ref. Fig. 202).

sure the damage is located in the center of the ply and at 45
degrees to the damaged ply. Use the roller to remove air caught in
the adhesive. Remove the remaining parting film.
other.
spatula.
14. Prepare to cure the adhesive (Ref. Fig. 203)
V2500 54-10-00 REPAIR No. 005

Page 207
Feb 1/09
film. Use one layer of breather fabric for each carbon ply used in
the repair.

2.0 in. (50,8 mm) larger than the breather fabric installed in step
D. above.
parting film.

to the repair area.
15. Cure the adhesive
V2500 54-10-00 REPAIR No. 005

Page 208
Feb 1/09
be faster than 5.4oF (3oC) in each minute. Start to measure the
time for the adhesive to cure when the temperature gets to 190oF
(88oC).
16. Remove the repair equipment
The nylon bagging film with its seal and the vacuum hose; the
temperature probes; the heat blanket; the breather cloth; the
silicone rubber sheet; the non-porous parting film; the breather
fabric; the fiberglass tows; the porous parting film and the teflon
tape.
17. Prepare the repair surface


area and the outer skin of the panel. Use the abrasive paper (CoMat
05-021).
V2500 54-10-00 REPAIR No. 005

Page 209
Feb 1/09

20. Apply the surface protection

(Ref. SPPM TASK 70-38-07-380-501).

(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-10-00 REPAIR No. 005

Page 210
Feb 1/09

Fig. 201
V2500 54-10-00 REPAIR No. 005

Page 211
Feb 1/09

Fig. 202
V2500 54-10-00 REPAIR No. 005

Page 212
Feb 1/09

Fig. 203
V2500 54-10-00 REPAIR No. 005

Page 213
Feb 1/09
V2500 54-10-00 REPAIR No. 005

Page 214
Feb 1/09
CANCELLATION NOTICE
REPAIR No. 006 VRS2814
THE ABOVE SRM REPAIR HAS BEEN CANCELLED AND SHOULD NO

LONGER BE APPLIED. FOR ACOUSTIC LINER HOLE REPAIRS REFER
TO VRS7504.
V2500 54-10-00 Repair No. 006

Page 201
Feb 1/09
V2500 54-10-00 Repair No. 006

Page 202
Feb 1/09
REPAIR NO. 007

AIR INTAKE COWL INNER BARREL CRACK AND DELAMINATION REPAIR
VRS2996
1. General.
A. This procedure may be used to repair damage (cracks and

delamination) to the inner barrel of the air intake cowl. On the
3-piece acoustic liner the delamination must be more than
1.5 in. (38,1 mm) from the edge of the acoustic panel. On the
2-piece acoustic liner the delamination must be more than 2.0 in.
(50,8 mm) from the edge of the acoustic panel. The delamination
must be confined to an area of 2.0 in. (50,8 mm) diameter or less.
B. This removes the damaged area, fills the repair area with epoxy
paste adhesive and then an outer ply is installed on top.
C. The damaged area must be more than 10.0 in. (254,0 mm) away from
any adjacent repairs.
D. This repair causes blockage in the acoustically treated areas. For

applicable allowable limits, refer to SRM 54-01-00, Acoustic
Treatment Blockage Area Limits.
E. Damage which is not within the limits of these repair must be

referred to Goodrich.

(SPPM)
Heat lamp, 104o - 212oF (40o - 100oC)

Temperature Probes, 32o - 248oF (0o - 120oC)
Steel Roller, 2.0 in. (50,8 mm) diameter, 2.0 in. (50,8 mm) long
Suction Cleaner
V2500 54-10-00 REPAIR No. 007

Page 201
Feb 1/09
B. Consumable Materials (Ref. Overhaul Processes and Consumables

Index)

CoMat 02-087 Brush tymex nylon
CoMat 05-021 Waterproof abrasive paper
CoMat 08-021 EA934NA Epoxy paste adhesive
CoMat 08-050 EA9390 Epoxy paste adhesive
C. Special Tools
D. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Air Intake Cowl Composite structure
4. Prepare the damaged area for repair (Ref. Figs. 201 and 202).
A. Clean the damaged area with methylethylketone (CoMat 01-076) and

lint-free cloth (CoMat 02-099). Wipe the repair area dry.
B. Inspect the damaged area using IAE 1N20444 tapping tool and the tap
test method, (Ref. SRM 54-01-00) Composite Structure Tap Test, to
find all areas of delamination.
C. Mark around the damage with a pencil and make sure all cracks and
areas of delamination are included.
V2500 54-10-00 REPAIR No. 007

Page 202
Feb 1/09
D. Put the teflon tape (CoMat 02-007) in 2.0 in. (50,8 mm) wide strips
approximately 1.0 in. (25,4 mm) away from the mark around the
damage.

NECESSARY.
E. Use hand tools and a high-speed rotary cutter to remove all the
damage (including cracks) from the facing sheet.
CAUTION: DO NOT DAMAGE THE INNER SKIN AND ADJACENT STRUCTURE WHEN YOU
REMOVE THE HONEYCOMB. IF YOU DAMAGE THE INNER SKIN AND
ADJACENT STRUCTURE YOU MAY HAVE TO DO A DIFFERNET REPAIR.
F. Use a high-speed rotary sander and remove the honeycomb from the
repair area.
G. Remove unwanted material from the repair area with a suction

cleaner. Make sure there is no unwanted material between the
acoustic structure and the outer barrel.
H. Let the repair area dry for 6 hours at 176oF (80oC) with a heat
lamp. The repair materials must be applied immediately after the 6
hours.

V2500 54-10-00 REPAIR No. 007

Page 203
Feb 1/09
6. Fill the repair cut-out (Ref. Fig. 202).
A. Mix the epoxy paste adhesive (CoMat 08-021) in accordance with the
B. Fill the repair cut-out with epoxy paste adhesive.
(1) Use the epoxy paste adhesive to fill the repair cut-out until
it is level with the facing sheet.
(2) Make sure the honeycomb cells that can be seen are filled
with epoxy paste adhesive.
C. Put a cover on top of the epoxy paste adhesive.
(1) Put a sheet of non-porous parting film (CoMat 02-367) on to

the top of the repair area.
(2) Put a cawl plate, and an applicable weight (e.g. sandbag) on

top of the non-porous parting film.
D. Cure the epoxy paste adhesive.
(1) Use heat lamps to cure the epoxy paste adhesive for 1 to 2
hours at 113o - 131oF (45o - 55oC).
(2) The rate of temperature increase and subsequent decrease must

not be greater than 5.5oF (3oC) in each minute.
E. When the repair is cool, remove the weight, the cawl plate and the
non-porous parting film.
F. Smooth the surface of the epoxy paste adhesive with waterproof

abrasive paper (CoMat 05-021).
V2500 54-10-00 REPAIR No. 007

Page 204
Feb 1/09
7. Prepare the outer ply (Ref. Fig. 202).

NECESSARY.
A. Put on lint free gloves (CoMat 02-097). Cut a piece of dry carbon
fibre fabric (CoMat 08-059) 1.0 in. (25,4mm) larger all around than
the area identified by the teflon tape.
NOTE: Make sure that the outer ply is not cut to its correct
dimension until it has been soaked with epoxy paste
adhesive.
B. Mix the epoxy paste adhesive (CoMat 08-050) in accordance with the
NOTE: After the ply is soaked, the remaining epoxy paste adhesive
(if it is kept cool) can be used in the installation
procedure.
C. Prepare the outer ply.
(1) Put the carbon fibre ply on a sheet of non-porous parting

film (CoMat 02-367).
(2) Apply the epoxy paste adhesive to the ply with the brush
(CoMat 02-087) and put a second sheet of non-porous parting
film on top.
(3) Use the roller to force the epoxy paste adhesive into the ply
thoroughly. Make sure the ply is soaked with the epoxy paste
adhesive.
V2500 54-10-00 REPAIR No. 007

Page 205
Feb 1/09
D. Cut the ply so that it is the same shape as the area identified by
the teflon tape.
NOTE: Make sure that the two pieces of non-porous parting film
stays on the ply until the installation procedure.
E. Keep the outer ply and the epoxy paste adhesive cool until the
installation procedure.
8. Install the outer ply (Ref. Fig. 202).
A. Use the brush (CoMat 02-087) and apply an equal layer of epoxy
paste adhesive (CoMat 08-050) to the area identified by the teflon
tape.
B. Put the outer ply into position.
(1) Remove one sheet of the non-porous parting film from the
outer ply.
(2) Put the outer ply, with the epoxy paste adhesive side down,
on to the repair area in the correct position for
installation. Make sure the outer ply has an equal overlap
around the repair cut-out and touches the teflon tape.
(3) Use the roller and smooth the surface of the outer ply until
all air bubbles are removed.
(4) Remove any unwanted epoxy paste adhesive with a clean metal
spatula.
(5) Put a cawl plate, and an applicable weight (e.g. sandbag) on

V2500 54-10-00 REPAIR No. 007

Page 206
Feb 1/09
C. Cure the epoxy paste adhesive.
(1) Position the temperature probes adjacent to the adhesive.
(2) Use the heat lamp to keep the temperature of the repair area
between 194o - 200oF (90o - 93oC) for 220 minutes.
(3) The rate of temperature increase and subsequent decrease

must not be greater than 5.5oF (3oC) in each minute.
(4) Start to measure the cure time when the temperature reaches
194oF (90oC).
D. When the repair area is cool, remove the lamp, temperature probes,
weight, cawl plate, teflon tape and non-porous parting film.
9. Make the edges of the outer ply smooth (Ref. Fig. 202).

NECESSARY.
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. ONLY
LIQUID WITH THE ABRASIVE PAPER.
A. Rub the edges of the outer ply, with waterproof abrasive paper
(CoMat 05-021) until smooth with the adjacent structure.
A. Remove all unwanted material with a suction cleaner. Make sure that
no particles of the materials stay in the acoustic panel.
V2500 54-10-00 REPAIR No. 007

Page 207
Feb 1/09
B. Clean the surface with methylethylketone (CoMat 01-076) and a lint-

free cloth (CoMat 02-099). Wipe the surface dry.
A. Make a visual inspection to make sure that the repair has been done
tap test method, (Ref. SRM 54-01-00) Composite Structure Tap Test,
to confirm that the repair is correctly bonded.

(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-10-00 REPAIR No. 007

Page 208
Feb 1/09
Acoustic Structure Repair Details

Fig. 201 (Sheet 1)
V2500 54-10-00 REPAIR No. 007

Page 209
Feb 1/09
Acoustic Structure Repair Details (3 Acoustic Panels)

Fig. 201 (Sheet 2)
V2500 54-10-00 REPAIR No. 007

Page 210
Feb 1/09
Acoustic Structure Repair Details (2 Acoustic Panels)

Fig. 201 (Sheet 3)
V2500 54-10-00 REPAIR No. 007

Page 211
Feb 1/09

Fig. 202
V2500 54-10-00 REPAIR No. 007

Page 212
Feb 1/09
CANCELLATION NOTICE
THE ABOVE SRM REPAIR HAS BEEN CANCELLED AND SHOULD NO

LONGER BE APPLIED. IF PREVIOUSLY ACCOMPLISHED, CONTACT
GOODRICH FOR DISPOSITION.
V2500 54-10-00 Repair No. 008

Page 201
Feb 1/09
V2500 54-10-00 Repair No. 008

Page 202
Feb 1/09
REPAIR NO. 009

AIR INTAKE COWL T2P2 PROBE ACCESS PANEL OPENING INTERFACE LAND REPAIR
VRS2844
1. General.
A. This repair may be used to repair damage to the interface land on

the nose cowl P2T2 probe access panel.
B. This repair removes the damaged area and installs carbon fibre
fill-in plies, a carbon fibre patch and a fiberglass sanding ply.
C. Only one repair is permitted on each land.
TASK 73-22-11-000-010 Aircraft Maintenance Manual (AMM)

(SPPM)
(SPPM)

Heat lamp, 32o - 212oF (0o - 100oC)
Suction cleaner
Countersink tool, 100 degree
B. Special Tools
V2500 54-10-00 REPAIR No. 009

Page 201
Feb 1/09

(PCI)).

CoMat 06-127 Metal marking crayon
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Air intake cowl Composite structure
4. Remove the access panel from the nose cowl.
A. Remove the access panel from the nose cowl

(Ref. AMM TASK 73-22-11-000-010).

lint free cloth (CoMat 02-099). Wipe the repair area dry.
V2500 54-10-00 REPAIR No. 009

Page 202
Feb 1/09
6. Prepare the damaged area for repair (Ref. Fig. 201).
A. Mark the center of the damaged area.
B. Mask around the repair area with teflon tape (CoMat 02-007).
Calculate the distance that the tape must be from the damage as
follows:
(1) Measure a minimum of 3.75 in. (95,25 mm) each side along the
panel land.
(2) On the external surface, measure 4.85 in. (123,2 mm) from the
panel edge.
(3) Measure along the skin contour, approximately 1.0 in.

(24,4 mm) from each corner, and make a mark at 45 degrees
across the two corners, using the metal marking crayon
(CoMat 06-127) to apply temporary marks to the measured
repair area.
(4) Carefully apply the teflon tape along the marks on the
measured repair area.
C. Measure the damage cut-out area.
(1) Find the center of the damaged area, measure 0.5 in.
(12,7 mm) each side along the panel land and make a mark.
(2) Measure 1.6 in. (40,6 mm) from the panel edge and make a mark
to show the panel land area.
(3) Make the two corners of the marked area to a radius of

0.25 in. (6,3 mm).
7. Remove the damaged material (Ref. Fig. 201).

NECESSARY.
A. Use standard workshop tools to carefully remove all the damaged

material from the cut-out area.
B. Make the repair area smooth with waterproof abrasive paper

(CoMat 05-021).
V2500 54-10-00 REPAIR No. 009

Page 203
Feb 1/09
A. Use heat lamps to dry the repair area. Keep the repair area at 176oF
(80oC) for six hours. The repair materials must be applied
immediately at the end of the six hours.
9. Prepare the fill-in and repair plies (Ref. Fig. 201).

NECESSARY.
A. Prepare seven fill-in plies.
(1) Wear lint-free gloves (CoMat 02-097) and cut seven pieces of
dry carbon fibre fabric (CoMat 08-059) 1.0 in. (25,4 mm)
larger all around (except at the panel edge) than the cut-out
repair area.
B. Prepare the first repair ply.
(1) Wear lint-free gloves (CoMat 02-097) and cut one piece of dry
carbon fibre fabric (CoMat 08-059) a minimum of 2.0 in. (50,8
mm) larger all around (except at the panel edge) than the
cut-out repair area.
C. Prepare the six subsequent repair plies.
(1) Wear lint-free gloves (CoMat 02-097) and cut the six
subsequent repair plies from dry carbon fibre fabric
(CoMat 08-059), each piece 0.25 in. (6,3 mm) larger all
around (except at the panel edge) than the previous piece.
D. Prepare the fiberglass sanding ply.
(1) Wear lint-free gloves (CoMat 02-097) and cut one piece of
fiberglass fabric (CoMat 02-167) so that it is 0.75 in.
(19,0 mm) larger all around (except at the panel edge) than
the largest ply.
V2500 54-10-00 REPAIR No. 009

Page 204
Feb 1/09
10. Prepare the repair area (Ref. Fig. 201).
A. Install the aluminium backing plate.
(1) Make the backing plate to the internal surface contour.
(2) Wrap a piece of non-porous parting film (CoMat 02-168)

around the backing plate.
(3) Temporarily attach the backing plate to the internal surface

side of the panel land and align it with the panel edge.
(4) Make sure that the backing plate has a good contour with the
panel land and a good overlap of the cut-out area.
11. Prepare the repair materials.

manufacturer’s instructions. The weight of the adhesive required
will be approximately the same as the weight of the carbon fabric.
NOTE: After the plies are soaked, the remaining adhesive (if it is
kept cool) can be used in the installation procedure.
B. Soak the carbon fibre and fiberglass plies with the mixed adhesive.

(CoMat 02-168).
film.
thoroughly.
V2500 54-10-00 REPAIR No. 009

Page 205
Feb 1/09
C. Cut the seven fill-in plies to their finished dimensions.
(1) Cut each fill-in ply to the smae dimensions as the cut-out
area.
(2) Find a short side on each ply and cut two corners to a radius
of 0.25 in. (6,3 mm).
D. Cut the repair plies to their finished dimensions.
(1) Cut the first repair ply 1.0 in. (25,4 mm) larger all around
(except at the panel edge) than the cut-out repair area.
(2) Cut each subsequent repair ply 0.5 in. (12,7 mm) longer and
0.25 in. (6,3 mm) wider.
(3) Find a long side on each ply and cut two corners
approximately 0.5 in. (12,7 mm) from the end at an angle of
45 degrees.
E. Cut the fiberglass sanding ply to its finished dimensions.
(1) Cut the fiberglass sanding ply 0.75 in. (19,0 mm) larger all
around (except at the panel edge) than the largest repair
ply.
(2) Find a long side and cut the two corners approximately
1.0 in. (25,4 mm) from the end at an angle of 45 degrees.
A. Remove any unwanted material from the repair area with a suction
cleaner.

lint free cloth (CoMat 02-099). Wipe the area dry.
V2500 54-10-00 REPAIR No. 009

Page 206
Feb 1/09
13. Fill the cut-out area (Ref. Fig. 201).
A. Apply an equal layer of adhesive to the cut-out area and the edges
using a brush (CoMat 02-087).
B. Apply the first fill-in ply.
(1) Remove the parting film from one side of the first fill-in
ply.
(2) Put the first fill-in ply, with the adhesive side down, in
the cut-out area, and align it with the edge of the panel
land.
(3) Remove air and unwanted adhesive with a clean metal spatula.
(4) Remove the remaining parting film from the first fill-in
ply.
C. Apply the six subsequent fill-in plies.
(1) Repeat step B for each fill-in ply.
A. Use a brush (CoMat 02-087) to apply an even layer of EA9390

adhesive to all of the repair area.
V2500 54-10-00 REPAIR No. 009

Page 207
Feb 1/09
B. Apply the first repair ply.
(1) Remove one sheet of non-porous parting film from the first
repair ply.
(2) Put the first repair ply, with the adhesive side down, onto
the repair area and align it with the panel edge, making sure
that it has a 1.0 in. (25,4 mm) overlap around the repair
area.
(3) Use the roller to remove air and unwanted adhesive from the
ply.
(4) Remove the remaining non-porous parting film from the first
repair ply.
C. Apply the six subsequent repair plies.
(1) Repeat step B above for the remaining repair plies, making
sure each subsequent repair ply has a 0.25 in. (6,3 mm) over-
lap around the previous ply.
D. Apply the fiberglass sanding ply.
(1) Repeat step B above for the fiberglass sanding ply, making
sure that the ply has a 0.75 in. (19,0 mm) overlap around the
top repair ply.
(2) Make sure that the fiberglass ply is adjacent to, but not on,
the teflon tape.
spatula.
area.
3.0 in. (76,2 mm) around the fiberglass ply.
C. Cut nine sheets of breather fabric (CoMat 08-057), making sure that
the breather fabric has the same dimensions as the porous parting
film.
V2500 54-10-00 REPAIR No. 009

Page 208
Feb 1/09
D. Put the porous parting film on to the repair area, making sure that
it has an equal overlap around the repair area. Put the layers of
E. Cut one sheet of non-porous parting film (CoMat 02-168) and

silicone rubber sheet (CoMat 02-170), making sure that the two
pieces of material have an overlap of 2.0 in. (50,8 mm) around the
breather fabric installed in step D.
F. Put four fiberglass tows on to the repair area.
(1) Put one strand of the fiberglass fabric (CoMat 02-167) in

each of four positions around the repair.
(2) Make sure that each strand connects the breather fabric with
the area around the silicone rubber sheet.
G. Put the non-porous parting film on to the repair area, making sure
that it has an equal overlap around the repair area. Put the
silicone rubber sheet on top of the non-porous parting film.
H. Put the heat blanket and breather cloth on to the repair area.
(1) Cut two sheets of breather cloth (CoMat 02-166), at least 2.0
in. (50,8 mm) larger on each side than the silicone rubber
sheet.
(2) Put the two sheets of breather cloth on to the repair area.
repair area.
I. Put at least two temperature probes on the teflon tape adjacent to

the repair area.
J. Install the vacuum bag on to the repair area.
(CoMat 08-051).
(2) Make sure that the bagging film is approximately four times
larger than the panel.
(3) Make sure that the vacuum has an overlap of approximately

V2500 54-10-00 REPAIR No. 009

Page 209
Feb 1/09
(5) Attach and seal the vacuum bag to the panel with the sealant
tape (CoMat 08-051).
A. Use the vacuum pump to decrease the pressure in the repair area,
making sure it gives an indication of at least 25.0 in. (635,0 mm)
of mercury while the adhesive cures.
B. Use the heat blanket to keep the temperature of the repair at


be faster than 5.5oF (3oC) in each minute.
(82oC).
A. When the cure process is completed, remove the layup materials from
the repair area.
B. Remove and discard the aluminium backing plate.
18. Prepare the access panel (Ref. Fig. 201).

NECESSARY.
CAUTION: DO NOT CAUSE DAMAGE TO THE REPAIR PLIES OR THE GRAPHITE PLIES
OF THE PANEL.
A. Make the fiberglass sanding ply smooth with waterproof abrasive

paper (CoMat 05-021).
B. Prepare the panel land.
(1) Make the panel land to the original contour.
V2500 54-10-00 REPAIR No. 009

Page 210
Feb 1/09
(2) Close the access panel, and make sure that the aerodynamic
contour of the external surface is correct and the hinge area
does not catch.
(3) Make sure that the aerodynamic clearances are correct.
C. If necessary, drill the fastener hole(s)

(Ref. AMM TASK 73-22-11-400-010).
(1) Use the intake cowl as a template and make a mark for the
fastener hole(s).
(2) Drill the hole(s) as necessary using standard workshop

tools.
(3) Countersink the holes on the external surface to a depth of

0.063 in. (1,6 mm) at an angle of 100 degrees.
D. Chamfer the repair plies.
(1) Measure approximately 0.35 in. (8,9 mm) from the panel edge
and apply teflon tape (CoMat 02-007).
(2) Radius chamfer the repair plies and the sanding ply.
(3) Remove the teflon tape.
A. Remove all unwanted material from the repair area with a suction
cleaner.
B. Clean the surface with methylethylketone (CoMat 01-076) and a

lint-free cloth (CoMat 02-099). Wipe the surface dry.
V2500 54-10-00 REPAIR No. 009

Page 211
Feb 1/09


(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-10-00 REPAIR No. 009

Page 212
Feb 1/09
Access Panel, Repair Land Area

Fig. 201
V2500 54-10-00 REPAIR No. 009

Page 213
Feb 1/09

Fig. 202
V2500 54-10-00 REPAIR No. 009

Page 214
Feb 1/09
REPAIR NO. 010

AIR INTAKE COWL PROBE ACCESS PANEL INTERFACE LAND REPAIR
VRS2808
1. General
A. This procedure may be used to repair damage to the P2T2 probe

access panel interface land on the air intake cowl.
fill-in plies and a carbon fibre patch.
C. Only one repair for each access panel interface land is permitted.
2. Referenced Information

(SPPM)

Steel roller, 2.0 in. (50.8 mm) diameter, 2.0 in. (50.8 mm) long
Suction cleaner
V2500 54-10-00 REPAIR No. 010

Page 201
Feb 1/09

Index)

C. Repair Parts
--------------------------------------------
PART NO. PART IDENT
--------------------------------------------
NAS1791-C4-1P Captive nut
CCR264CS-3-4 Rivet
ST1729E/20/X Nut plate packer
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
4. Remove the access panel from the nose cowl.
A. Remove the access panel from the nose cowl

(Ref. AMM TASK 73-22-11-000-010).
V2500 54-10-00 REPAIR No. 010

Page 202
Feb 1/09

lint-free cloth (CoMat 02-099). Wipe the area dry.
6. Prepare the damaged area for repair (Ref Fig 201).
follows.
(1) Measure a minimum of 2.25 in. (57.2 mm) each side along the
panel land, making sure that this dimension is between
adjacent captive nuts.
(2) On the internal surface, measure 3.00 in. (76.2 mm) from the
edge of the panel land.

(12.7 mm) from each corner, and make a mark at 45 degrees
across the two corners, using the marking pen (CoMat 06-131)
to apply temporary marks to the measured repair area.
measured repair area, making sure that the teflon tape (on
the panel land) is between the captive nuts.
C. Measure the damage cut-out area.
(12.7 mm) each side along the panel land and make a mark.
(2) Measure 1.6 in. (40.6 mm) from the panel edge and make a mark

0.25 in. (6.3 mm).
V2500 54-10-00 REPAIR No. 010

Page 203
Feb 1/09
D. Remove the surface protective treatment.
WARNING: WEAR PROTECTIVE CLOTHING, GLOVES, DUST MASKS, AND SAFETY

GOGGLES. WHEN COMPOSITE MATERIALS ARE CUT OR SANDED, DUST AND
LOOSE PARTICLES ARE PRODUCED WHICH ARE POTENTIAL HEALTH
HAZARDS. DO NOT BREATHE THE DUST.
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. DO NOT
USE A LIQUID WITH THE ABRASIVE PAPER.
(1) Rub the repair area with waterproof abrasive paper

(CoMat 05-021). Make the edges of the area smooth, and rub
the external surface side of the panel land.
7. Remove the damaged material (Ref Fig 201).



(CoMat 05-021).
8. Make a template for the first repair ply.
A. Make a template from a piece of rigid card.
(1) Find the edges of the cut-out area and measure a minimum of
1.0 in. (25.4 mm) from each side.
(2) Make sure that this dimension is approximately halfway

between the adjacent captive nuts on the panel land.
(3) Change the dimension as necessary, and mark the dimensions on

the rigid card and cut the card.
(4) Find a long side and cut the two corners 0.5 in. (12.7 mm)
from the end, at an angle of 45 degrees.
V2500 54-10-00 REPAIR No. 010

Page 204
Feb 1/09
A. Use heat lamps to dry the repair area. Keep the temperature at
176oF (80oC) for 6 hours. The repair materials must be applied
immediately at the end of the 6 hours.
10. Prepare the fill-in and repair plies (Ref Fig 201).

GOGGLES. WHEN COMPOSITE MATERIALS ARE CUT OR SANDED, DUST
AND LOOSE PARTICLES ARE PRODUCED WHICH ARE POTENTIAL HEALTH
A. Prepare four fill-in plies.
(1) Wear lint-free gloves (CoMat 02-097) and cut four pieces of
dry carbon fibre fabric (CoMat 08-059) 1.0 in. (25.4 mm)
repair area.
carbon fibre fabric (CoMat 08-059) a minimum of 2.0 in.
(50.8 mm) larger all around (except at the panel edge) than
the cut-out repair area.
C. Prepare the three subsequent repair plies.
(1) Wear lint-free gloves (CoMat 02-097) and cut the three
subsequent repair plies from dry carbon fibre fabric
(CoMat 08-059), each piece 0.25 in. (6.3 mm) larger all
around (except at the panel edge) than the previous piece.
11. Prepare the repair area (Ref Fig 201).
A. Install the aluminum backing plate.
(1) Make the backing plate using standard tools.
(2) Wrap a piece of non-porous parting film (CoMat 02-168)

around the backing plate.
(3) Temporarily attach the backing plate to the external surface

side of the panel land and make sure it touches the edge of
the external surface.
V2500 54-10-00 REPAIR No. 010

Page 205
Feb 1/09
A. Mix the adhesive (CoMat 08-050) in accordance with the

manufacturer's instructions. The weight of adhesive required will
be approximately the same as the weight of the dry carbon fibre
fabric.
B. Soak the carbon fibre plies with the mixed adhesive.

(CoMat 02-168).
film.
thoroughly.
C. Cut the four fill-in plies to their finished dimensions.
(1) Cut each fill-in ply to the same dimensions as the cut-out
area.
(2) Find a long side on each ply and cut two corners to a radius
of 0.25 in. (6.3 mm).
D. Cut the repair plies to their finished dimensions.
(1) Put the template (refer to step 8.) on the first repair
ply, and cut the ply to the template dimensions.
(2) Cut each subsequent repair ply 0.5 in. (12.7 mm) longer and
0.25 in. (6.3 mm) wider than the previous ply.
V2500 54-10-00 REPAIR No. 010

Page 206
Feb 1/09
approximately 0.5 in. (12.7 mm) from the end at an angle of
45 degrees.
A. Remove unwanted material from the repair area with a suction

cleaner.
B. Clean an area 18 in. (457 mm) all around the repair area with
(CoMat 02-099). Wipe the repair area dry.
14. Fill the cut-out area (Ref Fig 201).
ply.
the cut-out area, and align it with the edge of the panel
land.
(3) Remove air and unwanted adhesive from the ply with a clean
metal spatula.
V2500 54-10-00 REPAIR No. 010

Page 207
Feb 1/09
ply.
C. Apply the three subsequent fill-in plies.
A. Use a brush (CoMat 02-087) to apply an equal layer of adhesive to

all of the repair area.
repair ply.
the repair area and align it with the edge of the inner
surface, making sure that the edge of the repair ply is
approximately halfway between the adjacent captive nuts.
ply.
repair ply.
V2500 54-10-00 REPAIR No. 010

Page 208
Feb 1/09
C. Apply the three subsequent repair plies.
(1) Repeat step B above for the remaining repair plies, making
sure each subsequent repair ply has an equal 0.25 in.
(12.7 mm) overlap around the previous one.
(2) Make sure that the fourth repair ply is adjacent to, but not
on, the teflon tape.
D. Remove unwanted adhesive from the teflon tape with a clean metal
spatula.
16. Prepare to cure the adhesive (Ref Fig 202).
area.
B. Cut a sheet of porous parting film (CoMat 02-169) making sure

that it is larger than the heat blanket and has an overlap of at
least 3.0 in. (76.2 mm) around the top repair ply.
C. Cut four sheets of breather fabric (CoMat 08-057), making sure

that the breather fabric has the same dimensions as the porous
parting film.
D. Put the porous parting film on to the repair area, making sure
layers of breather fabric on top of the porous parting film.

pieces of material have an overlap of 2.0 in. (50.8 mm) around the
F. Put the four fiberglass tows on to the repair area.
(1) Put one strand of fiberglass fabric (CoMat 02-167) in each

of the four positions around the repair.
V2500 54-10-00 REPAIR No. 010

Page 209
Feb 1/09
(1) Cut two sheets of breather cloth (Comat 02-166), at least

2.0 in. (50.8 mm) larger on each side than the silicone
rubber sheet.
repair area.
I. Put at least two temperature probes on the teflon tape, on the

external surface and the inner surface.
(CoMat 08-051).
(2) Make sure that the vacuum bag has an overlap of

approximately 2.0 in. (50.8 mm) around the breather cloth.
tape.
making sure it gives an indication of at least 20.0 in (508 mm) of
mercury while the adhesive cures.

(90oC).
V2500 54-10-00 REPAIR No. 010

Page 210
Feb 1/09
A. When the cure process is completed, remove the layup materials

from the repair.
B. Remove and discard the aluminum backing plate.
19. Prepare the access panel (Ref Fig 201).

OF THE PANEL.
A. Make the repair area smooth with waterproof abrasive paper

(CoMat 05-021).
(2) Temporarily install the access panel, and make sure that the
aerodynamic contour on the external surface is correct.
C. Drill the fastener hole(s) in the panel land.
(1) Use the access panel as a template and make a mark for the
fastener hole(s).

tools.
D. Drill the captive nut holes in the panel land.
(1) Use a captive nut as a template and make a mark for the
fastener hole(s).

tools.
(3) Countersink the rivet holes on the external surface.
cleaner.
V2500 54-10-00 REPAIR No. 010

Page 211
Feb 1/09

A. Apply surface protection to the repair area in accordance with

22. Prepare the panel land.
A. Install the captive nuts using standard workshop tools, rivets

(CCR264CS-3-4), nut plate packers (ST1729E/20/X) and captive nuts
(NAS1791-C4-1P).
B. Remove unwanted material from the repair area using a suction

cleaner.
A. Make a visual inspection to make sure that the repair has been
done in accordance with these procedures.

(Ref. SPPM TASK 70-09-00-400-501).
25. Install the access panel.
A. Install the access panel on the nose cowl

(Ref. AMM TASK 73-22-11-400-010).
V2500 54-10-00 REPAIR No. 010

Page 212
Feb 1/09
Access Panel, Interface Land, Build-up Repair

Fig 201
V2500 54-10-00 REPAIR No. 010

Page 213
Feb 1/09

Fig 202
V2500 54-10-00 REPAIR No. 010

Page 214
Feb 1/09
CANCELLATION NOTICE
THE FOLLOWING SRM REPAIR HAS BEEN CANCELLED AND SHOULD NO

V2500 54-10-00 Repair No. 011

Page 201
Feb 1/09
V2500 54-10-00 Repair No. 011

Page 202
Feb 1/09
REPAIR NO. 012

AIR INTAKE COWL STIFFENER AREA REPAIR
VRS2810
1. General.
A. This repair may be used to repair damage to the stiffener area of

the nose cowl.
B. This repair fills the damaged area with resin and installs carbon
fibre repair plies and a fiberglass sanding ply.
C. The damage must not go beyond the stiffener area and must be a
minimum of 2D from a fastener. The damage must not go through all
the composite plies and into the stiffener. The damage must be more
than (4 repair plies + 1 sanding ply) 4.75 in. (120,7 mm) from the
edge of the panel and no more than 24.5 in. (622,3 mm) around the
circumference. The damage can be nearer to the edge if less than
four plies are damaged. Refer to Fig. 201 and 202. There must be a
minimum of 10 in. (254,0 mm) between damaged areas.
D. The orientation of the carbon fibre repair plies must follow the
sequence (±45)/(0-90)/(±45) for a 3-ply region,
(±45)/0-90)/(0-90)/(±45) for a 4-ply region. Refer to Fig. 201.
E. Repairs must be carried out in a controlled environment where

F. Where damage is beyond the scope of this repair refer to Goodrich.

(SPPM)
(SPPM)
V2500 54-10-00 REPAIR No. 012

Page 201
Feb 1/09

Heat lamp, 176o - 194oF (80o - 90oC)
Suction cleaner
B. Special Tools

(PCI)).

D. Repair parts
None.
V2500 54-10-00 REPAIR No. 012

Page 202
Feb 1/09
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------

fully penetrated the panel and is into the stiffener, repair is
beyond the scope of this document. In this event reference must be
made to alternative repair procedures.

cloth.
V2500 54-10-00 REPAIR No. 012

Page 203
Feb 1/09
of the damage as follows: from the edge of the damaged area measure
1.0 in. (25,4 mm) for each damaged ply of the cowl, i.e., if 4 plies
are damaged then measure 4.0 in. (101,6 mm) from the edge of the
damaged area. Add 0.75 in. (19,05 mm) for an outer layer of
fiberglass fabric (CoMat 02-167). Apply the teflon tape so that it
goes around the repair area in a 2.0 in. (50,8 mm) wide strip. Make
the corners at an angle of approximately 45 degrees and
approximately 1.0 in. (25,4 mm) length of side.
NOTE: The repair materials can go on top of the fasteners in the

stiffener area of the outer barrel panel.


the finished dimensions after soaking in adhesive (Ref. steps 1.D.
and 9.C.).
fabric (CoMat 08-059) and lint free gloves. Cut each subsequent
repair ply 2.0in. (50,8 mm) longer and 2.0in. (50,8 mm) wider. Cut
the last ply (sanding ply) from fiberglass fabric to give a 1.0in.
(25,4 mm) overlap beyond the teflon tape. There must be a repair
ply for each ply of the panel which is damaged. To prevent fraying,
the plies may be cut to the finished dimensions after soaking in
adhesive (Ref steps 1.D. and 9.C.).
V2500 54-10-00 REPAIR No. 012

Page 204
Feb 1/09


the plies are soaked, the remaining adhesive, if it is kept
cool, is used on the repair area (Ref step 12.).

procedure.
(12,7 mm).
D. Cut the fiberglass ply to the shape defined by the teflon tape
(CoMat 02-007).
V2500 54-10-00 REPAIR No. 012

Page 205
Feb 1/09
A. Clean the repair area with methylethylketone (CoMat 01-076) using

lint free cloth before the fluid dries. The repair area must be
cool after the drying procedure.

instructions.
filled damage must be level with the outermost existing carbon ply
of the repair area.
V2500 54-10-00 REPAIR No. 012

Page 206
Feb 1/09

C. Remove the parting film from one side of the remaining repair plies
(if required) and position it over the repair area with the
NOTE: Make sure that the ply fibres are (±45)/(0-90)/(±45) for a
3-ply region, (±45)/0-90)/(0-90)/(±45) for a 4-ply region.
D. Repeat step C. for fiberglass ply.
NOTE: The fiberglass (sanding) ply must touch the teflon tape
spatula.
V2500 54-10-00 REPAIR No. 012

Page 207
Feb 1/09
the repair.

D. above.
parting film.

to the repair area.
the panel with the sealant tape (CoMat 08-051).
V2500 54-10-00 REPAIR No. 012

Page 208
Feb 1/09
(88oC).
tape.


area and the outer skin of the panel. Use the abrasive paper (CoMat
05-021).
V2500 54-10-00 REPAIR No. 012

Page 209
Feb 1/09


(Ref SPPM TASK 70-38-07-380-501).

(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-10-00 REPAIR No. 012

Page 210
Feb 1/09

Fig. 201
V2500 54-10-00 REPAIR No. 012

Page 211
Feb 1/09
Stiffener Area Repair (Typical)

Fig. 202
V2500 54-10-00 REPAIR No. 012

Page 212
Feb 1/09

Fig. 203
V2500 54-10-00 REPAIR No. 012

Page 213
Feb 1/09
V2500 54-10-00 REPAIR No. 012

Page 214
Feb 1/09
REPAIR NO. 013

AIR INTAKE COWL ACCESS PANELS SURFACE DAMAGE REPAIR
VRS2845
1. General.
A. This repair may be used to repair damage to the access panels of

the air intake cowl.
B. This repair fills the damaged area with epoxy adhesive and installs
carbon fibre repair plies and a fiberglass sanding ply.
C. The damage must be more than (4 repair plies + 1 sanding ply)

4.75 in. (120,7 mm) from the edge of the panel. The damage can be
nearer to the edge if less than four plies are damaged. There must
be enough distance to install all the repair plies and sanding ply.
Refer to Para. 4A and 6A and Fig. 201 and 202. The damage must not
go through all the composite plies. Only one repair for each panel
is permitted.
sequence:(±45)/(0-90)/(0-90)/(±45) for each repair ply up to a
maximum of 4 repair plies. Applicable to both inner and outer
surfaces. Refer to Fig. 202.

F. If the damage goes through the panel, do REPAIR No. 014 (VRS2846).
If the damage goes to the edge of the panel, do REPAIR No. 009
(VRS2844).

(SPPM)
(SPPM)
V2500 54-10-00 REPAIR No. 013

Page 201
Feb 1/09

Heat lamp, 176o - 194oF (80o - 90oC)
Suction cleaner
B. Special Tools

(PCI)).


D. Repair parts
None.
V2500 54-10-00 REPAIR No. 013

Page 202
Feb 1/09
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Probe access panel Composite structure
Interphone access panel Composite structure

fully penetrated the panel, repair is beyond the scope of this
document. In this event reference must be made to alternative
repair procedures.

cloth.
V2500 54-10-00 REPAIR No. 013

Page 203
Feb 1/09
of the damage as follows: from the edge of the damaged area measure
1.0 in. (25,4 mm) for each damaged ply of the cowl, i.e., if 4 plies
damaged then measure 4.0 in. (101,6 mm) from the edge of the
damaged area. Add 0.75 in. (19,05 mm) for an outer layer of
fiberglass fabric (CoMat 02-167). Apply the teflon tape so that it
goes around the repair area in a 2.0 in. (50,8 mm) wide strip. Make
the corners at an angle of approximately 45 degrees and
approximately 1.0 in. (25,4 mm) length of side.
NOTE: If the repair is on the inner side of the access panel, it is

not necessary to include the fiberglass fabric.
NOTE: If the dimensions of the panel are not sufficient to do this

repair, reject the panel.

7. Cut the repair plies (Ref. Fig. 201 and 202).

the finished dimensions after soaking in adhesive (Ref. steps 1.D.
and 9.C.).
NOTE: If one ply is required to do the repair use carbon fabric

(CoMat 08-059) and fiberglass fabric (CoMat 02-167) (the
sanding ply).
V2500 54-10-00 REPAIR No. 013

Page 204
Feb 1/09
fabric and lint free gloves. Cut each subsequent repair ply 2.0in.
(50,8 mm) longer and 2.0in. (50,8 mm) wider. Cut the last ply
(sanding ply) from fiberglass fabric to give a 1.0in. (25,4 mm)
overlap beyond the teflon tape. There must be a repair ply for each
ply of the panel which is damaged. To prevent fraying, the plies
may be cut to the finished dimensions after soaking in adhesive
(Ref steps 1.D. and 9.C).



procedure.
V2500 54-10-00 REPAIR No. 013

Page 205
Feb 1/09
(12,7 mm). Cut the fiberglass ply to the shape defined by the
teflon tape (CoMat 02-007).
11. Fill the damaged area (Ref. Fig. 202).

instructions.
filled damage must be level with the top carbon ply of the panel.
V2500 54-10-00 REPAIR No. 013

Page 206
Feb 1/09

C. Remove the parting film from one side of the remaining repair plies
(if required) and position it over the repair area with the
NOTE: Make sure that the ply fibres follow the sequence:
(±45)/(0-90)/(0-90)/(±45).
D. Repeat step C. for fiberglass ply.
spatula.
V2500 54-10-00 REPAIR No. 013

Page 207
Feb 1/09
the repair.

D. above.
parting film.

to the repair area.
V2500 54-10-00 REPAIR No. 013

Page 208
Feb 1/09
Rohr, Inc., a subsidiary of Goodrich Corporation, operating as Goodrich Aerostructures; Goodrich Proprietary Jul 1/05
(88oC).
tape.


A. If the repair is on the outer side of this panel, make the repair
area smooth with waterproof abrasive paper (CoMat 05-021). The
contours of the repair area must be smooth and there must not be an
edge or step, between the repair area and the outer skin of the
panel.
NOTE: If the repair is on the inner side of the panel, do not do

this step.
17. Drill the attachment holes (if it is necessary).
A. Drill the attachment holes again if there is repair material on top

of the holes. Use a 0.2598 in. (6,579 mm) diameter drill, and
countersink the holes with a 100 degree countersink tool. Make sure
that the attachment bolts are level with the surface of the panel.
V2500 54-10-00 REPAIR No. 013

Page 209
Feb 1/09


(Ref. SPPM TASK 70-38-07-380-501).
A. Ident the component/log book with the REPAIR no. 2845

(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-10-00 REPAIR No. 013

Page 210
Feb 1/09

Fig. 201
V2500 54-10-00 REPAIR No. 013

Page 211
Feb 1/09
Surface Damage Build-up Repair (Typical)

Fig. 202
V2500 54-10-00 REPAIR No. 013

Page 212
Feb 1/09

Fig. 203
V2500 54-10-00 REPAIR No. 013

Page 213
Feb 1/09
V2500 54-10-00 REPAIR No. 013

Page 214
Feb 1/09
REPAIR NO. 014

AIR INTAKE COWL ACCESS PANELS HOLE REPAIR
VRS2846
1. General.
A. This procedure may be used to repair damage to the air intake cowl
probe access panel, including a hole, cracks and delamination.
B. This repair removes the damaged area and installs a support plate,
carbon fibre filler plies, a carbon fibre patch and a fiberglass
sanding ply.
C. The damage (which includes cracks) must be more than (4 repair

plies + 1 sanding ply) 4.75 in. (120,7 mm) from the edge of the
panel. It must be confined to a hole diameter 1.12 in.
(28,4 mm) by 3.9 in. (99,0 mm) or less. There must be only one
repair on each panel. Refer to Fig. 201 and 203.
D. The orientation of the carbon fibre repair plies must be

(±45)/(0-90)/(0-90)/(±45). Refer to Fig. 203.

percent or less.
F. If the damage goes to the edge of the panel, do REAPIR No. 009
(VRS2844). Where damage is beyond the scope of this repair refer to
Goodrich.

(SPPM)
(SPPM)
V2500 54-10-00 REPAIR No. 014

Page 201
Feb 1/09

Heat lamp, up to 212oF (100oC)
Vacuum suction pump, range 0 - 30 in. (0-762 mm) of mercury
Suction cleaner

Index).

C. Special Tools
V2500 54-10-00 REPAIR No. 014

Page 202
Feb 1/09
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Probe access panel Composite structure
Interphone access panel Composite structure
4. Clean the damaged area.

5. Prepare the Repair Area (Ref. Fig. 202).

A. Mark around the damage with a pencil, making sure to include cracks
and areas of delamination.
6. Apply teflon tape around the repair area (Ref. Fig. 203).
A. Mask around the repair area with teflon tape (CoMat 02-007).
Calculate the distance that the tape must be from the cut-out as
follows:
(1) Measure 1.0 in. (25,4 mm) from the edge of the damage for
each of the four plies of the panel, and add 0.75 in.
(19,05 mm) for an outer layer of fiberglass fabric (CoMat
02-167).
(2) Carefully apply the teflon tape so that it goes around the
area in a 2.0 in. (50,8 mm) wide strip.
V2500 54-10-00 REPAIR No. 014

Page 203
Feb 1/09
(3) Make the corners of the strip of tape at an angle of

approximately 45 degrees with a length of approximately 1.0
in. (25,4 mm).
7. Cut out the damaged area of the cowl (Ref. Fig. 202).
A. Use a high-speed rotary cutter, and make sure that the edges of the
cut-out have an angle of approximately 45 degrees.
B. The corners of the cut-out must have a radius of at least 0.5 in.
(12,7 mm).
C. Take care not to cause delamination of the inner plies.

D. Make the surface of the repair area rough with waterproof abrasive

cleaner.
B. Clean the area around the cut-out, on the inner and outer surfaces
of the panel, with methylethylketone (CoMat 01-076) and lint-free
cloth (CoMat 02-099). Wipe the repair area dry.
V2500 54-10-00 REPAIR No. 014

Page 204
Feb 1/09
9. Prepare the support plate (Ref. Fig. 202).

A. Wear lint-free gloves (CoMat 02-097) and cut three pieces of

fiberglass fabric (CoMat 02-167) 2.0 in. (50,8 mm) larger all
around than the cut-out.


same as the weight of the fiberglass fabric (CoMat 02-167).
(1) Put each fiberglass ply on a sheet of non-porous parting film

(CoMat 02-168).
film.
thoroughly.

1.0 in. (25,4 mm) around the repair cut-out.
V2500 54-10-00 REPAIR No. 014

Page 205
Feb 1/09
(1) Remove one sheet of non-porous film from two of the plies.
(2) Remove both sheets of non-porous film from the third ply.
(3) Align the three plies and put them on with their adhesive
three fiberglass plies.
E. Cure the adhesive (Ref. Fig. 203).
(1) Position the temperature probes adjacent to the support

plate.
(2) Use the heat lamp to cure the adhesive for 220 minutes at

190oF (88oC).
F. Drill holes in the support plate and attach lockwire.
(1) When the support plate is cool, remove the two remaining
pieces of non-porous film.
(2) Drill two pairs of holes, 0.050 in. (1,27 mm) diameter, a
sufficient distance apart to attach the support plate to a
clamp bar with lockwire (CoMat 02-127).
A. Use the heat lamps to dry the repair area. Keep the temperature at
176oF (80oC) for six hours. The repair materials must be applied
V2500 54-10-00 REPAIR No. 014

Page 206
Feb 1/09
B. Mix the EA934NA adhesive (CoMat 08-021) in accordance with the man-
ufacturer’s instructions.
C. Apply an equal layer of adhesive to the support plate and the

access panel interface using the brush (CoMat 02-087).
D. Put the support plate against the inner surface of the access
panel. Make sure the plate has an equal overlap around the cut-out.
E. Put a clamp bar across the repair area with the ends of the bar on
the teflon tape. Attach the support plate to the clamp bar with the
lockwire (CoMat 02-127). Tighten the lockwire to hold the support
plate in the correct position.
the increase mist not exceed 5.4oF (3oC) in each minute. Keep the
G. Remove the lockwire and the bar.
12. Prepare the filler and the repair plies (Ref. Fig. 203).

A. Prepare the filler plies.
(1) Wear lint-free gloves (CoMat 02-097) and cut out the filler
plies from the carbon fibre fabric (CoMat 08-059) so that
they have a 1.0 in. (25,4 mm) overlap around the cut-out. Cut
V2500 54-10-00 REPAIR No. 014

Page 207
Feb 1/09
sufficient filler plies to make the surface of the repair

cut-out level with the surface of the panel.
(50,8 mm) overlap around the cut-out (Ref. step 1.D.).
C. Prepare the three remaining repair plies.
(1) Wear lint-free gloves (CoMat 02-097) and cut the three
remaining repair plies from dry carbon fibre fabric (CoMat
08-059), each piece 2.0 in. (50,8 mm) larger all around than
the previous piece. Cut one repair ply for each ply of the
panel (Ref. step 1.D.).
fiberglass fabric (CoMat 02-167) so it has a 1.0 in.
(25,4 mm) overlap around the area identified by the teflon
tape.

manufacturer’s instructions. The weight of adhesive required will
be approximately the same weight of the dry carbon fibre fabric and
the fiberglass fabric.

(CoMat 02-168).
V2500 54-10-00 REPAIR No. 014

Page 208
Feb 1/09
film.
thoroughly.
C. Cut the filler plies to their finished dimensions.
(1) Cut the first filler ply so that it is a good fit in the
repair cut-out, making sure it lies flat on the support
plate, is the same shape as the cut-out and its edges do not
overlap on the sides of the cut-out.
(2) Cut each subsequent filler ply so that it lies flat on the
filler ply installed before it, making sure it is the same
shape as the cut-out and its edges do not overlap on the
sides of the cut-out.
D. Cut the repair plies to their finished dimensions (Ref. step 1.C.).
(1) Cut the first repair ply so it has a 1.0 in. (25,4 mm)
overlap on the sides of the cut-out.
(2) Cut each subsequent repair ply to overlap the ply before by
(3) Cut the corners of the repair plies to an angle of

approximately 45 degrees with a length of approximately
0.5 in. (12,7 mm).
E. Cut the fiberglass sanding ply to the same shape as the area
identified by the teflon tape.

cleaner.
V2500 54-10-00 REPAIR No. 014

Page 209
Feb 1/09

15. Install the filler plies (Ref Fig 203).
A. Apply an equal layer of EA9390 adhesive to the cut-out area and the
edges using a brush (CoMat 02-087).
B. Install the first filler ply.
(1) Remove the parting film from one side of the first filler
ply.
(2) Put the first filler ply, with the adhesive side down, into
the cut-out, making sure that the filler ply is flat on the
support plate.
NOTE: Make sure that the orientation of the plies are the
same as the damaged plies.
(3) Remove the remaining parting film from the filler ply, and
using a clean metal spatula, make sure that the filler ply is
flat and in the correct position.
C. Put the second filler ply into the cut-out.
(1) Remove the parting film from one side of the filler ply.
NOTE: Make sure that the orientation of the plies are the
same as the damaged plies.
(2) Put the filler ply, with the adhesive side down, into the
cut-out, making sure that the filler ply is flat.
(3) Remove the remaining parting film from the filler ply, and
using a clean metal spatula, make sure that the filler ply is
V2500 54-10-00 REPAIR No. 014

Page 210
Feb 1/09
D. Put the remaining filler plies (if they are necessary) into the
cut-out.
(1) Repeat step C. above for the remaining plies.
16. Install the repair plies and the fiberglass ply (Ref. Fig. 203).
A. Put the first repair ply on to the repair area.
repair ply.
the repair area, making sure that the repair cut-out is in
the center of the repair ply.
NOTE: Make sure that the ply fibres are

(±45)/(0-90)/(0-90)/(±45).
(3) Use the roller to remove air which is caught in the adhesive.
repair ply.
B. Put the second repair ply on to the repair area.
(1) Remove one sheet of non-porous parting film from the second
repair ply.
(2) Put the second repair ply, with the adhesive side down, onto
the repair area, making sure that the second repair ply has
an equal overlap around the first repair ply.
NOTE: Make sure that the ply fibres are

(±45)/(0-90)/(0-90)/(±45).
(3) Use the roller to remove air which is caught in the adhesive.
(4) Remove the remaining non-porous parting film from the second
repair ply.
C. Put the remaining plies (if they are necessary) on to the repair
area.
(1) Repeat step B. above for the remaining repair plies.
D. Put the fiberglass ply onto the repair area.
V2500 54-10-00 REPAIR No. 014

Page 211
Feb 1/09
(1) Remove one sheet of non-porous parting film from the

fiberglass ply.
(2) Put the fiberglass ply, with the adhesive side down, onto the
repair area, making sure that the fiberglass ply has an equal
overlap around the last repair ply and touches the teflon
tape.
(3) Use the roller to remove air which is caught in the adhesive
and to make the fiberglass smooth.
(4) Remove unwanted adhesive from the teflon tape with a clean
metal spatula.
(5) Remove the remaining non-porous parting film from the

fiberglass ply.
area.
B. Cut a sheet of porous parting film (CoMat 02-169). Make sure that
the film is larger than the heat blanket and has an overlap of at
least 3.0 in. (76,2 mm) around the fiberglass ply.
parting film.
D. Put the porous parting film on to the repair area. Make sure it has
an equal overlap around the repair area. Put the layers of breather
fabric on top of the porous parting film.

silicone rubber sheet (CoMat 02-170). Make sure that the two pieces
of material have an overlap of 2.0 in. (50,8 mm) around the
breather fabric installed in step D. above.
F. Put four fiberglass tows onto the repair area.
(1) Put one strand of fiberglass fabric (CoMat 02-167) in each of

the four positions around the repair.
the area around the silicon rubber sheet.
V2500 54-10-00 REPAIR No. 014

Page 212
Feb 1/09
NOTE: With the fiberglass tows installed, gasses can not

collect below the silicone rubber sheet when the
adhesive cures.
G. Put the non-porous parting film onto the repair area. Make sure

rubber sheet.
(3) Put the heat blanket on top of the breather cloth. Make sure
that the heat blanket has an overlap all around the repair
area.

the repair area.
(CoMat 08-051).

V2500 54-10-00 REPAIR No. 014

Page 213
Feb 1/09
(88oC).
repair.


A. Make all contours of the repair area smooth with waterproof silicon
carbide abrasive paper (CoMat 05-021), making sure that there is no
edge between the repair area and the outer skin of the panel.
21. Drill the attachment holes (if it is necessary).
A. Drill the attachment holes again if there is repair material on top

of the holes. Use a 0.2598 in. (6,579 mm) diameter drill, and
countersink the holes with a 100 degree countersink tool. Make sure
that the attachment bolts are level with the surface of the panel.

cleaner.
V2500 54-10-00 REPAIR No. 014

Page 214
Feb 1/09

tap test method, (Ref SRM 54-01-00) Composite Structure Tap Test,


(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-10-00 REPAIR No. 014

Page 215
Feb 1/09
Location Of Repair Area

Fig. 201
V2500 54-10-00 REPAIR No. 014

Page 216
Feb 1/09
Support Plate and Filler Ply Installation

Fig 202
V2500 54-10-00 REPAIR No. 014

Page 217
Feb 1/09

Fig 203
V2500 54-10-00 REPAIR No. 014

Page 218
Feb 1/09

Fig 204
V2500 54-10-00 REPAIR No. 014

Page 219
Feb 1/09
V2500 54-10-00 REPAIR No. 014

Page 220
Feb 1/09
REPAIR NO. 015

AIR INTAKE COWL ACOUSTIC STRUCTURE SURFACE DAMAGE REPAIR
VRS2815
1. General.
A. This procedure may be used to repair surface damage to the acoustic

structure of the air intake cowl. The damage must be more than
1.5 in. (38,1 mm) from the edge of the acoustic panel and be
confined to an area of 4.0 in. (101,6 mm) diameter or less. There
must be a minimum of 10 in. (254 mm) between damaged areas. Damage
is not allowed in the areas identified in Fig. 201.
B. This repair fills the damaged area with epoxy paste adhesive mixed
with microballoons and installs a carbon fibre repair ply.
C. The carbon fibre repair plies must be at 90 degrees to each other.

CAUTION: USE PROTECTIVE MATS WHEN YOU WORK IN THE AIR INTAKE COWL TO
PREVENT DAMAGE TO THE ACOUSTIC STRUCTURE.

(VRS2996)
(SPPM)
Heat lamp, 176o - 212oF (80o - 100oC)

Suction Cleaner
V2500 54-10-00 REPAIR No. 015

Page 201
Feb 1/09

Index)

CoMat 02-164 Phenolic microballoons
C. Special Tools
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
4. Examine the damaged area (Ref. Fig. 201).
A. The damage must be confined to a maximum area of 4.0 in.(101,6 mm)

diameter. Refer to step 1. A. for the allowable limits of this
repair and to section 54-01-00 for the maximum acoustic loss limit
for the inlet cowl.
B. If the damage goes through the outer stainless steel mesh, the
carbon ply and into the honeycomb, do REAPIR No. 007 (VRS2996).
V2500 54-10-00 REPAIR No. 015

Page 202
Feb 1/09

A. Mask around the damaged area with teflon tape (CoMat 02-007):
(1) Measure 1.0 in. (25,4 mm) from the edge of the damage.

45 degrees at 0.5 in. (12,7 mm).

NECESSARY.
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE PANEL. BE

CAREFUL WHEN YOU REMOVE THE SHARP EDGES OF THE DAMAGE. DO NOT
B. Make the surface of the repair area rough with waterproof abrasive
paper (CoMat 05-021), making sure to remove the sharp edges of the
damage. Do not increase the dimensions of the damage.
V2500 54-10-00 REPAIR No. 015

Page 203
Feb 1/09
7. Cut the repair ply (Ref. Fig. 202).

NECESSARY.
A. Wear lint-free gloves (CoMat 02-097) and cut one piece of dry
carbon fibre fabric (CoMat 08-059) so that it has a 1.5 in.
(38,1 mm) overlap around the damage.

dimensions after they are soaked with epoxy paste adhesive.
A. Use heat lamps to dry the repair area. Keep the temperature at 176oF
(80oC) for 6 hours. The repair materials must be applied
immediately at the end of 6 hours.
manufacturer’s instructions. The weight of epoxy paste adhesive
required will be approximately the same as the weight of the dry
carbon fibre fabric.
NOTE: After the ply has soaked, the remaining epoxy paste adhesive
(if it is kept cool) can be used in the installation
procedure.
B. Soak the outer ply with the mixed epoxy paste adhesive.
(1) Put the ply on a sheet of non-porous parting film

(CoMat 02-367).
V2500 54-10-00 REPAIR No. 015

Page 204
Feb 1/09
(2) Apply the epoxy paste adhesive to the two sides of the ply
with the brush (CoMat 02-087) and cover the ply with another
sheet of non-porous parting film.
(3) Use the roller to force the epoxy paste adhesive into the ply
thoroughly.
C. Cut the outer ply to its finished dimensions.
(1) Let the two pieces of the non-porous parting film stay on the
ply until the installation procedure.
(2) Cut the ply so that it is the same shape as the area which
the teflon tape identifies.
(3) Keep the outer ply and the epoxy paste adhesive mixture cool
until the installation procedure.

V2500 54-10-00 REPAIR No. 015

Page 205
Feb 1/09
manufacturer’s instructions. When fully mixed, add the
the microballoons to 100 parts (by weight) of the mixture.
B. Fill the damaged area with the mixture using a clean metal spatula.
Make sure the mixture is level with the outer stainless steel mesh.
12. Install the outer ply (Ref. Fig. 202).
A. Use a brush (CoMat 02-087) to apply an equal layer of epoxy paste

adhesive to all of the repair area.
B. Install the outer ply on to the repair area.
(1) Remove one sheet of non-porous parting film from the outer
ply.
(2) Put the outer ply, with the epoxy paste adhesive side down,
on to the repair area. The outer ply must have an equal
overlap around the repair cut-out and touch the teflon tape.
NOTE:Make sure that the ply fibres are at 90 degrees to each

other.
(3) Use the roller to remove the air which is caught in the epoxy
paste adhesive and to make the outer ply smooth.
V2500 54-10-00 REPAIR No. 015

Page 206
Feb 1/09
(4) Remove the unwanted epoxy paste adhesive from the teflon
(5) Remove the remaining non-porous film from the outer ply.
13. Prepare to cure the epoxy paste adhesive.
A. Put the temperature probes in position adjacent to the epoxy paste

adhesive.
B. Use the heat lamp to keep the temperature of the repair area

D. Start to measure the time for the epoxy paste adhesive to cure when
the temperature reaches 194oF (90oC).
A. When the cure process is completed, remove the lamp, the

temperature probes and the teflon tape.

NECESSARY.
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE REPAIR AREA OR
THE OUTER SURFACE OF THE ACOUSTIC STRUCTURE. BE CAREFUL AND
ONLY REMOVE MATERIAL FROM THE EDGE OF THE OUTER PLY. DO NOT

(CoMat 05-021). There must not be an edge between the repair area
and the acoustic panel.
V2500 54-10-00 REPAIR No. 015

Page 207
Feb 1/09
cleaner.


(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-10-00 REPAIR No. 015

Page 208
Feb 1/09
Acoustic Structure Damage Limits

Fig. 201(Sheet1)
V2500 54-10-00 REPAIR No. 015

Page 209
Feb 1/09
Acoustic Structure Damage Limits (3 Acoustic Panels)

Fig. 201(Sheet 2)
V2500 54-10-00 REPAIR No. 015

Page 210
Feb 1/09
Acoustic Structure Damage Limits (2 Acoustic Panels)

Fig. 201(Sheet 3)
V2500 54-10-00 REPAIR No. 015

Page 211
Feb 1/09

Fig. 202
V2500 54-10-00 REPAIR No. 015

Page 212
Feb 1/09
REPAIR 016
AIR INTAKE COWL HAND BLEND AND POLISH PROCEDURE REPAIR
(VRS2867)
1. General
A. This procedure may be used to repair surface damage to the air

intake cowl.
B. This repair hand blends out the damage and polishes the repair
to the necessary surface finish.
TASK 71-11-11-300-015 VRS2867 V2500 Engine Manual

TASK 70-38-07-380-501 Standard Practices and
Processes Manual (SPPM)
NOTE: Equivalent materials and equipment may be used.
A. Standard Tools
B. Consumable Materials (Reference Overhaul Processes and

Consumable Index)

CoMat 05-016 Garnet paper
C. Component Materials
PART IDENT MATERIAL

Air Intake Cowl Aluminum/Composite
V2500 54-10-00 REPAIR 016

Page 201
Feb 1/09
4. Repair the Damage

PPE IS NECESSARY.
CAUTION: REMOVE THE MINIMUM QUANTITY OF MATERIAL NECESSARY TO MAKE

THE SHAPE OF THE PART SMOOTH. IF YOU REMOVE TOO MUCH
MATERIAL YOU WILL HAVE TO DO A DIFFERENT REPAIR.
A. Carefully hand blend the damaged area.
(1) Remove the high-points, the burrs and radius the bottom of
the damage.
(2) Blend to a depth sufficient only to remove all traces of

damage. If the depth of damage is more than 0.010 in.
(0.25 mm) from the original undamaged surface, do
B. Polish the damaged area with waterproof silicon carbide

abrasive paper (CoMat 05-020) and (CoMat 05-064) and garnet
paper (CoMat 05-016) to get the necessary surface finish.
5. Clean the Repair Area
A. Clean the surface with methylethylketone (CoMat 01-076) and

lint free cloth (CoMat 02-099). Wipe the area dry with a clean
piece of lint free cloth before the solvent evaporates.
V2500 54-10-00 REPAIR 016

Page 202
Feb 1/09
6. Apply the Surface Protection

7. Make an Inspection of the Repair
A. Do a visual inspection to make sure that the repair has been

V2500 54-10-00 REPAIR 016

Page 203
Feb 1/09
THIS PAGE LEFT INTENTIONALLY BLANK
V2500 54-10-00 REPAIR 016

Page 204
Feb 1/09
REPAIR NO. 021

AIR INTAKE COWL OR P2/T2 SENSOR - AERODYNAMIC SEALANT REPLACEMENT
VRS2725
1. General.
A. This procedure may be used to repair damage to the aerodynamic

sealant of the air intake cowl or the P2/T2 sensor.
B. This repair removes the damaged sealant and installs new sealant.

(SPPM)
Suction cleaner
B. Consumable Materials (Ref. Overhaul Processes and Consumable

Index)

CoMat 02-087 Brush
CoMat 08-146 Sealant (semkit cartridge model 285)
C. Special Tools
D. Repair Parts
None
V2500 54-10-00 REPAIR No. 021

Page 201
Feb 1/09
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
PROCEDURE OR INJURY CAN OCCUR.
CAUTION: BE CAREFUL WHEN YOU MOVE THE COWL. DAMAGE TO THE EDGES OR THE
CORNERS OF THE COWL CAN OCCUR.
A. Attach the lifting sling (1N20406) to the cowl, in accordance with

procedure, and position it so that the repair area is horizontal.
CAUTION: DO NOT CAUSE DAMAGE TO THE ANODIZED SURFACE OF THE LIP SKIN
OR THE ACOUSTIC STRUCTURE. USE ONLY PLASTIC TOOLS AND PUT
PROTECTIVE MATS ON THE COWL.
A. Remove the sealant.
(1) Use a plastic spatula to remove as much of the damaged or

disbonded sealant as you can.
B. Put a strip of the teflon tape (CoMat 02-007) on each side of the
repair area.
V2500 54-10-00 REPAIR No. 021

Page 202
Feb 1/09
CAUTION: DO NOT CAUSE DAMAGE TO THE ANODIZED SURFACE OF THE LIPSKIN OR

THE ACOUSTIC STRUCTURE. USE ONLY THE SPECIFIED MATERIALS AND
PUT PROTECTIVE MATS ON THE COWL.
C. Remove the remaining sealant and clean the repair area.
(1) Soak the waterproof silicon carbide abrasive paper

(CoMat 05-020) in the methylethylketone (CoMat 01-076).
(2) Rub the repair area with the soaked abrasive pad and fully
remove the sealant and contamination.
(3) Wipe the area with a clean piece of lint free cloth
(CoMat 02-099) before the fluid dries.
7. Prepare the aerodynamic sealant (Ref. Fig. 204).
A. Prepare the sealant (CoMat 08-141) or (CoMat 08-146) for manual

mix.
(1) Use the sealant in a pre-filled semkit cartridge.
(2) Hold the cartridge and pull the dasher rod out approximately
25% of the way up the cartridge.
V2500 54-10-00 REPAIR No. 021

Page 203
Feb 1/09
(3) Push the ramrod into the hollow end of the dasher rod and
inject approximately 33% of the contents of the dasher rod
into the cartridge.
NOTE: Make sure that you do not use too much force or tap the
ramrod if the piston does not move easily.
(4) Inject the remaining contents of the dasher rod into the
cartridge in two equal movements.
(5) Remove the ramrod from the dasher rod.
8. Mix the sealant (Ref. Fig. 204).
A. Mix the sealant manually.
(1) Push the dasher rod fully into the cartridge.
(2) Pull out and then push the dasher rod in a clockwise
direction into the cartridge (equals one movement).
NOTE: Make sure that the dasher rod rotates approximately 90o
during each movement.
(3) Refer to the manufacturer’s instructions for the number of

movements required to mix the sealant.
NOTE: Make sure that after the last movement the dasher rod is
pushed fully into the cartridge.
(4) Hold the cartridge tightly and turn the dasher rod
approximately 3 times in an anti-clockwise direction. Remove
the dasher rod from the cartridge.
V2500 54-10-00 REPAIR No. 021

Page 204
Feb 1/09
9. Apply the aerodynamic sealant (Ref. Fig. 201, 202, 203 and 204).
CAUTION: DO NOT CAUSE DAMAGE TO THE ANODIZED SURFACE OF THE LIPSKIN OR

THE ACOUSTIC STRUCTURE. USE ONLY THE SPECIFIED MATERIALS AND
PUT PROTECTIVE MATS ON THE COWL.
A. Fill the repair area with the sealant (CoMat 08-146).
(1) Use a plastic spatula or a sealing gun.
NOTE: Make sure that the sealant is pushed along in front of the
nozzle tip when you use the sealant gun.
NOTE: Make sure that no air gets between the repair area and the
sealant.
(2) The top of the sealant must be level with the surface of the
cowl.
B. Cure the sealant.
(1) Let the sealant cure for approximately 48 hours at 77oF

(25oC).
NOTE: A 9oF (5oC) increase in the cure temperature decreases the

cure time by one half.
C. When the sealant has cured, remove the teflon tape (CoMat 02-007)
from each side of the repair area.
10. Examine the repair area (Ref. Fig. 201).
(1) If the surface of the repair area is below the surface of the
cowl, do steps 7 thru 9 again.
V2500 54-10-00 REPAIR No. 021

Page 205
Feb 1/09

(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-10-00 REPAIR No. 021

Page 206
Feb 1/09
Aerodynamic Sealant Replacement

Fig 201
V2500 54-10-00 REPAIR No. 021

Page 207
Feb 1/09
Aerodynamic Sealant Replacement (3 Acoustic Panels)

Fig 202 (Sheet 1)
V2500 54-10-00 REPAIR No. 021

Page 208
Feb 1/09
Aerodynamic Sealant Replacement (2 Acoustic Panels)

Fig 202 (Sheet 2)
V2500 54-10-00 REPAIR No. 021

Page 209
Feb 1/09

Fig 203
V2500 54-10-00 REPAIR No. 021

Page 210
Feb 1/09

Fig 204
V2500 54-10-00 REPAIR No. 021

Page 211
Feb 1/09
V2500 54-10-00 REPAIR No. 021

Page 212
Feb 1/09
REPAIR NO. 022

AIR INTAKE COWL - REPLACE PIN RECEPTACLES
VRS2739
1. General.
A. This repair may be used to replace the bal-lok receptacles when the
receptacle has been pushed through the outer barrel.
B. Where there is access to the inside of the outer barrel the 4-rivet
type receptacle must be used. Where there is no access the 2-rivet
type receptacle may be used again.
C. This repair removes the damaged bal-lok receptacle and installs

doubler plates, face plate and a new bal-lok receptacle.

(SPPM)
54-10-00 REPAIR No. 021 Structural Repair Manual (SRM)
VRS2725

Index).

CoMat 04-005 Jointing compound
CoMat 07-085 Varnish
V2500 54-10-00 REPAIR No. 022

Page 201
Feb 1/09
C. Repair parts
--------------------------------------------
PART NO. PART IDENT
--------------------------------------------
CCR264CS-5-2 Cherrylok rivet
CCR264CS-4-2 Cherrylok rivet
A4C3B2-069 Bal-lok Receptacle (2 rivet type)
A4C4B2-069 Bal-lok Receptacle (4 rivet type)
740-7601-501 Face plate A (2 rivet type)
740-7602-501 Doubler A (2 rivet type)
740-7603-501 Doubler B (4 rivet type)
740-7605-501 Face plate B (4 rivet type)
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Air Intake Cowl Composite structure
4. Prepare the repair area.
A. Mark out the repair area.
(1) Use a marking pen (CoMat 06-131).
(2) Use the center of the correct pin receptacle position as the
datum point.
(3) The mark must be a circle between 0.020 in. and 0.050 in.
(0,51 mm to 1,27 mm) larger than the face plate.
5. Cut out the hole for the face plate.

A. Carefully cut out the circular hole.
(1) Use the standard workshop tools.
(2) Make sure the diameter of the hole is between 0.020 in. and
0.050 in. (0,51 mm to 1,27 mm) larger than the face plate.
V2500 54-10-00 REPAIR No. 022

Page 202
Feb 1/09
B. Deburr the edges of the cut-out using waterproof silicon carbide

6. Attach the bal-lok receptacle to the face plate.
A. Using the two rivet type.
(1) Attach the bal-lok receptacle (A4C3B2-069) to the face plate

A with 2 cherrylok rivets (CCR264CS-4-2).
B. Using the four rivet type.
(1) Attach the bal-lok receptacle (A4C4B2-069) to the face plate

A with 4 cherrylok rivets (CCR264CS-4-2).
7. Drill the rivet holes in the air intake cowl.
A. Temporarily assemble the repair parts.
(1) Use temporary fasteners.
(2) Attach the receptacle/face plate assembly to the 2 doubler

plates.
(3) Make sure the doubler plates are pushed against each other.

B. Drill the pilot holes in the air intake cowl.
(1) Place the assembly on the outer skin of the air intake cowl
with the bal-lok receptacle in the center of the cut-out.
(2) Use a 0.09375 in. (2,382 mm) diameter drill and drill holes
through the doubler holes and into the air intake cowl.
(3) Make sure the holes align with those in the doubler plates.
C. Remove the temporary fasteners and release the doubler plates from
the receptacle/face plate assembly.
V2500 54-10-00 REPAIR No. 022

Page 203
Feb 1/09
D. Drill the rivet holes in the air intake cowl.
(1) Place the doubler plates on the inner side of the air intake
cowl and attach using temporary fasteners.
(2) Align the pilot holes in the air intake cowl with the holes
in the doubler plate.
(3) Use a 0.1563 in. (3,97 mm) diameter drill to increase the
pilot holes to align with those in the doubler plate.
E. Release the temporary fasteners and remove the doubler plates from
the air intake cowl cut-out.
F. Deburr the holes in the doubler plates and the air intake cowl. Use
the standard workshop tools and the waterproof silicon carbide
8. Clean the repair.
cleaner.
A. Clean the repair parts and the air intake cowl cut-out area with
methylethylketone (CoMat 01-076) and lint free cloth
(CoMat 02-099). Wipe the area with a clean piece of clean lint free
cloth before the solvent evaporates.
A. Apply the epoxy varnish (CoMat 07-085) with the tymex nylon brush
(CoMat 02-088) to the bare edges of the cut-out, to the edges of
the holes and to any exposed carbon fibers.
V2500 54-10-00 REPAIR No. 022

Page 204
Feb 1/09
11. Assemble the repair parts on to the air intake cowl.
A. Apply the jointing compound (CoMat 04-005) to the interfaces of the

air intake cowl, to the repair parts and to the rivets. Let the
compound dry for 10 minutes before the parts are assembled.
B. Attach the doubler plates to the inner surface of the air intake
skin.
(2) Use the cherrylok rivets (CCR264CS-5-2) as applicable.
C. Attach the receptacle/face plate assembly to the doubler plates.
(2) Use the cherrylok rivets (CCR264CS-5-2) as applicable.
(3) Make sure the receptacle is attached correctly to the face

plate.
V2500 54-10-00 REPAIR No. 022

Page 205
Feb 1/09
CAUTION: DO NOT USE TOO MUCH METHYLETHYLKETONE AS THIS MAY CAUSE DAM-
AGE TO THE VARNISH.
A. Remove all excess jointing compound from the repair area with a
clean metal spatula.

lint-free cloth (CoMat 02-099). Wipe the area dry with a clean
piece of lint-free cloth before the solvent evaporates.
13. Apply the aerodynamic sealant.
A. Apply aerodynamic sealant to the repair area (Ref. REPAIR No. 021
VRS2725).
A. Ident the component/log book with the REPAIR no.VRS2739

(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-10-00 REPAIR No. 022

Page 206
Feb 1/09

Fig. 201
V2500 54-10-00 REPAIR No. 022

Page 207
Feb 1/09
V2500 54-10-00 REPAIR No. 022

Page 208
Feb 1/09
REPAIR 023
AIR INTAKE COWL - COOLANT DUCT REPLACEMENT
(VRS2933)
1. General
A. This procedure may be used to replace the coolant duct on the

aft bulkhead of the air intake cowl.

Consumable Index)

C. Repair Parts
PART NO. PART IDENT

740-3195-503 Cooling duct - undrilled
CR3523-5-10 Blind Rivet
CR3523-5-11 Blind Rivet
PART IDENT MATERIAL

Cooling duct Steel
Rear bulkhead Composite structure
V2500 54-10-00 REPAIR 023

Page 201
Feb 1/09
4. Repair the Damaged Cooling Duct

PPE IS NECESSARY.
CAUTION: MAKE SURE THAT YOU DO NOT CAUSE DAMAGE TO THE AFT BULKHEAD
OF THE AIR INTAKE COWL.
A. Remove the heads of the rivets which attach the duct to the
bulkhead.
(1) Use standard workshop tools.
(2) The rivets have a 0.156 in. (3.97 mm) diameter and steel
shanks.
(3) Damage to the duct is permitted because the duct is to be

discarded.
B. Remove the remaining parts of the rivets and the duct.
CAUTION: BE CAREFUL WHEN YOU REMOVE THE REMAINING PARTS OF THE

RIVETS. THERE ARE METAL WASHERS BONDED TO THE FORWARD FACE
OF THE BULKHEAD.
(1) Use a drift to push the rivets from their holes.
(2) Carefully remove the duct from the bulkhead.
V2500 54-10-00 REPAIR 023

Page 202
Feb 1/09
A. Use a plastic spatula to remove any jointing compound from the

repair area.
B. Clean the interfaces between the bulkhead and the duct with
(CoMat 02-099). Wipe the area dry.
6. Examine the Rear Bulkhead
A. There must not be cracks or visible damage around the rivet

holes or the 1.62 in. (41.1 mm) diameter hole.
B. Using standard workshop tools, measure the diameter of the

rivet holes.
(1) The diameter of the rivet holes must not be larger than
0.164 in. (4.17 mm).
C. Make sure that the washers on the forward face of the bulkhead
are satisfactory.
7. Prepare the Replacement Duct
A. Align the duct with the 1.62 in. (41.1 mm) diameter hole.
B. Make a copy of the hole positions in the bulkhead on the duct.
(1) Use a hole finder or make a template.
V2500 54-10-00 REPAIR 023

Page 203
Feb 1/09
(2) Make sure that the rivet edge distance is 0.40 in. (10.2
mm) or smaller if approved by inspection.
NOTE: If possible, adapt the discarded duct to make a tem-

plate for drilling the holes.
C. Drill the rivet holes in the replacement duct.
(1) Use a 0.063 in. (1.60 mm) diameter drill for the pilot
holes.
(2) Hole sizes for the rivets must be 0.160 to 0.164 in. (4.06
to 4.16 mm) diameter.
(3) Make sure the holes in the replacement duct align

accurately with the holes in the bulkhead. Do not damage
or increase the diameter of the holes in the bulkhead.
D. Use standard workshop tools to remove all burrs from the rivet
holes in the replacement duct.
8. Examine the Rivet Holes In the Cooling Duct and the Aft Bulkhead
A. Make sure that the holes in the duct and the bulkhead are
aligned.
9. Clean the Repair Area and the Replacement Duct
A. Clean the interfaces of the bulkhead, the repair area and the
replacement duct with methylethylketone (CoMat 01-076) and
V2500 54-10-00 REPAIR 023

Page 204
Feb 1/09
10. Install the Replacement Duct
A. Apply the jointing compound
(1) Apply a thin layer of jointing compound (CoMat 04-005) on

the interfaces of the aft bulkhead and the replacement
duct.
(2) Let the parts dry in the air for 10 minutes before they
are assembled.
B. Align the holes in the rear bulkhead with the holes in the
replacement duct.
C. Install the seven rivets.
(1) Make sure that the correct length of rivet is installed

into each hole.
V2500 54-10-00 REPAIR 023

Page 205
Feb 1/09
A. Use a plastic spatula to remove any excess jointing compound.
B. Clean the repair area around the duct with methylethylketone

(CoMat 01-076) and lint-free cloth (CoMat 02-099). Wipe the
area dry.
V2500 54-10-00 REPAIR 023

Page 206
Feb 1/09
Coolant Duct Repair

Figure 201
V2500 54-10-00 REPAIR 023

Page 207
Feb 1/09
V2500 54-10-00 REPAIR 023

Page 208
Feb 1/09
REPAIR 025
AIR INTAKE COWL - LIP SKIN INNER SURFACE RIVET REPLACEMENT REPAIR
(VRS2746)
1. General
A. This repair procedure is used to replace rivets on the inner

surface on the lip skin of the air intake cowl.
B. This repair removes the defective rivets and installs

replacement rivets. The replacement rivet is a blind cherrylock
type.
C. There is no limit to the number of rivets which can be replaced

in the lipskin inner section using this repair.

Suction cleaner
Cherrylock rivet gun Type G784 or equivalent
Cherrylock pulling head Type H681-6C
Cherrylock hole gauge Type T172-600

Consumable Index)
CoMat 01-076 Methylethylketone CH3C0C2H5

V2500 54-10-00 REPAIR 025

Page 201
Feb 1/09
C. Repair Parts
PART NO. PART IDENT

CR2538-6-3 Cherrylock rivet
CR2538-6-4 Cherrylock rivet
PART IDENT MATERIAL

Lip skin Aluminum alloy

PPE IS NECESSARY.
A. Clean the lip skin of the air intake cowl with

(CoMat 02-099). Dry the area.
5. Gain Access to the ‘D’ Chamber
A. Remove the TAI access panel.
B. Remove the TAI duct.
C. Remove capping plate located on the forward bulkhead adjacent

to the TAI bulkhead connection by removing and retaining bolts
(8 off) type A104-1-D and washers (8 off) type SP151-D.
V2500 54-10-00 REPAIR 025

Page 202
Feb 1/09
6. Prepare the Damaged Area for Repair (Ref Fig 201)
A. Make a mark against the damaged rivets which are to be removed

with a marking pen (CoMat 06-131).

PPE IS NECESSARY.
CAUTION: MAKE SURE THAT YOU DO NOT CAUSE DAMAGE TO THE DISTRIBUTION
RING OF THE ENGINE ANTI-ICING SYSTEM.
B. If more than 5 rivets are to be removed in one adjacent length

do not drill the third rivet in the row at this time.
C. Drill out the countersunk heads of the defective rivets. do not

make the rivet holes larger.
CAUTION: MAKE SURE THAT YOU DO NOT CAUSE DAMAGE TO THE ANTI-ICING
DUCT ANGLES OR THE AIR INTAKE COWL LIP SKIN.
D. Remove the defective rivet tails.
7. Inspect Holes for Correct Size
A. Check that the holes in the lipskin are not damaged.
B. Inspect holes in the lipskin to make sure that the diameter is

between 0.205 in. (5.2 mm) and 0.209 in. (5.3 mm).
NOTE: (1) If the holes are below 0.205 in. (5.21 mm) they must
be drilled out to the specified size given in step
B.
(2) If the holes are over 0.209 in. (5.31 mm) in

diameter tell Goodrich.
V2500 54-10-00 REPAIR 025

Page 203
Feb 1/09
8. Inspect Holes for Depth of Material
A. Use a depth gauge to measure which length of rivet is required.

In areas where there are buttstraps at the height of angles use
a CR2538-6-4 rivet.
9. Install New Rivets
A. Install rivets CR2538-6-3 and CR2538-6-4 as applicable using

cherrylock rivet gun type G784 or equivalent with pulling head
H681-6C.
B. Replace the rivets that were not drilled out in step 6.B. Do
steps 6 through 9.
10. Inspect Rivet Installation
A. Make sure that the rivet heads make a continuous surface with
the lipskin.
11. Remove Unwanted Material
A. Use a suction cleaner through the capping panel hole to remove

all rivet tails and metal particles.
12. Install the TAI Duct and All Access Panels
A. Use fasteners retained in step 5.C. to install the capping

plate.
B. Install TAI duct.
C. Install TAI access panel.
13. Make a visual inspection to make sure that the repair has been done
V2500 54-10-00 REPAIR 025

Page 204
Feb 1/09
REPAIR 026
AIR INTAKE COWL - LIPSKIN OUTER SURFACE RIVET REPLACEMENT REPAIR
(VRS2770)
1. General
A. This repair gives the procedures to replace the loose or

damaged rivets of the lipskin inner surface. In this procedure,
the term “cowl” is used to mean “air intake cowl”.
B. This repair removes the loose or damaged rivets and installs

replacement rivets. The replacement rivet is a blind type. An
oversize rivet can be used if required.
C. There is no limit to the number of rivets which can be replaced.

Keep the rivet hole a minimum edge distance of 1.6d.
D. Related Repairs:
(1) REPAIR 010 (VRS2746), Replace the loose or damaged rivets

of the Lipskin Inner Surface.
2. Referenced Information (See Table 601)
Reference Designation
PCI-V2500-1IA Overhaul Processes and Consumable Index
V2500 SPPM, Procedures to make identification and
Task 70-09-00-400-501 location marks
Reference Information
Table 601

Drilling equipment
Rivet gun
Pulling head
V2500 54-10-00 REPAIR 026

Page 201
Feb 1/09
Hole gauge
Suction cleaner
B. Consumable Materials (See Table 602)
NOTE: To identify the consumable materials, refer to the

Consumable Materials Index in the Introduction.
CoMat Item Number Designation

CoMat 01-076 Methylethylketone;
Consumables
Table 602
E. Repair Parts
PART NO. PART IDENT

CR3522-5-3 Rivet
CR3522-5-6 Rivet
F. Component Materials (See Table 603)
Part Identification Material

Lipskin Aluminium Alloy
V2500 54-10-00 REPAIR 026

Page 202
Feb 1/09
4. Clean the Outer Surface of the Lipskin
A. Wipe the repair area clean with a CoMat 02-099 lint-free cloth
made moist with CoMat 01-076 methylethylketone. Wipe the area
dry with a CoMat 02-099 lint-free cloth before the fluid dries.
5. Remove the Anti-Ice Ducts and Access Panels to the Lipskin inside
area
NOTE: Removal of the anti-ice access panel is the same for air
intake cowls with SBN71-0184 or SBN70-0134.
A. Remove the 23 bolts and anti-ice access panels from the air
intake cowl. (See Figure 201).
B. Remove the anti-ice clamp insulation (1) and (2), and the clamp
and seal at the air intake cowl rear bulkhead. (See Figure
205).
C. Remove the 7 bolts from each of the two half locating plates.
Remove the two half locating plates from the air intake cowl
rear bulkhead. (See Figure 202).
D. Put your hand into the air exhaust and hold the inner duct. Pull
the inner and outer duct away from the anti-ice bulkhead
fitting. Keep the two ducts together and remove them through
the anti-ice access panel opening. (See Figure 203).
E. Seal the anti-ice bulkhead fitting with a cap. (See Figure

203).
F. Remove the 8 bolts, washers, and cover plate adjacent to the

anti-ice bulkhead fitting on the forward bulkhead. (See Figure
204).
V2500 54-10-00 REPAIR 026

Page 203
Feb 1/09
6. Remove the Loose or Damaged Rivets of the Lipskin Outer Surface

PPE IS NECESSARY.
CAUTION: WHEN REMOVING RIVETS DO NOT INCREASE THE RIVET HOLE SIZE.
DO NOT DRILL THROUGH THE RIVET. DAMAGE TO THE INTERNAL
PARTS MAY OCCUR. DO NOT REMOVE MORE THAN THREE ADJACENT
RIVETS AT ONE TIME. MISALIGNMENT OF THE PARTS MAY OCCUR.
NOTE: When drilling rivets or rivet holes, use a drill stop to

prevent damage.
A. Identify the loose or damaged rivets of the lipskin outer

surface with a CoMat 06-131 marking pen.
B. Remove the loose or damaged rivets. If more than five adjacent

rivets must be removed, leave each third rivet in place until
the adjacent rivets are replaced.
(1) When removing a blind type rivet, use a pilot drill to

drill the rivet stem through the head. Use a punch to
remove the rivet lock collar. Use a 0.156 in. (3,96 mm)
drill to drill the rivet head. Do not drill through the
rivet. Use a punch to remove the rivet head. Use a punch
to drive the remaining rivet shank from the hole.
V2500 54-10-00 REPAIR 026

Page 204
Feb 1/09
(2) When removing a standard rivet, use a 0.156 in. (3,96 mm)
drill to remove the rivet head. Do not drill through the
rivet. Use a punch to remove the rivet head. Use a punch
to drive the remaining rivet shank from the hole.
7. Clean the Repair Area Surface of the Lipskin
moistened with CoMat 01-076 methylethylketone. Wipe the area
8. Examine the Rivet Holes
A. Check that the rivet holes are not damaged. Use the hole gauge
to check the diameter of the holes. Rivet holes must not be more
than 0.166 in. (4,216 mm) for a standard rivet. If the rivet
hole is more than 0.166 in. (4,216 mm) contact Goodrich.
9. Replace the Loose or Damaged Rivets of the Lipskin Outer Surface
NOTE: Install the rivets flush with the lipskin surface.
A. Use a depth gauge to measure for the correct rivet length. Put
a thin layer of CoMat 04-005 jointing compound on the rivets
and in the rivet holes. Use the rivet gun, (type with the
pulling head), to install the rivets.
10. Remove Unwanted Material
A. Use a suction cleaner, through the access hole in the forward

bulkhead, to remove all rivet tails and metal particles. (See
Figure 204)
V2500 54-10-00 REPAIR 026

Page 205
Feb 1/09
11. Clean the Repair Area of the Lipskin
made moist with CoMat 01-076 methylethylketone. Wipe the area
A. Make sure the repair is satisfactory and that it agrees with

the repair instructions.
13. Install the Anti-Ice Ducts and the Access Panels
A. Install the cover plate, washers, and 8 bolts on the forward

bulkhead, (adjacent to the anti-ice bulkhead fitting). Torque
the 8 bolts to 23-27 lb in. (2,5 to 3,0 Nm). (See Figure 204).
B. Remove the cap from the anti-ice bulkhead fitting. (See Figure
203).
C. Remove the anti-ice inner duct from the outer duct. Turn the
anti-ice inner duct end for end and install back in the outer
duct. (The aft end of the inner duct will now become the forward
end of the inner duct). (See Figure 203).
D. Hold the inner and outer anti-ice ducts together. Put them into
the air intake cowl through the anti-ice access panel opening.
align the air exhaust with the anti-ice access panel. Push the
two ducts into the anti-ice bulkhead fitting. (See Figure 203).
NOTE: Make sure the inner duct with the two small D-rings (1)
and (2), and the outer duct with the large D-ring and 3
ring pack are correctly engaged. (See Figure 203).
V2500 54-10-00 REPAIR 026

Page 206
Feb 1/09
E. Install the two half locating plates with the 7 bolts each, on
the rear bulkhead. (Make sure the half locating plates are
engaged in the anti-ice outer duct). Torque the seven bolts of
each half locating plate to 40 lbs in. (4,5 Nm). (See Figure
202).
F. Install the anti-ice seal and clamp at the air intake cowl rear
bulkhead. Torque tighten clamp to 45-55 lbs in. (5,0 to 6,2
Nm). Attach the clamp insulation (1) and (2) on the clamp with
CoMat 02-147 Lockwire. (See Figure 505).
NOTE: Installation of the anti-ice Access Panel is the same

for air intake cowls with SBN71-0184 or SBn70-0134.
G. Install the anti-ice access panel with the 23 bolts. Torque the
23 bolts to 30-35 lbs in. (3,5 to 4,0 Nm). (See Figure 201).
A. Mark the repair scheme VRS2770 on the air intake cowl, adjacent
to the part number. (Refer to the V2500 SPPM, Task
70-09-00-400-501).
V2500 54-10-00 REPAIR 026

Page 207
Feb 1/09
Remove/Install the Anti-Ice Access Panel

Figure 201
V2500 54-10-00 REPAIR 026

Page 208
Feb 1/09
Remove/Install the Half Locating Plates

Figure 202
V2500 54-10-00 REPAIR 026

Page 209
Feb 1/09
Remove/Install the Anti-Ice Ducts

Figure 203
V2500 54-10-00 REPAIR 026

Page 210
Feb 1/09
Remove/Install the Cover Plate

Figure 204
V2500 54-10-00 REPAIR 026

Page 211
Feb 1/09
Remove/Install the Anti-Ice Insulation and Clamp at the Air Intake

Cowl Rear Bulkhead
Figure 205
V2500 54-10-00 REPAIR 026

Page 212
Feb 1/09
REPAIR NO. 027

ACOUSTIC LINER WIRE MESH/FACING SHEET DELAMINATION REPAIR
VRS2779
1. General.
A. This procedure can be used to repair delamination to either the

wire mesh or the wire mesh plus the facing sheet (carbon ply). On
the 3-piece acoustic liner the delamination must be more than
1.5 in. (38,1 mm) from the edge of the acoustic panel. On the
(50,8 mm) from the edge of the acoustic panel. The delamination
must be confined to an area of 4.0 in. (101,6 mm) diameter or less.
B. This type of damage can be repaired by the removal of the damaged

area (wire mesh only). The honeycomb core is filled with potting
compound and then a carbon fibre patch is installed.
C. Damage which is not in the limits of this repair must be referred

to Goodrich.


(SPPM)
Heat lamp, 176o - 212oF (80o - 100oC)

Suction Cleaner
Plastic Spatula
V2500 54-10-00 REPAIR No. 027

Page 201
Feb 1/09

Index)

C. Special Tools
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------

A. Inspect the damaged area using IAE 1N20444 tapping tool and the tap
test method, (Ref. SRM 54-01-00) Composite Structure Tap Test, to
find any areas of delamination.
V2500 54-10-00 REPAIR No. 027

Page 202
Feb 1/09
B. Make a mark around the damaged area with a pencil. Make sure that
all areas of delamination are included.
C. Apply a 2.0 in. (50,8 mm) wide strip of teflon tape approximately
1.0 in. (25,4mm) away from the mark around the damaged area.
6. Remove the damaged area.

NECESSARY.
A. Remove the damaged area.
(1) Use a scalpel and cut around the damaged wire mesh.
NOTE: Make sure that you do not damage the facing sheet when
you cut the wire mesh.
(2) Carefully remove the damaged wire mesh.
B. Remove unwanted material from the repair area with a suction

cleaner.
NOTE: Make sure that there is no unwanted material between the

C. Use the heat lamps to dry the repair area for 6 hours at a temper-
ature of 176oF (80oC).
V2500 54-10-00 REPAIR No. 027

Page 203
Feb 1/09

8. Fill the honeycomb core (Ref. Fig. 201).
B. Fill the honeycomb core in the damaged area.
(1) Use a clean plastic spatula and fill the damaged area with
epoxy paste adhesive.
(2) Push the epoxy paste adhesive through the facing sheet until
it is level with the acoustic panel wire mesh.
9. Cure the epoxy paste adhesive.
A. Put at least two temperature probes on the teflon tape adjacent to

the repair area.
V2500 54-10-00 REPAIR No. 027

Page 204
Feb 1/09
B. Use heat lamps to cure the epoxy paste adhesive for 1 hour between
190o - 210oF (88o - 99oC)
NOTE: The rate of temperature increase and subsequent decrease

10. Prepare the repair patch.

NECESSARY.
A. Cut the repair patch.
(2) Use lint-free gloves (CoMat 02-097) and cut the repair patch
from a piece of dry carbon fibre fabric (CoMat 08-059).
(3) Make the repair patch 1.0 in. (25,4 mm) larger all around
than the repair cut-out.
B. Mix the epoxy paste adhesive (CoMat 08-050) in accordance with the
NOTE: After the repair patch is soaked, the remaining adhesive (if
it is kept cool) can be used in the installation process.
C. Apply the epoxy paste adhesive to the repair patch.
(1) Put the repair patch on a sheet of non-porous parting film

(CoMat 02-367).
(2) Use the brush (CoMat 02-087) and apply the adhesive to the
repair patch.
V2500 54-10-00 REPAIR No. 027

Page 205
Feb 1/09

the top of the repair patch.
(4) Use a roller and force the epoxy paste adhesive

(CoMat 08-050) fully into the repair patch.
D. Use standard workshop tools. Cut the repair patch to the same
dimensions as the area identified by the teflon tape.
E. Keep the repair patch and the adhesive cool until the installation
process.
11. Install the repair patch (Ref. Fig. 201).
A. Use a brush (CoMat 02-087) to apply an equal layer of epoxy paste

adhesive to the area identified by the teflon tape.
B. Install the repair patch.
(1) Remove one sheet of non-porous parting film (CoMat 02-367)

from the repair patch.
(2) Put the repair patch, with the adhesive (CoMat 08-050) side
down, on to the repair area in the correct position for
installation.
NOTE: Make sure that the repair area has an equal overlap
around the repair cut-out and touches the teflon tape.
V2500 54-10-00 REPAIR No. 027

Page 206
Feb 1/09
C. Prepare to cure the adhesive.
(1) Put a sheet of porous parting film (CoMat 02-334) on top of

the repair patch.
NOTE: Make sure that the porous parting film is 1.0 in. (25,4
mm) larger all around than the repair patch.
(2) Put a sheet of breather cloth (CoMat 02-166) on to the repair

area.
NOTE: Make sure that the breather cloth is 2.0 in. (50,8 mm)
larger all around than the non-porous parting film.
(3) Put the heat blanket on top of the breather cloth

(CoMat 02-166) and keep an equal overlap all around the
repair area.
(4) Put at least two temperature probes on the teflon tape,

adjacent to the repair area.
(5) Put a sheet of breather cloth (CoMat 02-166) on top of, and
with an equal overlap all around, the heat blanket.
(6) Put a caul plate on top of the repair and weigh down with
weights.
NOTE: Use applicable weights (sand bags for example) that

will not cause damage to the intake cowl.
A. Use the heat blanket to keep the temperature of the repair area
B. The rate of temperature increase and subsequent decrease must not

C. Start to measure the time for the epoxy paste adhesive to cure when
the temperature reaches 194oF (90oC).
A. When the cure process is completed, remove the blanket, the

temperature probes and the teflon tape.
V2500 54-10-00 REPAIR No. 027

Page 207
Feb 1/09

NECESSARY.

(CoMat 05-021).
cleaner.
NOTE: Make sure that no unwanted particles stay in the acoustic

panel.

V2500 54-10-00 REPAIR No. 027

Page 208
Feb 1/09
A. Ident the component/log book with the REPAIR no. VRS 2779
(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-10-00 REPAIR No. 027

Page 209
Feb 1/09
Acoustic Liner Wire Mesh/Facing Sheet Delamination Repair

V2500 54-10-00 REPAIR No. 027

Page 210
Feb 1/09

Figure 201(Sheet 2)
V2500 54-10-00 REPAIR No. 027

Page 211
Feb 1/09

Figure 201(Sheet 3)
V2500 54-10-00 REPAIR No. 027

Page 212
Feb 1/09
REPAIR NO. 029

AIR INTAKE COWL ACOUSTIC LINER FACING SHEET HOLE REPAIR
VRS2780
1. General.
A. This procedure may be used to repair holes in the acoustic liner

facing sheet. The holes must be less than 0.25 in. (6,4 mm) in
diameter and a minimum of 12.0 in. (304,8 mm) between damaged
areas. On the 3-piece acoustic liner the delamination must be more
than 1.5 in. (38,1 mm) from the edge of the acoustic panel. On the
(50,8 mm) from the edge of the acoustic panel.
B. This type of damage can be repaired by drilling through the damaged

area (not through the sectum layer). The hole is then filled with
epoxy paste adhesive.
C. This repair causes blockage in the acoustically treated areas. For


to Goodrich.

(SPPM)

Syringe
Rotary file
Drill and drilling equipment
V2500 54-10-00 REPAIR No. 029

Page 201
Feb 1/09

Index)

C. Special Tools
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------

A. Make a mark around the damaged area with a pencil, make sure that
all cracks and areas of delamination are included.
NOTE: The maximum diameter of the damaged area must be less than
0.25 in. (6,4 mm).
V2500 54-10-00 REPAIR No. 029

Page 202
Feb 1/09

NECESSARY.
A. Remove the damaged area.
(1) Use an applicable drill to drill out any loose or frayed

facing sheet material in the damaged area.
NOTE: Make sure that you do not damage the septum layer.
(2) Use the rotary file and remove any sharp edges from the
damaged area.

V2500 54-10-00 REPAIR No. 029

Page 203
Feb 1/09
NOTE: Make sure that you do not mix more than 250 grams of the
epoxy paste adhesive in one container.
B. Use the syringe and apply the epoxy paste adhesive into the holes
in the facing sheet.
NOTE: Make sure that there is an overflow of epoxy paste adhesive

from each hole.
9. Seal the epoxy paste adhesive, if necessary (Ref. Fig. 202).
A. Cut a piece of non-porous parting film (CoMat 02-367) for each hole
in the facing sheet.
NOTE: Make sure that each piece of non-porous parting film is

larger all around than its applicable hole.
B. Put the pieces of non-porous parting film (CoMat 02-367) over each
applicable hole and safety into position with speed tape.
C. Clean all unwanted epoxy paste adhesive away from the repair holes.
10. Cure the epoxy paste adhesive.
A. Use the heat lamps to cure the epoxy paste adhesive for 1 hour at a
temperature of 194oF (90oC).
NOTE: Make sure that the cure temperature does not get higher than
194oF (90oC).
V2500 54-10-00 REPAIR No. 029

Page 204
Feb 1/09
11. Remove the repair equipment (if necessary).
A. Remove the speed tape and the non-porous parting film

(CoMat 02-367) from each repair hole.
12. Prepare the repaired surface (Ref. Fig. 202).

NECESSARY.
A. Use the waterproof abrasive paper (CoMat 05-019) and make the
repair holes smooth. The contours of the repair holes must be
smooth with the outer skin.
cleaner.
NOTE: Make sure that no unwanted particles stay in the acoustic

panel.

V2500 54-10-00 REPAIR No. 029

Page 205
Feb 1/09
(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-10-00 REPAIR No. 029

Page 206
Feb 1/09

V2500 54-10-00 REPAIR No. 029

Page 207
Feb 1/09

V2500 54-10-00 REPAIR No. 029

Page 208
Feb 1/09

V2500 54-10-00 REPAIR No. 029

Page 209
Feb 1/09

Figure 202
V2500 54-10-00 REPAIR No. 029

Page 210
Feb 1/09
REPAIR NO. 030

AIR INTAKE COWL WORN CAPPING STRAP REPAIR
VRS2792
1. General.
A. This repair gives the procedures to repair a worn capping strap on

the aft edge of the air intake cowl.
NOTE: This repair is an alternative to REPAIR No. 020 (VRS2788), in

the Air Intake Cowl CMM.
B. The A1 hybrid (serial no. V299 and subsequent) and all standards of
A5 air intake cowls only, have a capping strap. This repair is not
applicable to the panel edge landings on the A1 air intake cowl.
The damage must be only on the capping strap and not on the rub
strip. Refer to Fig. 201.
C. The length of the damage must not be more than 36.31 in. (922,3 mm)
at each side from the 12 o’clock position and 13.71 in. (348,2 mm)
across the bottom. Refer to Fig. 201.
D. Where damage is beyond the scope of this repair refer to Goodrich.

(SPPM)
(SPPM)
(SPPM)
TASK 71-11-00-300-020 Air Intake Cowl CMM
(CMM-AIC-V2500-1IA)
Drill
G-Clamps
Punch
Countersink tool
Spray gun (optional)
V2500 54-10-00 REPAIR No. 030

Page 201
Feb 1/09
B. Special Tools
None.

(PCI)).

CoMat 02-087 Tymex nylon brush (optional)
CoMat 02-357 Al-clad sheet
CoMat 07-156 Primer base
CoMat 07-057 Primer converter
CoMat 07-158 Thinner
D. Repair parts
--------------------------------------------
PART NO. PART IDENT
--------------------------------------------
HL11VF6-6 Pin/Rivet
HL97V-6 Collar
NAS9314AD5-5 Rivet
NAS9314AD5-6 Rivet
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Capping strap Aluminium alloy
4. Identify the damaged area (Ref. Fig. 201).
A. Using the marking pen (CoMat 06-131), mark around the damaged area.
Make sure that the mark is a minimum of 2D from the first hole on
each side of the undamaged capping strap.
V2500 54-10-00 REPAIR No. 030

Page 202
Feb 1/09

cloth.
A. If necessary, remove adjacent access panels.
B. If necessary, remove the rivets that attach the rubbing strip.
C. If necessary, hold the rubbing strip out of the way.
D. Remove the fasteners that attach the damaged area to the aft angle.
NOTE: Make sure the holes in the aft angle are not damaged during
removal of the fasteners.
(1) Use a 0.160 in. (4,0 mm) diameter drill to remove the heads
of the rivets.
(2) Use a punch to remove the rivets from the holes.
(3) Put an Allen key into the pin to hold it stable. Keep the
pins and discard the collars.
E. Cut out and remove the damaged area of the capping strap. Make sure
there is a minimum of 2D edge distance on adjacent fasteners. Do
not remove the part of the capping strap under the outer skin.
NOTE: Make sure not to damage the adjacent area.
F. Inspect the trimmed edges of the capping strap to make sure there
are no cracks (Ref. SPM TASK 70-25-01-250-501).
V2500 54-10-00 REPAIR No. 030

Page 203
Feb 1/09

cloth.
8. Make the replacement capping strap sections.
A. Make repair sections from al-clad sheet (CoMat 02-357). Use the
removed sections as a template.
9. Prepare the capping strap sections (Ref. Fig. 201).
A. Put the replacement capping strap sections in the correct position

for installation using g-clamps. Do not tighten the g-clamps too
much.
B. Put marks, for hole locations, through the aft angle onto the
capping strap section using a marking pen (CoMat 06-131).
C. Drill the rivet or pin holes in the aft side of the capping strap
section.
Where rivets are used, drill the holes in the capping strap between
0.160 and 0.164 in. (4,06 and 4,17 mm).
Where pins are used, drill the holes in the capping strap between
0.190 and 0.193 in. (4,82 and 4,90 mm).
NOTE: Make sure that the holes in the capping strap align with the
holes in the aft angle.
D. Countersink the rivet holes in the capping strap.
NOTE: Make sure the rivet head will be flush with the surface.
E. Remove the replacement sections from the repair area.
V2500 54-10-00 REPAIR No. 030

Page 204
Feb 1/09
F. Surface treat the repair replacement sections and the trimmed

edges of the capping strap using chromate conversion coating
(CoMat 07-023) (Ref. SPM TASK 70-38-02-300-503).
10. Apply primer to the replacement section and damaged area.
A. Mask around the repair area with the masking tape (CoMat 02-178) to
prevent overspray.
B. Mix the primer base (CoMat 07-156), the primer converter

(CoMat 07-157), and the thinner (CoMat 07-158) in accordance with
the manufacturers instructions. Let the mixture set for 30 minutes
before you use it.
C. Apply the primer to the replacement sections and repair area within
the masking tape with either the spray equipment or a brush.
CAUTION: ALLOW THE PAINT TO DRY FOR 15 MINUTES BEFORE THE HEAT IS
APPLIED.
D. Cure the primer for one hour at 180o - 200oF (82o - 93oC) with an
explosion proof heat lamp.
11. Install the replacement capping strap section.
A. Apply a thin layer of jointing compound (CoMat 05-057) to the

mating surfaces of the capping strap. Put the capping strap into
position for installation. Use the applicable rivets or pins (as
previously removed) and collars to attach the capping strap to the
aft angle.
B. If necessary, install the rivets that attach the rubbing strip.
V2500 54-10-00 REPAIR No. 030

Page 205
Feb 1/09

14. Install adjacent access panels.
A. If necessary, install adjacent access panels that were removed

before.
A. Mark the repair scheme number (VRS 2792) on the air intake cowl,
adjacent to the part number (Ref. IAE V2500 SPPM,
TASK 70-09-00-400-501).
V2500 54-10-00 REPAIR No. 030

Page 206
Feb 1/09
Repair Worn Capping Strap on the Aft Edge of Air Intake Cowl
Fig. 201 (Sheet 1)
V2500 54-10-00 REPAIR No. 030

Page 207
Feb 1/09
Fig. 201 (Sheet 2)
V2500 54-10-00 REPAIR No. 030

Page 208
Feb 1/09
Fig. 201 (Sheet 3)
V2500 54-10-00 REPAIR No. 030

Page 209
Feb 1/09
V2500 54-10-00 REPAIR No. 030

Page 210
Feb 1/09
REPAIR NO. 031

AIR INTAKE COWL - SURFACE DAMAGE BLEND REPAIR ON THE TITANIUM AFT BULKHEAD
VRS2501
1. General.
A. This repair is applicable to A5 titanium aft bulkheads only (serial

no. N7354 and sub). For A1, A1 hybrid and A5 composite aft
bulkheads (serial no. N5001 to N7353) refer to REPAIR No. 001
(VRS2803).
B. Use of this repair is restricted to the following types of damage

(Ref. SPPM TASK 70-02-02-350-501):
Abrasion
Scratch
Nick
Gouge
C. This repair blends out damage on the aft bulkhead.
D. The material thickness after the damage is removed is 0.035 in.

(0,9 mm) by a maximum length of 2.25 in. (57,2 mm) in any
direction. For damage more than these limits refer to VRS2794 or
VRS2793.
E. Damage must be a minimum of 6.5 in. (165,1 mm) between the edge of
one repair to the edge of the next repair.
F. Damage is not allowed within a 2D radius (D = diameter of fastener)

of a fastener and other features.
G. Damage must be more than 2D (D = diameter of fastener) from the

edge of the bulkhead.
H. The removed damage must have a minimum run-out to blend depth ratio
20:1.
I. Only one repair for each web bay (between each stiffener) is
permitted.
J. Damage which is not in the limits of this repair must be referred

to Goodrich.
V2500 54-10-00 REPAIR No. 031

Page 201
Feb 1/09

(VRS2803)
(VRS2793)
(VRS2794)
(SPPM)
(SPPM)
Suction cleaner
B. Special tools
None

Index).

CoMat 05-020 Waterproof silicone carbide abrasive paper
D. Expendable parts
None
E. Repair parts
None
F. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Aft bulkhead Titanium
V2500 54-10-00 REPAIR No. 031

Page 202
Feb 1/09
4. Examine the repair area (Ref. Fig. 201).
A. Examine the repair area of the cowl. Make a note of the depth of
damage. If the damage goes through the panel, do 54-10-00
REPAIR No. 032 (VRS2793). If the damage does not go fully through
the panel but is greater than 0.005 in. (0,13 mm) it is possible to
do 54-10-00 REPAIR No. 032 (VRS2793) or REPAIR No. 033 (VRS2794).

CAUTION: REMOVE THE MINIMUM QUANTITY OF MATERIAL NECESSARY TO MAKE

THE SHAPE OF THE PART SMOOTH. IF YOU REMOVE TOO MUCH MATERIAL
YOU WILL HAVE TO DO A DIFFERENT REPAIR.
CAUTION: YOU MUST USE SILICON CARBIDE TYPE WHEELS, STONES AND ABRA-
SIVE PAPERS TO DRESS, MAKE SMOOTH AND POLISH TITANIUM COMPO-
NENTS. YOU MUST NOT USE ALUMINIUM OXIDE TYPES.
A. Carefully hand blend the damaged area.
(1) Remove the high-points, the burrs and radius the bottom of
the damage.
(2) Blend to a depth to width ratio of 1:20, sufficient only to

remove all traces of damage to ensure no increase in damage
depth exists.
V2500 54-10-00 REPAIR No. 031

Page 203
Feb 1/09
B. Polish the damaged area with waterproof silicon abrasive paper

(CoMat 05-020) and (CoMat 05-064) to get the necessary surface
finish.
A. When the repair is completed, remove the repair materials from the
repair area.
B. Clean the repair area with methylethylketone (CoMat 01-076) using

A. Make a mark of the REPAIR number, VRS2501, on the aft bulkhead

adjacent to the part number,(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-10-00 REPAIR No. 031

Page 204
Feb 1/09

Fig. 201
V2500 54-10-00 REPAIR No. 031

Page 205
Feb 1/09
V2500 54-10-00 REPAIR No. 031

Page 206
Feb 1/09
REPAIR NO. 032

AIR INTAKE COWL TITANIUM AFT BULKHEAD WEB - HOLE REPAIR
VRS2793
1. General.

no. N7354 and subs). For A1, A1 hybrid and A5 composite aft
bulkheads (serial no. N5001 to N7353) refer to REPAIR No. 004
(VRS2802).
B. This repair removes the damaged area and installs a doubler plate.
C. The area of damage must not be more than 1.0 in. (25,4 mm) in
diameter when the damage is cleaned up. The damage can only be
repaired on the web where the web area is sufficiently large to
permit a doubler plate to be installed. If the damage is more do
REPAIR No. 033 (VRS2794).
D. Only one repair for each web segment is permitted, and three
repairs for each bulkhead. Refer to Fig. 201.
E. Damage which is not in the limits of this repair must be referred

to Goodrich.

(VRS2802)
(VRS2794)
(SPPM)
(SPPM)
Suction cleaner
B. Special tools
None
V2500 54-10-00 REPAIR No. 032

Page 201
Feb 1/09

Index).

CoMat 02-255 Titanium sheet 0.05 in. (2,27 mm) thick (AMS 4901)
CoMat 08-024 Sealant, PR-1422
D. Expendable parts
None
E. Repair parts
--------------------------------------------
PART NO. PART IDENT
--------------------------------------------
NAS9307M-5 Monel blind rivet
F. Component material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
V2500 54-10-00 REPAIR No. 032

Page 202
Feb 1/09
A. Mark around the repair area using marking pen (CoMat 06-131). Make
sure the area is a regular shape.

B. Use a high speed rotary cutter to remove the damaged area.
C. Remove the sharp edges from the damage with the abrasive paper
(CoMat 05-021).
6. Make the doubler plate (Ref. Fig. 202).

CAUTION: YOU MUST USE SILICON CARBIDE TYPE WHEELS, STONES AND
ABRASIVE PAPERS TO DRESS, MAKE SMOOTH AND POLISH TITANIUM
COMPONENTS. YOU MUST NOT USE ALUMINIUM OXIDE TYPES.
DO NOT USE FORCE WITH MECHANICAL CUTTERS OR THE MATERIAL WILL

BECOME TOO HOT.
IF THE MATERIAL SHOWS A CHANGE IN COLOR, FROM A LIGHT STRAW

TO A DARK STRAW/BLUE COLOR, THE COMPONENT MUST BE REJECTED.
A. Make a rectangular doubler plate from titanium sheet (AMS 4901),

0.05 in. (1,27 mm) thick (CoMat 02-255). The doubler plate must be
large enough to incorporate a minimum of two rows of rivets all
around the damaged area. Refer to Fig. 202.
V2500 54-10-00 REPAIR No. 032

Page 203
Feb 1/09
B. Make a mark of the two rows of rivet holes on the doubler plate. The
edge distance must be a 2D minimum and the pitch of the rivet holes
as follows. Refer to Fig. 202.
(1) Draw a square around the damaged clean-up area 2D larger than
the damage. Mark a rivet hole at each corner and a rivet hole
centrally between each corner, a total of 8 rivet holes.
(2) Draw an outer square 3D larger than the inner square. Mark a
rivet hole at each corner. Position the pitch of two rivet
holes equally between the pitch of the inner row, a total of
12 rivet holes.
NOTE: Make sure that the distance between two rivets is

always between 4D and 6D.
C. Put the doubler plate in position on the damaged web. Make sure
that the damaged area is in the center of the doubler plate.
D. Temporarily install the doubler plate on to the web with soft

clamps.
E. Drill two 0.094 in. (2,38 mm) diameter pilot holes through the
doubler plate and the web. Ref. step B.
F. Temporarily install the doubler plate. Use temporary fasteners to

hold the plate in position.
G. Drill all the pilot holes in the repair pattern, 0.094 in.
(2,38 mm) diameter.
H. If necessary, install a fastener in each corner of the plate. Drill

pilot holes 0.094 in. (2,38 mm) diameter. Make sure there is an
edge distance of 2D.
I. Drill the holes to their final size, 0.160 in. (4,06 mm).
J. Remove the doubler plate from the repair area.
K. Remove the burrs and sharp edges using the abrasive paper
(CoMat 05-021).
V2500 54-10-00 REPAIR No. 032

Page 204
Feb 1/09
7. Make an inspection of the repair area and the doubler plate.
A. Do a visual check of the repair area and the drilled holes to make
sure there is no more damage.
B. Use the applicable fluorescent penetrant examination to inspect

the doubler plate, the repair area and the drilled holes, refer to
Standard Practices Manual (SPPM) 70-23-01-200-501. Make sure there
are no cracks.
8. Install the doubler plate.
A. Apply PR-1422 sealant (CoMat 08-024) to the faying surfaces of the

doubler plate and the web.
B. Let the sealant dry for 10 minutes before assembly of the parts.
C. Put the doubler plate into position. Make sure the holes are
aligned. Use temporary fasteners to hold the plate in position.
D. Install the doubler plate to the web using NAS9307M-5 rivets.
A. Do a visual inspection to make sure that the rivets are installed

correctly, and for signs of damage around the rivet heads.
B. Do a visual inspection to make sure that the repair has been done
in accordance with this procedure.
V2500 54-10-00 REPAIR No. 032

Page 205
Feb 1/09
A. Make a mark of the REPAIR number, VRS2793, on the aft bulkhead

adjacent to the part number,(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-10-00 REPAIR No. 032

Page 206
Feb 1/09

Fig. 201
V2500 54-10-00 REPAIR No. 032

Page 207
Feb 1/09
Repair Doubler
Fig. 202
V2500 54-10-00 REPAIR No. 032

Page 208
Feb 1/09
REPAIR NO. 033

AIR INTAKE COWL - TITANIUM AFT BULKHEAD DAMAGED WEB REPAIR SECTION REPLACEMENT
VRS2794
1. General.

no. N7354 and sub). For A1, A1 hybrid and A5 composite aft
bulkheads (serial no. N5001 to N7353) refer to REPAIR No.1
(VRS2803).
B. This repair removes a damaged section of the web and replaces it

with a new section. Use this repair if the damage is more than the
limits permitted to repair with VRS2501 or VRS2793.
C. Only one repair for each web segment is permitted, and three
repairs for each bulkhead. The damage should not extend more than
two stiffeners. The maximum web section permitted to be removed is
one full section and the two adjacent half sections. Refer to
Fig. 201.

to Goodrich.

(VRS2803)
(VRS2501)
(VRS2793)
(SPPM)
(SPPM)
(SPPM)
(SPPM)
V2500 54-10-00 REPAIR No. 033

Page 201
Feb 1/09
Suction cleaner
B. Special tools
None

Index).

CoMat 02-255 Titanium sheet 0.05 in. (2,27 mm) thick (AMS 4901)
CoMat 08-021 Adhesive, EA934NA
CoMat 08-024 Sealant, PR-1422
D. Expendable parts
None
E. Repair parts
--------------------------------------------
PART NO. PART IDENT
--------------------------------------------
MS20615-5 Rivet
NAS9307M-5 Monel blind rivet
745-3440-501 Titanium aft bulkhead web section
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
V2500 54-10-00 REPAIR No. 033

Page 202
Feb 1/09
A. Clean the damage and repair area of the bulkhead with

A. Use a marking pen (CoMat 06-131) to make a mark around the repair
area. Identify the middle of the web bay each side of the damaged
area, and make a mark for the cut-lines. Refer to Fig. 202.
NOTE: If damage is near to a joint position on the bulkhead, only

one cut-line, on the opposite side of the damage, is
necessary.

B. Remove all the rivets contained in the identified repair area.
C. Record the position of the zed stiffener on the attachment flanges.
V2500 54-10-00 REPAIR No. 033

Page 203
Feb 1/09

CAUTION: YOU MUST USE SILICON CARBIDE TYPE WHEELS, STONES AND ABRASIVE
PAPERS TO DRESS, MAKE SMOOTH AND POLISH TITANIUM COMPONENTS.
YOU MUST NOT USE ALUMINIUM OXIDE TYPES.

BECOME TOO HOT.

A. Put a protective plate between the web and the engine ring to
prevent damage to the engine ring when the web is cut.
B. Use a high speed rotary cutter to cut along the marked lines to
remove the damaged area.
C. Remove the sharp edges from the web cut-out with the abrasive paper
(CoMat 05-021).
7. Make the repair piece.
A. Use a marking pen (CoMat 06-131) to mark the repair piece on a

replacement segment. Use the damaged section as a template. The
repair piece must be removed from the same area of a replacement
web segment.
V2500 54-10-00 REPAIR No. 033

Page 204
Feb 1/09


BECOME TOO HOT.

B. Use a high speed rotary cutter to cut-out the repair piece.
C. Remove the sharp edges from the repair piece with the abrasive
D. Use clamps to temporarily attach the template to the repair piece.
E. Pilot drill all the rivet holes from the template to the repair
piece. Use a 0.1719 in. (4,366 mm) drill to open the holes to their
final size.
NOTE: Do not drill the holes for the zed stiffener.
F. Disassemble the template and the repair piece and remove the burrs
and sharp edges with abrasive paper (CoMat 05-021).
G. Use temporary fasteners to attach the repair piece in position on

the rear bulkhead.
H. Use soft clamps to temporarily attach the replacement zed stiff-

ener to the repair piece in the correct position.
I. Pilot drill the rivet holes to from the zed stiffener to the repair
final size.
J. Disassemble the zed stiffener and the repair piece and remove the
burrs with abrasive paper (CoMat 05-021).
V2500 54-10-00 REPAIR No. 033

Page 205
Feb 1/09
8. Make the doubler plates.

CAUTION: YOU MUST USE SILICON CARBIDE TYPE WHEELS, STONES AND ABRASIVE
PAPERS TO DRESS, MAKE SMOOTH AND POLISH TITANIUM COMPONENTS.
YOU MUST NOT USE ALUMINIUM OXIDE TYPES.

BECOME TOO HOT.

A. Make the doubler plates from titanium sheet (AMS 4901), 0.05 in.
(1,27 mm) (CoMat 02-255). Make sure the doubler plates have
sufficient area to rivet to the web.
NOTE: Only one doubler plate is necessary if the damaged area is

near to an original joint position on the bulkhead. Use the
segment joint as an attachment position.
B. Use a marking pen (CoMat 06-131) to make a mark along the center of
the doubler plates.
C. Use a marking pen (CoMat 06-131) to make a mark of the drill

pattern of rivet holes on the doubler plates. The edge distance
must be 2D minimum and the pitch is 4D minimum and 6D maximum.
Refer to Fig. 203.
D. Pilot drill holes through the doubler plates at the marked

positions. Use a 0.1719 in. (4,366 mm) drill to open the holes to
their final size. Remove the burrs with abrasive paper
(CoMat 05-021).
E. Temporarily install the doubler plates on to each end of the repair

piece with soft clamps.
F. Pilot drill the rivet holes from the doubler plates to the repair
final size.
G. Disassemble the doubler plates and the repair piece and remove the
V2500 54-10-00 REPAIR No. 033

Page 206
Feb 1/09
H. Use temporary fasteners to attach the doubler plates to the outer

face of repair piece. Put the repair assembly in position on the
web segment of the aft bulkhead. Use soft clamps to temporarily
attach the assembly.
I. Pilot drill the rivet holes from the doubler plates to the web
segment. Use a 0.1719 in. (4,366 mm) drill to open the holes to
their final size.
J. Disassemble the doubler plates and the web segment and remove the
A. Remove all unwanted material from the repair area and the inner
surfaces of the air inlet cowl with a suction cleaner.
B. Clean the damage and repair area of the bulkhead with the
10. Make an inspection of the repair area and the repair parts.
A. Do a visual check of the repair area and the drilled holes to make
sure there is no more damage.
V2500 54-10-00 REPAIR No. 033

Page 207
Feb 1/09
B. Inspect the doubler plate, the web sections (adjacent to the repair
area) and the replacement web sections using applicable fluorescent
penetrant examination, Standard Practices Manual (SPPM) 70-23-01-
200-501. Make sure there are no cracks.
11. Install the doubler plate.
A. Apply PR-1422 sealant (CoMat 08-024) to the faying surfaces of the

repair parts.
B. Let the sealant dry for 10 minutes before assembly of the parts.
C. Use temporary fasteners to attach the zed stiffener to the repair

piece.
D. Use MS20615-5 rivets to install the zed stiffener to the repair

piece. Use a depth gauge to find the correct rivet depth.
NOTE: Do not install rivets in the end positions where the

stiffener attaches to the attachment angles.
E. Use MS20615-5 rivets to install the doubler plates to the repair

piece. Use a depth gauge to find the correct rivet depth.
F. Put the repair piece assembly in position and align the holes in
the doubler plates with the web segment.
G. Use NAS9307M-5 blind rivets to install the doubler plates to the

web segment.
V2500 54-10-00 REPAIR No. 033

Page 208
Feb 1/09
H. Use NAS9307M-5 blind rivets to install the repair piece to the

inner and outer attachment angles.

A. Do a visual inspection to make sure that the rivets are installed

correctly, and for signs of damage around the rivet heads.
B. Do a visual inspection to make sure that the repair has been done
A. Make a mark of the repair number, VRS2794, on the aft bulkhead

adjacent to the part number, (Ref. SPPM TASK 70-09-00-400-501).
V2500 54-10-00 REPAIR No. 033

Page 209
Feb 1/09

Fig. 201
V2500 54-10-00 REPAIR No. 033

Page 210
Feb 1/09
Repair Area
Fig. 202
V2500 54-10-00 REPAIR No. 033

Page 211
Feb 1/09
Repair Doubler
Fig. 203
V2500 54-10-00 REPAIR No. 033

Page 212
Feb 1/09
REPAIR NO. 034

AIR INTAKE COWL INNER BARREL ACOUSTIC STRUCTURE HOLE REPAIR
VRS7504
1. General.
A. This procedure may be used to repair damage to the air intake cowl
(including cracks and delamination). The damage must be more than
2.5 in. (63,5 mm) from the forward edge and 7.0 in. (177,8 mm) from
the aft edge of the acoustic panel. On the 3-piece acoustic liner
the damage must be more than 2.5 in. (63,5 mm) from the axial edges
of the acoustic panel. On the 2-piece acoustic liner the damage
must be more than 3.5 in. (88,9 mm) from the axial edges of the
acoustic panel. Damage is not permitted in the 6 in. (152,4 mm)
area along I.R. 230o (ref. figs. 204 and 205). The cleaned up
damage must be confined to a maximum area of 0.5 in. (12,7 mm)
diameter of the backing tray (internal skin) and 2.0 in. (50,8 mm)
diameter of the facing sheet (carbon ply) (ref. Fig. 202). There
must be a minimum of 10.0 in. (254,0 mm) between damaged areas.
B. This repair removes the damaged area and installs a repair plate.
The repair area is filled with potting compound or structural
adhesive and then an outer ply is installed on top.
C. This repair causes blockage in the acoustically treated areas. For


to Goodrich.

(SPPM)
Heat lamp, 104o - 212oF (40o - 100oC)

Suction Cleaner
V2500 54-10-00 REPAIR No. 034

Page 201
Feb 1/09
B. Special Tools
C. Consumable Materials (Ref. Overhaul Processes and Consumables

Index)

D. Repair Parts
None.
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
4. Prepare the damaged area for repair (Ref. Fig. 201 and 202).

B. Inspect the damgeded area using IAE 1N20444 tapping tool and the
tap test method, SRM 54-01-00 Composite Structure Tap Test, to find
any areas of delamination.
V2500 54-10-00 REPAIR No. 034

Page 202
Feb 1/09
C. Mark around the damage with a pencil, making sure to include cracks
D. Put the teflon tape (CoMat 02-007) in 2.0 in. (50,8 mm) wide strips
approximately 1.0 in. (25,4 mm) away from the mark around the
damage.
NOTE: Make sure that the corners of the tape have a minimum radius
of 0.5 in. (12,7 m).

NECESSARY.
E. Use a high-speed rotary cutter and remove all the damage (including
cracks) from the carbon ply. Make sure the maximum diameter is not
more than 2.0 in. (50,8 mm).
CAUTION: DO NOT DAMAGE THE INTERNAL SKIN AND ADJACENT STRUCTURE WHEN
YOU REMOVE THE HONEYCOMB. IF YOU DAMAGE THE INNER SKIN AND
ADJACENT STRUCTURE YOU MAY HAVE TO DO A DIFFERNET REPAIR.
F. Use a high-speed rotary sander and remove the honeycomb from the
repair area.
G. Use a high-speed rotary cutter and remove all the damage (including
cracks) from the internal skin. Make sure the maximum diameter is
not more than 0.5 in. (12,7 mm) and there is a minimum overlap of
0.75 in. (19,1 mm) on the internal skin to support the repair
plate.
H. Trim and smooth the edges of the honeycomb with a scalpel.
NOTE: Make sure that the internal skin is not damaged when the
honeycomb is removed.
I. Remove unwanted material from the repair area with a suction

cleaner. Make sure there is no unwanted material between the
J. Let the repair area dry for 6 hours at 176oF (80oC) with a heat
lamp. The repair materials must be applied immediately after the 6
hours.
V2500 54-10-00 REPAIR No. 034

Page 203
Feb 1/09
5. Prepare the repair plate (Ref. Fig. 201 and 202).

NECESSARY.
A. Wear lint-free gloves (CoMat 02-097) and cut three pieces of dry
carbon fibre fabric (Comat 08-059) 1.0 in. (25,4 mm) larger all



same as the weight of the dry carbon fibre fabric
(CoMat 08-059).
C. Prepare the repair plate plies.
(1) Put each carbon fibre ply on a sheet of non-porous parting

film.
thoroughly.
(4) Cut each ply so that it has an overlap of appromimately

0.75 in. (19,1 mm) around the cut-out on the internal skin.
V2500 54-10-00 REPAIR No. 034

Page 204
Feb 1/09
D. Put the plies together to make the repair plate.
(a) Remove one sheet of non-porous film from two of the

plies.
(b) Remove both sheets of non-porous film from the third

ply.
(c) Use the roller to remove unwanted adhesive and air

from the three carbon fibre plies.
E. Cure the adhesive.

plate.

190oF (88oC).
6. Clean the repair area and the repair plate.
A. Clean the repair area and repair plate with methyletheylketone

(CoMat 01-076) and lint-free cloth (CoMat 02-099). Wipe the repair
area and repair plate dry.
V2500 54-10-00 REPAIR No. 034

Page 205
Feb 1/09
7. Install the repair plate (Ref. Fig. 202).
A. Mix the EA934NA adhesive (CoMat 08-021) in accordance with the

B. Install the repair plate.
(1) Apply a thin layer of structural adhesive to the mating

surfaces of the repair plate and the internal skin.
(2) Put the repair plate in the correct on the internal skin
position and install.
8. Fill the repair cut-out (Ref. Fig. 202).
A. Mix the potting compound (CoMat 08-072) or structural adhesive

(CoMat 08-021) in accordance with the manufacturer’s instructions.
B. Fill the repair cut-out with potting compound.
(1) Use the potting compound/structural adhesive to fill the

repair cut-out until it is level with the carbon ply.
(2) Make sure the honeycomb cells that can be seen are filled
with potting compound/structural adhesive.
V2500 54-10-00 REPAIR No. 034

Page 206
Feb 1/09
C. Put a cover on top of the potting compound/structural adhesive.

the top of the repair area.
(2) Put a cawl plate, and an applicable weight (eg. sandbag) on

D. Cure the potting compound/structural adhesive.
(1) Use heat lamps to cure the potting compound/structural

adhesive for 1 to 2 hours at 113o - 131oF (45o - 55oC).

E. When the repair is cool, remove the weight, the cawl plate and the
F. Smooth the surface of the potting compound/structural adhesive

with waterproof abrasive paper (CoMat 05-021).
9. Prepare the outer ply (Ref. Fig. 203).

NECESSARY.
A. Cut a piece of dry carbon fibre fabric (CoMat 08-059) 1.0 in.
(25.4 mm) larger all around than the area identified by the teflon
tape.
NOTE: Make sure that the outer ply is not cut to its correct
dimension until it has been soaked with adhesive.
V2500 54-10-00 REPAIR No. 034

Page 207
Feb 1/09
B. Mix the adhesive (CoMat 08-050) in accordance with the

NOTE: After the ply is soaked, the remaining adhesive (if it is

C. Prepare the outer ply.
(1) Put the carbon fibre ply on a sheet of non-porous parting

(2) Apply the adhesive to the ply with the brush (CoMat 02-087)
and put a second sheet of non-porous parting film on top.
(3) Use the roller to force the adhesive into the ply thoroughly.
Make sure the ply is soaked with the adhesive.
D. Cut the ply so that it is the same shape as the area identified by
the teflon tape.
NOTE: Make sure that the two pieces of non-porous parting film stay
on the ply until the installation procedure.
E. Keep the outer ply and the resin cool until the installation
procedure.
V2500 54-10-00 REPAIR No. 034

Page 208
Feb 1/09
10. Install the outer ply (Ref. Fig. 203)
A. Use the brush (CoMat 02-087) and apply an equal layer of adhesive
to the area identified by the teflon tape.
B. Put the outer ply into position.
(1) Remove one sheet of the non-porous parting film from the
outer ply.
(2) Put the outer ply, with the adhesive side down, on to the
repair area in the correct position for installation. Make
sure the outer ply has an equal overlap around the repair
cut-out and touches the teflon tape.
(3) Use the roller and smooth the surface of the outer ply until
all air bubbles are removed.
(4) Remove any unwanted adhesive with a clean metal spatula.
(5) Put a cawl plate, and an applicable weight (eg. sandbag) on

C. Cure the adhesive.
(1) Position the temperature probes adjacent to the adhesive.
(2) Use the heat lamp to keep the temperature of the repair area

190oF (88oC).
D. When the repair area is cool, remove the lamp, temperature probes,
weight, cawl plate, teflon tape and non-porous parting film.
V2500 54-10-00 REPAIR No. 034

Page 209
Feb 1/09
11. Make the edges of the outer ply smooth (Ref. Fig. 203)

NECESSARY.
A. Rub the edges of the outer ply, with waterproof abrasive paper
(CoMat 05-021), until smooth with the adjacent surface.
A. Remove all unwanted material with a suction cleaner. Make sure that
no particles of the materials stay in the acoustic panel.

(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-10-00 REPAIR No. 034

Page 210
Feb 1/09

Fig. 201
V2500 54-10-00 REPAIR No. 034

Page 211
Feb 1/09

Fig. 202
V2500 54-10-00 REPAIR No. 034

Page 212
Feb 1/09

Fig. 203
V2500 54-10-00 REPAIR No. 034

Page 213
Feb 1/09

Fig. 204
V2500 54-10-00 REPAIR No. 034

Page 214
Feb 1/09

Fig. 205
V2500 54-10-00 REPAIR No. 034

Page 215
Feb 1/09
V2500 54-10-00 REPAIR No. 034

Page 216
Feb 1/09
FAN COWL DOORS - STRUCTURE IDENTIFICATION
1. General.
A. The fan cowl is made up of two doors that enclose the fan section
of the engine. The doors form an aerodynamic faring from the aft
end of the inlet cowl to the forward end of the thrust reverser.
B. The fan cowl doors are made of bonded aluminum honeycomb structures
approximately 0.90 in. (22,9 mm) thick. The structure uses
composite lamintaed skins of graphite fiber, graphite tape, and
honeycomb core bonded together with epoxy paste adhesive under
pressure and elavated temperatures.
C. The doors are hinged from the engine pylon and fastened at the
lower bifurcation splitline by tension latches. The doors are
interchangeable from engine to engine.
2. Structure Description.
A. The materials used in the construction of the fan cowl doors are
graphite composites, machined CRES bar, aluminum alloy castings,
molded silicon rubber sections, and various fittings made from
formed CRES sheet and forged steel alloys.
B. The main structure of the fan cowl doors is a sandwich of graphite

composite, between 2 and 7 plies thick, and a aluminum alloy
honeycomb of two different densities.
C. The V2500 A5 derivative incorporates a wire mesh lightning strike

protection screening on the outer surface of the door.
3. Structure Identification.

(figures) and tables. The tables list the structural components used in
the fan cowl door except for fasteners. Each component is identified by
an item number in the table. The same item number also appears in the
figure. The tables give the component's description, gage (thickness),
and material.
A. Determine those parts which an operator should or should not

attempt to fabricate.
V2500 54-20-00 Page 1

Feb 1/09
Left Fan Cowl Door

Figure 1 (Sheet 1)
V2500 54-20-00 Page 2

Feb 1/09
Left Fan Cowl Door

Figure 1 (Sheet 2)
V2500 54-20-00 Page 3

Feb 1/09
Left Fan Cowl Door

Figure 1 (Sheet 3)
V2500 54-20-00 Page 4

Feb 1/09
Left Fan Cowl Door

Figure 1 (Sheet 4)
V2500 54-20-00 Page 5

Feb 1/09
Left Fan Cowl Door

Figure 1 (Sheet 5)
V2500 54-20-00 Page 6

Feb 1/09
Left Fan Cowl Door

Figure 1 (Sheet 6)
V2500 54-20-00 Page 7

Feb 1/09

(INCH)
1 HINGE BRACKET S80 CRES BAR
3 LATCH KEEPER BRACKET HC101 CASTING
4 FAN COWL PANEL, LH GRAPHITE/HONEYCOMB SANDWICH
5 OUTER SKIN 2 - PLY GRAPHITE COMPOSITE
6 CORE 0.76 ALUM HONEYCOMB, 3/8 INCH

(9,5 MM), TYPE AA5052
3.6 LBS/CU.ft (57,67 kg/M3)

(6,3 MM), TYPE AA5056
5.2 LBS/CU.ft (83,30 kg/M3)
8 INNER SKIN 2 - PLY GRAPHITE COMPOSITE
9 OIL FILLER DOOR 4 - PLY GRAPHITE COMPOSITE OUTER

SKIN/2 - PLY GRAPHITE COMPOSITE
INNER SKIN/ALUM ALLOY HONEYCOMB
CORE, 1/4 INCH (6,3 MM),
0.50 INCH (12,7 MM) THICK,
2.3 LBS/CUFT (36,85 MM)
9A OIL FILLER DOOR 8 - PLY GRAPHITE COMPOSITE

POST SB V2500-NAC-70-0751 10 - PLY GRAPHITE COMPOSITE
14 - PLY GRAPHITE COMPOSITE
10 RETAINING STRIP 0.028 S527 CRES SHEET
12 --
13 PACKER 7 - PLY GRAPHITE COMPOSITE
14 ACCESS DOOR HINGE S527 CRES - FABRICATED
15 SEAL RUBBER SILICON RUBBER MOLDED SECTION
Left Fan Cowl Door

Table 1 (Sheet 1)
V2500 54-20-00 Page 8

Feb 1/09

(INCH)
17 DOOR HINGE HC104 CASTING
18 LATCH PROPIETARY ITEM
19 HOLD-OPEN ROD PROPIETARY ITEM
20 HOLD-OPEN ROD PROPIETARY ITEM
21 STOW BRACKET PROPIETARY ITEM
23 CHIP DETECTOR DOOR 12 - PLY GRAPHITE COMPOSITE
24 STRAKE (N0001 THRU N0054) 2024 T3 CLAD ALUMINUM SHEET

QQ-A-250/5
25 STRAKE (N0055 AND ON) GRAPHITE COMPOSITE
Left Fan Cowl Door

Table 1 (Sheet 2)
V2500 54-20-00 Page 9

Feb 1/09
Right Fan Cowl Door

Figure 1 (Sheet 1)
V2500 54-20-00 Page 10

Feb 1/09
Right Fan Cowl Door

Figure 1 (Sheet 2)
V2500 54-20-00 Page 11

Feb 1/09
Right Fan Cowl Door

Figure 1 (Sheet 3)
V2500 54-20-00 Page 12

Feb 1/09
Right Fan Cowl Door

Figure 1 (Sheet 4)
V2500 54-20-00 Page 13

Feb 1/09
Right Fan Cowl Door

Figure 1 (Sheet 5)
V2500 54-20-00 Page 14

Feb 1/09
Right Fan Cowl Door

Figure 1 (Sheet 6)
V2500 54-20-00 Page 15

Feb 1/09
Right Fan Cowl Door

Figure 1 (Sheet 7)
V2500 54-20-00 Page 16

Feb 1/09
Right Fan Cowl Door

Figure 1 (Sheet 8)
V2500 54-20-00 Page 17

Feb 1/09

(INCH)
3 LATCH KEEPER BRACKET S80 CRES SHEET - FABRICATED
4 FAN COWL PANEL, RH GRAPHITE/HONEYCOMB SANDWICH
5 OUTER SKIN 2 - PLY GRAPHITE COMPOSITE

(9,5 MM), TYPE AA5052
3.6 LBS/CU.ft (57,67 kg/M3)

(6,3 MM), TYPE AA5056
5.2 LBS/CU.ft (83,30 kg/M3)
8 INNER SKIN 2 - PLY GRAPHITE COMPOSITE
9 AIR-START DOOR 8 - PLY GRAPHITE COMPOSITE
14 AIR-START HINGE PROPRIETARY ITEM
Right Fan Cowl Door

Table 1 (Sheet 1)
V2500 54-20-00 Page 18

Feb 1/09

(INCH)
17 DOOR HINGE BRACKET PROPRIETARY ITEM
18 LATCH PROPRIETARY ITEM
19 STOW BRACKET PROPRIETARY ITEM
20 HOLD-OPEN ROD PROPRIETARY ITEM
21 HOLD-OPEN ROD PROPRIETARY ITEM
22 LATCH PROPRIETARY ITEM
23 STRAKE (N0001 THRU N0054) 2024 T3 CLAD ALUMINUM SHEET

QQ-A-250/5
24 STRAKE (N0055 AND ON) GRAPHITE COMPOSITE
Right Fan Cowl Door

Table 1 (Sheet 2)
V2500 54-20-00 Page 19

Feb 1/09
V2500 54-20-00 Page 20

Feb 1/09
FAN COWL DOORS - ALLOWABLE DAMAGE
1. Introduction
This section contains the allowable damage limits for both sheet metal
and bonded panel structural components of the V2500 fan cowl doors. Any
damage which is found to be more than the allowable damage limits should
be repaired in accordance with the procedures found in 54-20-00, Repairs,
Page Block 201.
2. Zones
Each of the individual components is divided into zones. The zones which
are affected by the different types of allowable damage are identified in
the figures and tables which follow.
The information in this section is given in two paragraphs. Paragraph A

gives general information about allowable damage, structure material,
and damage types. Paragraph B gives the allowable damage limits for the
left and right Fan Cowl Door structure.
A. General

may be returned to service without repair. Damage permitted
by these data will have no significant effect on the strength
or fatigue life of the structure, which will still be able to
fulfill its design function. The types of allowable damage
permitted are defined and brief descriptions are given of
the cleanup procedures needed to either prevent damage
propagation or improve the aerodynamic smoothness of the
damaged part.
(2) Material Types - The materials used in the construction of

the fan cowl doors are graphite composites, machined
corrosion resistant steel (CRES) bar, aluminum alloy
castings, molded silicon rubber sections and various
fittings made from CRES sheet and forged steel alloys. The
main structure of the fan cowl doors is a sandwich of
graphite composite, two to seven plies thick, and aluminum
alloy honeycomb of two different densities.
V2500 54-20-00 Page 101

Feb 1/09
(3) Damage - All damage limits assume that exposed edges do not
extend above the skin contour. Any damage should be reworked
to remove or feather the extensions. Holes and cracks in the
pressure boundaries must be sealed with applicable tape
material. Allowable damage is classified as either unlimited
usage or time limited.
(a) Unlimited usage damage is defined as minor damage which

does not affect the structural integrity or functional
capability of the component and which needs no repairs
over the aircraft design life.
(b) Time limited damage is defined as minor damage which

design life of the component. Therefore, damage must be
permanently repaired no later than 6000 Flight Hours/
4500 Flight Cycles/20 Months. The location and size of
the damage is to be noted and checked at 600 Flight
Hours/750 Flight Cycles/100 Days intervals to make sure
that the damage has not grown beyond the time limited
damage allowances.
(4) Damage Types - The types of allowable damage permitted on the

fan cowl components are defined below. They apply only to the
parent material and do not include damage to surface finishes
such as paint.
(a) Abrasion - An abrasion is a damage area which results

in a cross sectional area change because the area was
scuffed, rubbed, scraped or had other surface erosion.
An abrasion usually appears rough and irregular.

results in a cross sectional area change. It is usually
caused by contact with a relatively sharp object which
produces a continuous, sharp or smooth channel-like
groove in the material.

Consider a series of nicks in a line to be a gouge.

V2500 54-20-00 Page 102

Feb 1/09
(e) Crack - A crack is a partial fracture or complete break

in the material and produces a most significant cross
sectional area change. It usually appears as an
irregular line.

respect to its normal contour. Area boundaries are
smooth. Its form is usually the result of contact with
a smoothly contoured object.
(g) Hole - A hole is a complete penetration of the

material.
(h) Disbond - A disbond is a separation of the face sheet

(i) Delamination - A delamination is the separation of two

B. Fan Cowl Door Structure - Allowable Damage (See Figure 101, Figure
102 and Table 101).
The allowable damage zones for the fan cowl door structure are:
A - Hinge area, Figure 101 (Sheets 1 & 5) and Figure 102 (Sheets
1 & 5).
B - Latch area, Figure 101 (Sheets 1 & 5) and Figure 102 (Sheets
1 & 5).
C - Main panel body, Figure 101 (Sheets 3 & 7) and Figure 102
(Sheets 3 & 7).
D - Access panel area, Figure 101 (Sheets 2 & 6) and Figure 102
(Sheets 2 & 6).
E - Forward/Aft edge coaming area, Figure 101 (Sheet 9) and Fig-

ure 102 (Sheet 9).
F - Latch region - Laminate area, Figure 101 (Sheet 9) and Figure

102 (Sheet 10).
G - Latch area - Closing ramp, Figure 101 (Sheet 5) and Figure

102 (Sheet 5).
H - Hinge area - Edge laminate, Figure 101 (Sheet 9) and Figure

102 (Sheet 10).
V2500 54-20-00 Page 103

Feb 1/09
K - Forward/Aft edge sandwich area, Figure 101 (Sheets 4 & 8) and

Figure 102 (Sheets 4 & 8).
V2500 54-20-00 Page 104

Feb 1/09
Left Fan Cowl Door Zones - Outer Skin Only

V2500 54-20-00 Page 105

Feb 1/09

V2500 54-20-00 Page 106

Feb 1/09

V2500 54-20-00 Page 107

Feb 1/09

V2500 54-20-00 Page 108

Feb 1/09
Left Fan Cowl Door Zones - Inner Skin Only

V2500 54-20-00 Page 109

Feb 1/09

V2500 54-20-00 Page 110

Feb 1/09

V2500 54-20-00 Page 111

Feb 1/09

V2500 54-20-00 Page 112

Feb 1/09
Left Fan Cowl Door Zones - Laminate Skin Only (No Honeycomb)
V2500 54-20-00 Page 113

Feb 1/09
Right Fan Cowl Door Zones - Outer Skin Only

V2500 54-20-00 Page 114

Feb 1/09

V2500 54-20-00 Page 115

Feb 1/09

V2500 54-20-00 Page 116

Feb 1/09

V2500 54-20-00 Page 117

Feb 1/09
Right Fan Cowl Door Zones - Inner Skin Only

V2500 54-20-00 Page 118

Feb 1/09

V2500 54-20-00 Page 119

Feb 1/09

V2500 54-20-00 Page 120

Feb 1/09

V2500 54-20-00 Page 121

Feb 1/09
Right Fan Cowl Door Zones - Laminate Skin Only (No Honeycomb)
V2500 54-20-00 Page 122

Feb 1/09
Right Fan Cowl Door Zones - Laminate Skin Only (No Honeycomb)
V2500 54-20-00 Page 123

Feb 1/09
Abrasion A, B C, Surface resin only, over Max. depth within 6000 FH

D, E, F unlimited area. Protect local resin. 4500 FC
G, H, K with sealing tape (CoMat Unlimited use. 20 Months
02-006). No abrasion
permitted in Zone K1.
Abrasion E Outerskin of forward Max. depth of Fly on limit

edge. 0.075 in. (1.91 only.
Protect with sealing tape mm)/five plies by Inspect
(CoMat 02-006)/paint. max. width of 0.25 tape/paint
Repair at earliest in. (6.35 mm) in at 600 FH
opportunity (no later the fwd or aft 750 FC
than next 6000FH/4500FC/ direction by 100 Days.
20 Months). length up to full
door circumfer-
ence and/or
Max. depth of
0.020 in (0.51
mm)/one ply by
max. width of 1.50
in. (38.1 mm) in
the fwd and aft
direction by
length up to full
door circumfer-
ence.
Time Limited.
Scratch/ A, B, C, No nearer than 8.00 in. Max. depth of 6000 FH

Gouge D, E, F (203.2 mm) to other 0.010 in. (0.254 4500 FC
G, H, K damage. mm) by max. length 20 Months
No more than 8 scratches/ of 7.00 in. (177.8
gouges on each door. mm).
Protect with sealing tape Unlimited use.
(CoMat 02-006). No
scratches/gouges
permitted in Zone K1.
Fan Cowl Door Allowable Damage Limits

Table 101 (Sheet 1)
V2500 54-20-00 Page 124

Feb 1/09
Nick A, B, C, No nearer than 4.00 in. Max. depth of 6000 FH
D, E, F (101.6 mm) to other 0.010 in. (0.254 4500 FC
G, H, K damage. mm) by max. length 20 Months
Protect with sealing tape of 1.00 in. (25.4
(CoMat 02-006). If length mm).
is more than limit, then Unlimited use.
consider as a gouge. No
nicks permitted in Zone
K1.
Delami- E No nearer than 6.00 in. Max. depth of 600 FH

nations (152.4 mm) to other 0.075 in. (191 750 FC
damage. mm)/five plies 100 Days
No surface cracks. (measured from the
Protect with sealing tape outer skin) by
(CoMat 02-006). No max. length of
delamination 0.20 in. (5.1 mm)
permitted in zone E1. in the fwd and aft
Repair no later than next direction by max.
6000 FH, 4500 FC or 20 length of 0.50 in.
Months. (12.7 mm) circum-
ferentially.
Time Limited.
Delami- C No nearer than 6.00 in. Max. diameter of 600 FH

nations (152.4 mm) to other 1.0 in. (25.4 mm) 750 FC
damage. in inner skin 100 Days
Protect with sealing tape only.
(CoMat 02-006). Repair no Time Limited.
later than next 6000 FH,
4500 FC or 20 Months.
Delami- A, B, D, No nearer than 6.00 in. Max. diameter of 600 FH

nations F, G, H (152.4 mm) to other 3.0 in. (76.2 mm). 750 FC
damage. Time Limited. 100 Days
Protect with sealing tape
(CoMat 02-006). Repair no
later than next 6000 FH,
4500 FC or 20 Months.

Table 101 (Sheet 2)
V2500 54-20-00 Page 125

Feb 1/09
Hole C No nearer than 6.00 in. Max. diameter of Fly on limit
(152.4 mm) to other 1.0 in. (25.4 mm) only.
unrepaired damage. in inner skin Inspect tape
Protect with sealing tape only. at each
(CoMat 02-006). Maximum Time Limited. flight.
of three holes on each
door. Repair no later
than next 600 FH, 750 FC
or 100 Days.
Hole A, B, D, No nearer than 6.00 in. Max. diameter of Fly on limit

F, G, H (152.4 mm) to other 3.0 in. (76.2 mm) only.
damage. in inner skin or Inspect tape
Protect with sealing tape outer skin only at each
(CoMat 02-006). Maximum (not through flight
of three holes on each both). (outer skin
door. Repair no later Time Limited. only).
or 100 Days.
Crack C No nearer than 6.00 in. Max. length of 1.0 Fly on limit
(152.4 mm) to other in. (25.4 mm) in only.
damage. inner skin only. Inspect tape
Protect with sealing tape Time Limited. at each
(CoMat 02-006). Maximum flight.
of three cracks on each
door. Repair no later
or 100 Days.
Crack A, B, D, No nearer than 6.00 in. Max. length of 3.0 Fly on limit
F, G, H (152.4 mm) to other in. (76.2 mm) in only.
damage. inner skin or Inspect tape
Protect with sealing tape outer skin only at each
(CoMat 02-006). Maximum (not through flight
of three cracks on each both). (outer skin
door. Repair no later Time Limited. only).
or 100 Days.

Table 101 (Sheet 3)
V2500 54-20-00 Page 126

Feb 1/09
Dent C (inner No nearer than 11.00 in. Max. diameter of 6000 FH
skin (279.4 mm) to other 1.25 in. (31.8 mm) 4500 FC
only) damage or to change in in inner skin only 20 Months
laminate construction. by max. depth of
Maximum of three dents on 0.03 in. (0.76
each door. No mm).
delamination/disbond Unlimited use.
permitted on dent.
Dent C (outer No nearer than 6.00 in. Max. diameter of 6000 FH

only) damage or to change in in outer skin only 20 Months
laminate construction. by max. depth of
Maximum of three dents on 0.03 in. (0.76
each door. No mm).
delamination/disbond Unlimited use.
permitted on dent.
Dent A, B No nearer than 6.00 in. Max. diameter of 6000 FH

(152.4 mm) to other 3.0 in. (76.2 mm) 4500 FC
damage or to change in by max. depth of 20 Months
laminate construction. 0.09 in. (2.28
Maximum of three dents on mm). Unlimited
each door. No use.
delamination/disbond
permitted on dent.
Dent D (inner No nearer than 6.00 in. Max. diameter of 6000 FH

only) damage or to change in by max. depth of 20 Months
Maximum of three dents on mm).
each door. No Unlimited use.
permitted on dent.

Table 101 (Sheet 4)
V2500 54-20-00 Page 127

Feb 1/09
Dent D (outer No nearer than 6.00 in. Max. diameter of 6000 FH
only) damage or to change in by max. depth of 20 Months
permitted on dent.
Dent F No nearer than 6.00 in. Max. diameter of 6000 FH

permitted on dent.
Dent G No nearer than 6.00 in. Max. diameter of 6000 FH

permitted on dent.
Dent H No nearer than 6.00 in. Max. diameter of 6000 FH

permitted on dent.

Table 101 (Sheet 5)
V2500 54-20-00 Page 128

Feb 1/09
C. Fan Cowl Door Corner Plates - Allowable Damage (See Figure 103 and
Table 102).
The Allowable damage zones for the fan cowl door corner plates are:
L - Corner Plate - left fan cowl door, upper aft

- right fan cowl door, upper forward
M - Corner Plate - left fan cowl door, upper forward

- right fan cowl door, upper aft
N - Corner Plate - left/right fan cowl door, lower aft/forward
V2500 54-20-00 Page 129

Feb 1/09
Fan Cowl Door Corner Plate Zones

Figure 103
V2500 54-20-00 Page 130

Feb 1/09
Wear on L Min. thickness 6000 FH
the M 0.040 in. (1.0 mm) 4500 FC
corner N remaining and min. 20 Months
plate length 0.120 in.
(3.0 mm)
remaining.
Unlimited use.
Fan Cowl Door Corner Plates Allowable Damage Limits

Table 102
V2500 54-20-00 Page 131

Feb 1/09
V2500 54-20-00 Page 132

Feb 1/09
GENERAL REPAIR
1. General
Repairs given in this section are for structural damage exceeding the
limits shown in the Allowable Damage section. The repairs are written
to restore a part to it’s original strength and configuration as when
it was manufactured. Procedures to refinish a repaired area are also
given.

DISCARD CHEMICALS.


adhesive mixture.

Page 201
Feb 1/09

store in a cool place until you are ready to use it.
NOTE: The useful life of a one-pound mixture is about

seven hours. Heat accelerates both the adhesive
mixture gel time and cure time.
B. EA956 Adhesive

DISCARD CHEMICALS.

adhesive mixture.

store in cool place until you are ready to use it.
NOTE: The useful life on a one-pound mixture is about 30

minutes. Heat accelerates both the adhesive
mixture gel time and cure time.

Page 202
Feb 1/09
C. EA934NA Adhesive

DISCARD CHEMICALS.

adhesive mixture.
(2) Cover container to prevent contamination of the mixture

and store in cool place until you are ready to use it.
NOTE: The useful life of a one-pound mixture is about 40

minutes at 77ºF (25ºC). Heat makes both the gel
time and the cure time of the adhesive mixture
faster.
A. The fan cowl is made of carbon/epoxy bonded structure. This

type of material is repaired with “wet-layup hot-bonded”
procedures. In these procedures, carbon fabric is soaked with
epoxy and put on the damaged area. Repair equipment (parting
film, bleeder and breather cloth, heat blanket, silicone rubber
sheet, and vacuum bag) are installed over the carbon fabric.
The repair is cured at high temperatures for a specified time,
after which the repair equipment is removed. The repair may
then be smoothed as necessary for an aerodynamic finish.
B. The number of carbon fabric repair plies used is equal to the

number of damaged plies. See the Structural Identification
section to find the number of plies in the damaged area. You
cannot examine the damaged skin to count the plies. Cured
carbon plies are very difficult to separate at ply interfaces.

Page 203
Feb 1/09
C. A single ply of fiberglass is used on top of repairs exposed to

the free airstream. This is to permit the repair to be made
smooth for an aerodynamic finish.
D. Both the original skin and the repair material must be clean
and dry before the repair can be started. Water on the surface
or in the materials will make the repair weak. All water must be
removed before the repair can be done. Use heat lamps at 230ºF-
250ºF (115ºC-127ºC) for one hour.

Page 204
Feb 1/09

P.O. Box 312
Adhesive System, Epoxy EA956 Dexter Hysol Aerospace, Inc.
Base Part A
Catalyst Part B
Base Part A
Catalyst L3
Polyvinyl
Chloride
Ketone


Table 201

Page 205
Feb 1/09

Page 206
Feb 1/09
FAN COWL - LIST OF APPROVED REPAIRS

Limits before you do repairs to acoustic areas of the Fan Cowls.
001 FAN COWL EDGE EROSION DAMAGE REPAIR

(VRS2728) (REF 71-13-00 LEFT FAN COWL)
(VRS2729) (REF 71-13-00 RIGHT FAN COWL)
002 FAN COWL MAIN AREA FULL PENETRATION REPAIR

003 FAN COWL SURFACE DAMAGE REPAIR

004 FAN COWL HONEYCOMB DENT REPAIR

005
(VRS2838) CANCELLED
006 FAN COWL SCRATCHES OR GOUGES REPAIR

(REF 71-13-00 RIGHT FAN COWL ACCESS PANELS)
(VRS2842)
007 FAN COWL ACCESS PANEL OPENING LAND SURFACE DAMAGE
(VRS2839) REPAIR
(REF 71-13-00 RIGHT FAN COWL)
008 LEFT FAN COWL OIL FILLER AND CHIP DETECTOR ACCESS DOOR
(VRS2868) LAND REPAIR
(REF 71-13-00 LEFT FAN COWL ACCESS PANEL)
009 FAN COWL ACCESS PANEL INTERFACE LAND REPAIR

Page 201
Feb 1/09

010 LEFT FAN COWL ACCESS PANELS MAIN AREA SURFACE DAMAGE
(VRS2869) REPAIR
(REF 71-13-00 LEFT FAN COWL ACCESS PANELS)
011 TO BE SUPPLIED
012 FAN COWL DOOR EDGE DELAMINATION REPAIR

013 FAN COWL DELAMINATION REPAIR

014 FAN COWL DOOR LANDS SURFACE DAMAGE REPAIR

015 FAN COWL ACCESS PANEL LANDS SURFACE DAMAGE REPAIR
(VRS2832) (REF 71-13-00 LEFT FAN COWL ACCESS PANELS)
016
(VRS2835) CANCELLED
017
(VRS2831) CANCELLED
(VRS2878)
018 FAN COWL AFT DOOR LANDS REPAIR
019
(VRS2843) CANCELLED
020 FAN COWL PART PENETRATION REPAIR
021 FAN COWL - EXTERNAL PAINT DAMAGE REPAIR

Page 202
Feb 1/09

022 FAN COWL - DRAINS MAST WALL DAMAGE REPAIR
(VRS2957) (REF 71-13-00 DRAIN MAST)
023 FAN COWL - LATCH BEARING PLATE REPLACE
024 RIGHT FAN COWL - AIR START BLOW-OFF DOOR INTERFACE

(VRS2722) LAND REPAIR
025 RIGHT FAN COWL ACCESS PANELS MAIN AREA SURFACE AREA
(VRS2880) REPAIR
(REF 71-13-00 RIGHT FAN COWL ACCESS PANEL)
026 FAN COWL ACCESS PANELS INSTALL OVERSIZE FASTENERS
(VRS2721) (REF 71-13-00 RIGHT FAN COWL ACCESS PANELS)
028 FAN COWL - AIR START BLOW-OFF DOOR HINGE REPAIR
(VRS2950) (REF 71-13-00 RIGHT FAN COWL ACCESS PANELS)
029 LEFT FAN COWL - ACCESS PANELS INSTALL OVERSIZE
(VRS2741) FASTENERS
(REF 71-13-00 LEFT FAN COWL ACCESS PANEL)
030 LEFT FAN COWL - OIL FILTER DOOR HINGE REPAIR
(VRS2849) (REF 71-13-00 LEFT FAN COWL ACCESS PANEL)
031 FAN COWL LIGHTNING STRIKE PROTECTION REPAIR
(VRS2748) (REF 71-13-00 SURFACE TREATING)
(VRS2749)
033 FAN COWL - DOOR LATCH HANDLES PAINT REPAIR
034 FAN COWL DOOR LEADING EDGE ERROSION REPAIR
035 LEFT FAN COWL LAMINATE OIL FILLER ACCESS DOOR LAND
(VRS7501) REPAIR
(REF 71-13-00 LEFT FAN COWL)
036 LEFT FAN COWL LAMINATE OIL FILLER ACCESS DOOR MAIN
(VRS2795) AREA SURFACE DAMAGE REPAIR

Page 203
Feb 1/09

037 LEFT FAN COWL LAMINATE OIL FILLER ACCESS DOOR LANDS
(VRS7502) SURFACE DAMAGE REPAIR
038 FAN COWL MAIN AREA DISBOND REPAIR
039 FAN COWL - REPLACE THE CORNER PLATES
055 FAN COWL MAIN AREA FILLER PLATE REPAIR

Page 204
Feb 1/09
REPAIR 001
FAN COWL EDGE EROSION DAMAGE REPAIR
(VRS2728/2729)
1. General
A. This procedure may be used to repair edge erosion damage on the

left or right fan cowl.
B. The edge erosion must be confined to an area 1.0 in. (25.4 mm)
long and 0.02 in. (0.51 mm) deep.
TASK 71-13-00-300-005 VRS2728/ Fan Cowls CMM (RDN 604)

VRS2729
54-20-00, REPAIR 031 Structure Repair Manual (SRM)
A. Standard Tools
Heat lamp, 0º - 212ºF (0º - 100ºC)

Suction Cleaner

Consumable Index)

CoMat 08-021 EA934NA Resin
V2500 54-20-00 REPAIR 001

Page 201
Feb 1/09
C. Component Materials
PART IDENT MATERIAL

Left Fan Cowl Composite structure
Right Fan Cowl Composite structure
4. Examine the Damaged Area
A. If lightening strike protection wire mesh is present and the

loss of wire mesh (after repair) is more than 3 square inches,
refer to Chapter 54-20-00, REPAIR 031 (VRS2748/2749).
5. Prepare the Damaged Area

PPE IS NECESSARY.
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. DO

NOT USE A LIQUID WITH THE ABRASIVE PAPER.
A. Cut the loose fibers from the repair area. Use the waterproof
abrasive paper (CoMat 05-021) to remove the surface protection.
Make the repair area even with the adjacent surface.
V2500 54-20-00 REPAIR 001

Page 202
Feb 1/09

cleaner.

7. Fill the Erosion Damage
A. Mix the resin (CoMat 08-021) in accordance with the

B. Use the resin mixture to fill the damaged area.
C. Put a piece of teflon tape (CoMat 02-007) on the resin mixture

to make a smooth surface.
D. Cure the resin for 60 minutes at 200ºF (93ºC) with an explosion

proof heat lamp.
E. After the resin has cured, remove the teflon tape.
V2500 54-20-00 REPAIR 001

Page 203
Feb 1/09
8. Smooth the Repair Surface

PPE IS NECESSARY.
A. Smooth the repair surface even with the adjacent surface with
waterproof abrasive paper (CoMat 05-021).

lint free cloth (CoMat 02-099). Wipe the surface dry.
C. Apply surface protection to the repair area in accordance with

standard painting procedures (Ref. SPPM Task 70-38-07-380-501).
V2500 54-20-00 REPAIR 001

Page 204
Feb 1/09
Fan Cowl Edge Erosion Damage Repair

Figure 201
V2500 54-20-00 REPAIR 001

Page 205
Feb 1/09
V2500 54-20-00 REPAIR 001

Page 206
Feb 1/09
REPAIR NO. 002

FAN COWL MAIN AREA FULL PENETRATION REPAIR
VRS2827/2872
1. General.
A. This procedure may be used to repair damage to the fan cowl door
sandwich (Ref. Fig. 201 for applicable regions) (including cracks)
which must be more than 0.5 in. (12,7 mm) from the fittings,
brackets, hinges and flanges. The damage must be confined to an
area of 1.0 in. (25,4 mm) diameter or less in the main panel area.
The damage in all other applicable areas must be confined to
2.0 in. (50,8 mm) diameter or less. If the damage is beyond these
limits or above the horizontal center-line, refer to Goodrich.
B. This type of damage may be repaired by the removal of the damaged

area, application of a support plate, replacement of the honeycomb
core with potting compound and the application of a carbon fibre
patch with adhesive.
C. The damage must be a sufficient distance from the edge of the

panel, fittings, brackets, hinges and flanges to install all the
repair plies, sanding ply and the support plate. Refer to step 5.B.
and Fig. 203.
D. This repair can only be done in the areas indicated, Ref. Fig. 201.
E. The orientation of the carbon fibre repair plies must follow the
sequence as follows:
Zone B - Latch area (0-90)/(0-90)/(±45)/(±45)/(0-90)/(±45)
Zone C - Main panel body (0-90)/(0-90)
Zone D - Access panel area (0-90)/(0-90)/(±45)/(±45)/(0-90).
Ply orientation is given from the outer most ply to the inner.
F. This repair must be done in a room with a controlled temperature of

percent or less.
G. Damage which is not within the limits of these repairs must be

H. If the damage or repair patch overlaps two zones refer to Goodrich.
V2500 54-20-00 REPAIR No. 002

Page 201
Feb 1/09

54-20-00, REPAIR 031 Structural Repair Manual (SRM)
(VRS2748/2749)
(SPPM)
(SPPM)

Suction cleaner
V2500 54-20-00 REPAIR No. 002

Page 202
Feb 1/09

Index).

C. Special Tools
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Fan cowl Composite structure
4. Examine the damaged area.
A. If lightning strike protection wire mesh is present and the loss of

wire mesh (after repair) is more than 3 square inches, refer to
REPAIR 031 (VRS 2748/2749) when you do this repair.
A. Mark around the damage with a pencil, making sure to include cracks
V2500 54-20-00 REPAIR No. 002

Page 203
Feb 1/09
B. Mask around the repair area with 2.0 in (50,8 mm) wide strips of
teflon tape (CoMat 02-007). Calculate the distance that the tape
must be from the area identified in step A as follows:
each of the outer plies.
(2) Add 0.75 in. (19,05 mm) for an outer layer of fiberglass
fabric (CoMat 02-167).

NECESSARY.
C. Make the surface of the repair area rough with waterproof abrasive
D. Use a high-speed rotary cutter to remove the plies and honeycomb

identified in step A, taking care not to cause delamination of the
plies.

cleaner.
B. Clean the repair with methylethylketone (CoMat 01-076) and lint-

free cloth (CoMat 02-099). Wipe the repair area dry.
V2500 54-20-00 REPAIR No. 002

Page 204
Feb 1/09
7. Prepare the support plate (Ref. Fig. 202).

NECESSARY.
A. Wear lint-free gloves (CoMat 02-097) and cut three pieces of

fiberglass fabric (CoMat 02-167) 2.0 in. (50,8 mm) larger all


same as the weight of the fiberglass fabric (CoMat 02-167).
(1) Put each fiberglass ply on a sheet of non-porous parting film

(CoMat 02-168).
film.
thoroughly.

1.0 in. (25,4 mm) around the repair cut-out.
(1) Remove one sheet of non-porous film from two of the plies.
V2500 54-20-00 REPAIR No. 002

Page 205
Feb 1/09
(2) Remove both sheets of non-porous film from the third ply.
three fiberglass plies.
E. Cure the adhesive.

plate.

190oF (88oC).
F. Drill holes in the support plate and attach lockwire.
(1) When the support plate is cool, remove the two remaining
pieces of non-porous film.
(2) Drill two pairs of holes, 0.050 in. (1,27 mm) diameter, a
sufficient distance apart to attach the support plate to a
clamp bar with lockwire (CoMat 02-127).
A. Use the heat lamps to dry the repair area. Keep the temperature at
V2500 54-20-00 REPAIR No. 002

Page 206
Feb 1/09
A. Put a loop of the lockwire through each pair of holes on the

support plate, long enough to hold during installation. Do not let
the lockwire fall into the cowl
B. Mix the EA934NA adhesive (CoMat 08-021) in accordance with the

C. Apply an equal layer of adhesive to the support plate and the cowl
D. Put the support plate into position.
(1) Put the support plate against the inner surface of the cowl,
making sure that the support plate has an equal overlap
around the repair area.
(2) Put a clamp bar across the repair cut-out.
(3) Put lockwire (CoMat 02-127) around the clamp bar and twist
the ends together to hold the support plate in the correct
position.
the increase must not exceed 5.4oF (3oC) in each minute. Keep the
F. Remove the lockwire and the bar.
V2500 54-20-00 REPAIR No. 002

Page 207
Feb 1/09
10. Prepare the filler plies, the repair plies, and the honeycomb
(Ref. Fig. 202 and 203).

NECESSARY.
A. Wear lint-free gloves (CoMat 02-097) and cut the lower filler plies
(Ref. step 1.E.):
The lower filler plies and fiberglass cap ply must overlap the cut-
out in the cowl inner skin by 1.0 in. (25,4 mm) all around.
NOTE: Make sure that the ply fibres follow the orientation as given
in step 1.E.
Wear lint free gloves (CoMat 02-097) and cut the upper filler plies
(Ref. step 1.E.):
The upper filler plies and fiberglass cap ply must overlap the cut-
out in the cowl outer skin by 1.0 in. (25,4 mm) all around.
in step 1.E.
Wear lint free gloves (CoMat 02-097) and cut the repair plies:
Carbon fabric (CoMat 08-059) and one ply of fiberglass fabric

(CoMat 02-167). Cut the first repair ply so that it has a 2.0 in.
(50,8 mm) overlap around the cut-out in the cowl outer skin. Cut
each subsequent repair ply 2.0 in. (50,8 mm) longer and 2.0 in.
(50,8 mm) wider.
in step 1.E.

B. Cut the repair plug from the honeycomb (CoMat 08-063, 08-065,
08-066) to be a good fit in the repair hole. Use lint-free gloves
(CoMat 02-097).
V2500 54-20-00 REPAIR No. 002

Page 208
Feb 1/09
A. Clean the repair with methylethylketone (CoMat 01-076) and lint-

12. Install the lower filler plies (Ref. Fig. 202 and 203).

two sides of each ply. Put another layer of parting film on these
plies and roll the adhesive into the plies so that they are fully
procedure.
C. Cut each lower filler ply to be a good fit in the cut-out. They
must be flat on the support plate and have the same shape as the
cut-out. The edges of the plies must not overlap on the sides of
the cut-out (Ref. step 1.E.).
in step 1.E.
V2500 54-20-00 REPAIR No. 002

Page 209
Feb 1/09
D. Remove the non-porous parting film from one side of the first
carbon filler ply. Put the ply into the cut-out, adhesive side
down. The ply must be located correctly and flat against the
support plate. Remove the remaining non-porous parting film and use
a clean metal spatula to keep the ply flat on the support plate.
Repeat this step for each subsequent carbon filler ply and
fiberglass cap ply. Make sure that the plies are flat and located
correctly.
temperature at 190o - 210oF (88o - 99oC) for 220 minutes. Start to
When the adhesive has cured, remove the non-porous parting film.

manufacturer’s instructions
B. Fill the open cells of the honeycomb in the cowl and the repair
plug with potting compound. Use a clean metal spatula and make sure
all of the cells are filled.
C. Install the honeycomb plug into the hole and make sure it is flat
against the inner plies. Use a clean metal spatula to remove
unwanted potting compound and make the surface smooth.
V2500 54-20-00 REPAIR No. 002

Page 210
Feb 1/09
D. Cure the potting compound as follows:
temperature at 113o - 131oF (45o - 55oC) for between one and two
hours. Start to measure the curing time when the temperature gets
to 113oF (45oC).

15. Install the upper filler plies and the repair plies (Ref. Fig. 205).

install the upper filler plies.

repair area.
V2500 54-20-00 REPAIR No. 002

Page 211
Feb 1/09
two sides of each ply. Put another layer of parting film on the
plies and roll the adhesive into the carbon plies so that they are
fully soaked. Do not remove the parting film until the installation
procedure.
C. Cut each upper filler ply and the fiberglass cap ply to be a good
fit in the cut-out of the outer skin. They must be flat on the
honeycomb plug and have the same shape as the cut-out. The edges of
the plies must not overlap on the edges of the cut-out.
in step 1.E.
D. Cut the first carbon repair ply to its finished dimensions so that
it overlaps the cut-out in the outer skin by 1.0 in. (25,4 mm) all
around. Cut each subsequent carbon ply to overlap the previous by
1.0 in (25,4 mm). Cut the fiberglass repair ply so that it has the
same shape as the area defined by the teflon tape.
in step 1.E.
E. Apply an equal layer of adhesive to the top of the honeycomb plug

F. Remove the non-porous parting film from one side of the fiberglass
cap ply. Put the ply into the cut-out resin side down. The ply must
be located correctly and flat against the honeycomb plug. Remove
the remaining non-porous parting film and use a clean metal spatula
to keep the ply flat on the plug. Repeat this step for the first and
any subsequent carbon filler plies. Make sure that the plies are
flat and located correctly.
in step 1.E.
G. Remove the parting film from one side of the first carbon repair
ply and position it over the damage with the adhesive side down.
Make sure that the damage is located in the centre of the ply. Use
the roller to remove air caught in the adhesive. Remove the
remaining parting film.
in step 1.E.
H. Remove the parting film from one side of the second carbon repair
ply and position it over the repair area with the resin side down.
V2500 54-20-00 REPAIR No. 002

Page 212
Feb 1/09
Make sure it has an equal overlap around the first ply. Use the
roller to remove air caught in the resin. Remove the remaining
parting film.
in step 1.E.
I. Remove the parting film from one side of the fiberglass repair ply
and position it over the repair area with the adhesive side down.
Make sure it has an equal overlap around the last ply.
NOTE: The fiberglass repair ply must touch the teflon tape.
J. Use the roller to remove air caught in the adhesive. Remove the
remaining parting film. Remove unwanted adhesive from the teflon
area.
B. Cut a sheet of porous parting film (CoMat 02-169). Make sure that
the film is larger than the heat blanket and has an overlap of at
parting film.
D. Put the porous parting film on to the repair area. Make sure it has
an equal overlap around the repair area. Put the layers of breather

of material have an overlap of 2.0 in. (50,8 mm) around the

V2500 54-20-00 REPAIR No. 002

Page 213
Feb 1/09

adhesive cures.
G. Put the non-porous parting film onto the repair area. Make sure

rubber sheet.
area.

the repair area.
(CoMat 08-051).

V2500 54-20-00 REPAIR No. 002

Page 214
Feb 1/09
(88oC).
repair.

NECESSARY.


cleaner.

V2500 54-20-00 REPAIR No. 002

Page 215
Feb 1/09

A. Ident the component/log book with the REPAIR no. VRS2827/2872

(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-20-00 REPAIR No. 002

Page 216
Feb 1/09

Fig. 201 Sheet 1
V2500 54-20-00 REPAIR No. 002

Page 217
Feb 1/09

Fig. 201 Sheet 2
V2500 54-20-00 REPAIR No. 002

Page 218
Feb 1/09

Fig. 201 Sheet 3
V2500 54-20-00 REPAIR No. 002

Page 219
Feb 1/09

Fig. 201 Sheet 4
V2500 54-20-00 REPAIR No. 002

Page 220
Feb 1/09

Fig. 201 Sheet 5
V2500 54-20-00 REPAIR No. 002

Page 221
Feb 1/09

Fig. 201 Sheet 6
V2500 54-20-00 REPAIR No. 002

Page 222
Feb 1/09

Fig. 201 Sheet 7
V2500 54-20-00 REPAIR No. 002

Page 223
Feb 1/09
Support Plate and Filler Ply Installation

Fig. 202
V2500 54-20-00 REPAIR No. 002

Page 224
Feb 1/09

Fig. 203
V2500 54-20-00 REPAIR No. 002

Page 225
Feb 1/09

Fig. 204
V2500 54-20-00 REPAIR No. 002

Page 226
Feb 1/09
REPAIR NO. 003

FAN COWL SURFACE DAMAGE REPAIR
VRS2828/2873
1. General.
A. This procedure may be used to repair surface damage to the left or

right fan cowl which does not fully penetrate the outer skin.
B. This type of damage may be repaired by the application of a filler

material and a carbon fibre patch with adhesive.
C. The damage must be a sufficient distance from the edge of the fan
cowl to install all the repair plies and sanding ply. Refer to
Para. 4A and Fig. 201 and 202. The repair should be at least 10 in.
(254,0 mm) from any other damage in 2-ply skin region, 15 in.
(381,0 mm) elsewhere.
D. This repair can only be done in the areas indicated, ref. Fig. 201.
This repair should not be done on the inner surface.
Zone A - Hinge area (0-90)/(0-90)/(±45)/(±45)/(0-90)/(±45)
Zone B - Latch area (0-90)/(0-90)/(±45)/(±45)/(0-90)/(±45)
Zone D - Access panel area (0-90)/(0-90)/(±45)/(±45)/(0-90)
Zone K - Forward/Aft edge sandwich area (0-90)/(0-90)/(±45)/(±45).

percent or less.
G. When damage is beyond the scope of this repair refer to Goodrich.
V2500 54-20-00 REPAIR No. 003

Page 201
Feb 1/09

(VRS2748/2749)
(SPPM)
(SPPM)
(SPPM)

Suction cleaner
B. Special Tools
V2500 54-20-00 REPAIR No. 003

Page 202
Feb 1/09

Index).

CoMat 02-164 Phenolic microballoons (135 micron)
D. Repair parts
None.
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Fan cowl door Composite structure
V2500 54-20-00 REPAIR No. 003

Page 203
Feb 1/09
A. Referring to Fig. 202 examine the repair area to assess the amount

penetration, i.e. deciding between 0.065 in. (1,65 mm) and
0.066 in. (1,68 mm), assume the larger figure as the criteria for
selecting the number of repair plies to use. That is, 6 plies
rather than 5, for this example.
If lightning strike protection wire mesh is present and the loss of

Chapter 54-20-00, REPAIR No. 031 (VRS2748/VRS2749).
A. Clean the damage and repair area with the methylethylketone

(CoMat 01-076) and lint free cloth (CoMat 02-099). Wipe the area
with a clean piece of lint free cloth before the fluid dries.
V2500 54-20-00 REPAIR No. 003

Page 204
Feb 1/09

NECESSARY.
A. Apply the teflon tape (CoMat 02-007) to the repair area. Fig. 202
shows the dimensions of the area to be covered with the tape
(repair of 2 ply damage shown).
edges from the damage with the abrasive paper (CoMat 05-021). Do
not damage the carbon plies of the cowl.

INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND GOV-
ERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS NEC-
ESSARY.
the finished dimensions after soaking in adhesive (Ref. steps 1.E
and 9.C).
repair ply for each ply of the area which is damaged and these must
be covered by a sanding ply (CoMat 02-167). To prevent fraying, the
plies may be cut to the finished dimensions after soaking in
adhesive (Ref. steps 1.E and 9.C).
the cowl at 176oF (80oC) for six hours. The repair materials must
V2500 54-20-00 REPAIR No. 003

Page 205
Feb 1/09



(12,7 mm). Cut the last (fiberglass) ply to the shape defined by
V2500 54-20-00 REPAIR No. 003

Page 206
Feb 1/09

the microballoons to 100 parts (by weight) of the mixture
B. Fill the damage with the mixture using a clean metal spatula. The
filled damage must be level with the existing carbon plies of the
repair area.
V2500 54-20-00 REPAIR No. 003

Page 207
Feb 1/09
A. Apply an even layer of EA9390 adhesive (Ref. step 9.A.) to the

film.
in step 1.E.
in step 1.E.
spatula.
V2500 54-20-00 REPAIR No. 003

Page 208
Feb 1/09
the porous parting film (Ref. step B. above). The number of pieces

D. above.
G. Put the non-porous parting film (Ref. step E. above) onto the
repair area first. Make sure that it has an equal overlap around
the repair area. Put the silicone rubber sheet on top of the non-
porous parting film.

to the repair area.
V2500 54-20-00 REPAIR No. 003

Page 209
Feb 1/09
the nylon bagging film with its seal and the vacuum hose;
the temperature probes; the heat blanket; the breather cloth;
the silicone rubber sheet; the non-porous parting film;
the breather fabric; the fiberglass tows; the porous parting film

INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND GOVERN-
MENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE PPE.
GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS NECES-
SARY.

(CoMat 05-021).
V2500 54-20-00 REPAIR No. 003

Page 210
Feb 1/09


(Ref. SPPM TASK 70-38-07-380-501).

(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-20-00 REPAIR No. 003

Page 211
Feb 1/09
Location of Repair Area - Left Fan Cowl Door

Fig. 201 Sheet 1
V2500 54-20-00 REPAIR No. 003

Page 212
Feb 1/09
Location Of Repair Area - Left Fan Cowl Door

Fig. 201 Sheet 2
V2500 54-20-00 REPAIR No. 003

Page 213
Feb 1/09

Fig. 201 Sheet 3
V2500 54-20-00 REPAIR No. 003

Page 214
Feb 1/09

Fig. 201 Sheet 4
V2500 54-20-00 REPAIR No. 003

Page 215
Feb 1/09
Location Of Repair Area - Right Fan Cowl Door

Fig. 201 Sheet 5
V2500 54-20-00 REPAIR No. 003

Page 216
Feb 1/09

Fig. 201 Sheet 6
V2500 54-20-00 REPAIR No. 003

Page 217
Feb 1/09

Fig. 201 Sheet 7
V2500 54-20-00 REPAIR No. 003

Page 218
Feb 1/09

Fig. 201 Sheet 8
V2500 54-20-00 REPAIR No. 003

Page 219
Feb 1/09

Fig. 202
V2500 54-20-00 REPAIR No. 003

Page 220
Feb 1/09

Fig. 203
V2500 54-20-00 REPAIR No. 003

Page 221
Feb 1/09
V2500 54-20-00 REPAIR No. 003

Page 222
Feb 1/09
REPAIR NO. 004

FAN COWL HONEYCOMB DENT REPAIR
VRS2726/2727
1. General.
A. This procedure may be used to repair a dent in the honeycomb area

of the left and right fan cowl.
B. This is a cosmetic repair and does not add strength to the fan
cowl.
C. The repair is only applicable in the areas that follow (refer to

Figs 201 and 202):
Zone A - Hinge area

Zone B - Latch area
Zone C - Main panel body
Zone D - Access panel area
Refer to 54-20-00, Fan Cowl Doors - Allowable Damage, Dent section,

for maximum damage limits in each area.
D. Damage which is not within the limits of this repair must be

54-20-00, Allowable Damage Structural Repair Manual

(SPPM)
V2500 54-20-00 REPAIR No. 004

Page 201
Feb 1/09

Index).

Comat 08-072 Potting compound
NOTE: CoMat 08-072 is an alternative to CoMat 02-164 and

CoMat 08-021.
C. Repair Parts
--------------------------------------------
PART NO. PART IDENT
--------------------------------------------
4. Prepare the damaged area for repair.

NECESSARY.
CAUTION: BE CAREFUL WHEN YOU MAKE THE SURFACE OF THE REPAIR AREA
ROUGH. DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL.
DO NOT USE A LIQUID WITH THE ABRASIVE PAPER.
A. Lightly roughen the outer skin of the repair area with abrasive
paper (CoMat 05-021) to remove all the surface protection.
V2500 54-20-00 REPAIR No. 004

Page 202
Feb 1/09

5. Method 1: Fill the repair area with the potting compound.
WARNING: DO NOT TOUCH THE CLEANED SURFACE OF THE REPAIR AREA. IF THE
SURFACE IS NOT FULLY CLEANED THE COMPOUND CAN NOT BOND
SATISFACTORILY.

B. Apply the potting compound mix to fill the damaged area of the cowl
and using a clean plastic spatula make the contours of the repair
area the same as the contours of the adjacent area of the cowl.
C. Cure the compound for 24 hours at 68oF (20oC).

NECESSARY.
D. Smooth the repair area level with the adjacent surface with
V2500 54-20-00 REPAIR No. 004

Page 203
Feb 1/09
6. Method 2: Fill the repair area with the adhesive/microballoons.
CAUTION: DO NOT TOUCH THE CLEANED SURFACE OF THE REPAIR AREA. IF

SURFACE IS NOT FULLY CLEAN THE ADHESIVE CAN NOT BOND
SATISFACTORILY
CAUTION: DO NOT HEAT CURE MORE THAN 3.66 CUBIC INCHES (60 CUBIC
CENTIMETERS) OF THE ADHESIVE. MORE THAN 3.66 CUBIC INCHES
(60 CUBIC CENTIMETERS) OF THE ADHESIVE WILL INCREASE IN
VOLUME IF IT IS HEAT CURED.

manufacturer’s instructions. Add 5 percent by weight of
microballoons (CoMat 02-164) and mix thoroughly to a paste
thickness.
B. Apply the adhesive mix to fill the damaged area of the cowl and
using a clean plastic spatula make the contours of the repair area
the same as the contours of the adjacent area of the cowl.
C. Cure the adhesive for between 5 and 7 days at 68oF (20oC). If there
is less than 3.66 cubic inches (60 cubic centimeters) of the
adhesive, increase the temperature of the adhesive to 199.4oF
(93oC) for 1 hour.

NECESSARY.
D. Smooth the repair area level with the adjacent surface with
V2500 54-20-00 REPAIR No. 004

Page 204
Feb 1/09


A. Make a mark VRS2726 (left fan cowl) and VRS2727 (right fan cowl)
adjacent to the assembly number. Use a CoMat 06-131 marking pen of
a colour that contrasts.
V2500 54-20-00 REPAIR No. 004

Page 205
Feb 1/09
Location of Repair Area (Left Fan Cowl Door - Outer Skin)

Fig. 201 (Sheet 1)
V2500 54-20-00 REPAIR No. 004

Page 206
Feb 1/09

Fig. 201 (Sheet 2)
V2500 54-20-00 REPAIR No. 004

Page 207
Feb 1/09

Fig. 201 (Sheet 3)
V2500 54-20-00 REPAIR No. 004

Page 208
Feb 1/09
Location of Repair Area (Left Fan Cowl Door - Inner Skin)

Fig. 201 (Sheet 4)
V2500 54-20-00 REPAIR No. 004

Page 209
Feb 1/09

Fig. 201 (Sheet 5)
V2500 54-20-00 REPAIR No. 004

Page 210
Feb 1/09

Fig. 201 (Sheet 6)
V2500 54-20-00 REPAIR No. 004

Page 211
Feb 1/09
Location of Repair Area (Right Fan Cowl Door - Outer Skin)

Fig. 202 (Sheet 1)
V2500 54-20-00 REPAIR No. 004

Page 212
Feb 1/09

Fig. 202 (Sheet 2)
V2500 54-20-00 REPAIR No. 004

Page 213
Feb 1/09

Fig. 202 (Sheet 3)
V2500 54-20-00 REPAIR No. 004

Page 214
Feb 1/09
Location of Repair Area (Right Fan Cowl Door - Inner Skin)

Fig. 202 (Sheet 4)
V2500 54-20-00 REPAIR No. 004

Page 215
Feb 1/09

Fig. 202 (Sheet 5)
V2500 54-20-00 REPAIR No. 004

Page 216
Feb 1/09

Fig. 202 (Sheet 6)
V2500 54-20-00 REPAIR No. 004

Page 217
Feb 1/09
Repair a Dent in the Cowl

Fig. 203
V2500 54-20-00 REPAIR No. 004

Page 218
Feb 1/09
CANCELLATION NOTICE

V2500 54-20-00 REPAIR No. 005

Page 201
Feb 1/09
V2500 54-20-00 REPAIR No. 005

Page 202
Feb 1/09
REPAIR NO. 006

FAN COWL SCRATCHES OR GOUGE REPAIR
VRS2836/2920/2842
1. General.
A. This procedure may be used to repair scratches or gouges on the

left and right fan cowl and access panels, where the depth of
damage does not extend beyond the surface adhesive into the fibres
of the laminate.
B. The damage is not permitted in the area identified in Fig. 201.
C. Damage which is not within the limits of this repair must be

54-20-00, Repair No.31 Structural Repair Manual (SRM)

(VRS2748/2749)
(SPM)


Index)

V2500 54-20-00 REPAIR No. 006

Page 201
Feb 1/09
C. Repair Parts
--------------------------------------------
PART NO. PART IDENT
--------------------------------------------
Air Start Door Composite structure

wire mesh (after repair) occurs, refer to REPAIR 031 (VRS2748/2749)
when you do this repair.
5. Prepare the damaged area for repair.

B. Let the repair area dry for a maximum of 6 hours at 176oF (80oC)
using heat lamps.
V2500 54-20-00 REPAIR No. 006

Page 202
Feb 1/09
6. Apply the adhesive to the repair area.

thickness.
B. Apply the adhesive mix to fill the damaged area using a clean metal
spatula.
A. Clean all unwanted adhesive from the repair area with

A. Cure the adhesive for 220 minutes at 194o to 200oF (90o to 93oC)
with an explosion proof heat lamp. Temperature increase up to cure
temperature or subsequent decrease must not be more than 5.4oF
(3oC) in each minute. Start the cure time when the temperature gets
to 194oF (90oC).
V2500 54-20-00 REPAIR No. 006

Page 203
Feb 1/09

(Ref. SPPM TASK 70-38-07-380-501).
A. Make a mark VRS2836 (left fan cowl), VRS2920 (right fan cowl) and
VRS2842 (right fan cowl access panels) adjacent to the assembly
number. Use a CoMat 06-131 marking pen of a colour that contrasts.
V2500 54-20-00 REPAIR No. 006

Page 204
Feb 1/09

Fig. 201
V2500 54-20-00 REPAIR No. 006

Page 205
Feb 1/09
V2500 54-20-00 REPAIR No. 006

Page 206
Feb 1/09
REPAIR NO. 007

FAN COWL ACCESS PANEL OPENING LANDS SURFACE DAMAGE REPAIR
VRS2839/2923
1. General.
A. This procedure may be used to repair surface damage to the access

panel opening lands of the left and right fan cowls. Refer to
Fig. 201.
B. This repair fills the damaged area with epoxy adhesive mixed with
microballoons and installs carbon fibre repair plies and a
fiberglass sanding ply.
C. There must be enough distance to install all the repair plies and
sanding ply and not be within the interface area of the land, refer
to Para. 4A and 6A and Fig. 202. The damage must not go through
more than 5 plies on the outer skin and 4 plies on the inner skin.
Only one repair for each access panel opening land is permitted.
There must be a minimum of 10.0 in. (254,0 mm) between damaged
areas.
Oil Filler and Chip Detector Panel Lands - Inner Skin

(0-90)/(±45)/(±45)/(0-90)
Oil Filler and Chip Detector Panel Lands - Outer Skin
(0-90)/(0-90)/(±45)/(±45)/(0-90)
Air starter Access Panel Lands - Inner Skin
(0-90)/(±45)/(±45)/(0-90)
Air starter Access Panel Lands - Outer Skin
(0-90)/(0-90)/(±45)/(±45)/(0-90).

percent or less.
F. When damage is beyond the scope of this repair refer to Goodrich.
V2500 54-20-00 REPAIR No. 007

Page 201
Feb 1/09

(VRS 2837/2949)
(VRS 2748/2749)
(SPPM)
(SPPM)

Suction cleaner
B. Special Tools
V2500 54-20-00 REPAIR No. 007

Page 202
Feb 1/09

Index).

--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
A. Referring to Fig 202 examine the repair area to assess the amount

V2500 54-20-00 REPAIR No. 007

Page 203
Feb 1/09
penetration, i.e. deciding between 0.060 in. (1,52 mm) and
0.061 in. (1,55 mm), assume the larger figure as the criteria for
selecting the number of repair plies to use. That is, 5 plies
rather than 4, for this example. If the damage is on the interface
of the land or it goes to the edge of the cowl, do REPAIR No. 009
(VRS2837/VRS2924).

5. Clean the access panel.
A. Clean the repair area with the methylethylketone (CoMat 01-076) and
lint free cloth (CoMat 02-099). Wipe the dry.
follows:
each damaged ply of the cowl (ref. step 4.), and add 0.75 in.
(19,05 mm) for an outer layer of fiberglass fabric
(CoMat 02-167).

1.0 in. (25,4 mm).
V2500 54-20-00 REPAIR No. 007

Page 204
Feb 1/09

NECESSARY.
B. Make the surface of the repair area rough with the abrasive paper
(CoMat 05-021) making sure to remove the sharp edges of the damage.
A. Cut the first repair ply
carbon fabric (CoMat 08-059) so that it has a 2.0 in.
(50,8 mm) overlap around the damage.
in step 1.D.
B. Cut the remaining repair plies (if they are required).
(1) Wear lint-free gloves (CoMat 02-097) and use dry carbon
fabric, and cut each subsequent repair ply 2.0 in. (50,8 mm)
longer and 2.0 in. (50,8 mm) wider. There must be one repair
ply for each ply of the cowl which is damaged.
in step 1.D.
C. Cut the fiberglass ply.
fiberglass fabric (CoMat 02-167) so that it has a 1.0 in.
(25,4 mm) overlap around the area identified by the teflon
tape.

V2500 54-20-00 REPAIR No. 007

Page 205
Feb 1/09
9. Prepare the repair materials (Ref Fig 202).

manufacturer’s instructions. The weight of the adhesive needed will
fabric (CoMat 08-059) and the fiberglass fabric (CoMat 02-167).
kept cool) can be used in the installation process.

(CoMat 02-168).
film.
(3) Use the roller force the adhesive into each ply thoroughly.
C. Cut the plies to their finished dimensions.
(1) Cut approximately 1.0 in. (25,4 mm) off each edge of the
plies.
(2) Make sure the first ply has a 1.0 in. (25,4 mm) overlap
around the damage.
(3) Make sure that each subsequent ply extends 1.0 in. (25,4 mm)
more around the damage.
V2500 54-20-00 REPAIR No. 007

Page 206
Feb 1/09

0.5 in. (12,7 mm).
(5) Cut the fiberglass ply so that it is the same shape as the
area defined by the teflon tape.


the phenolic microballoons to 100 parts (by weight) of the mixture.
B. Fill the damaged area of the panel with the mixture using a clean
metal spatula. Make sure the mixture is level with the top carbon
ply of the cowl.
V2500 54-20-00 REPAIR No. 007

Page 207
Feb 1/09

B. Install the first repair ply.
repair ply.
the repair area, making sure that the damage is located in
the center of the ply.
in step 1.D.
(3) Use a roller to remove air and unwanted adhesive from the
ply.
repair ply.
C. Install the second repair ply (if necessary).
repair ply.
the repair area, making sure that it has an equal overlap
around the first repair ply.
in step 1.D.
ply.
V2500 54-20-00 REPAIR No. 007

Page 208
Feb 1/09
repair ply.
D. Install the subsequent repair plies.
(1) Repeat step C. above for the subsequent repair plies.
E. Install the fiberglass sanding ply.
(1) Repeat step C. above for the fiberglass sanding ply, making
sure that it has an equal overlap around the last carbon
fibre repair ply, and is touching the teflon tape.
F. Remove unwanted adhesive from the teflon tape with a clean metal
spatula.
area.
B. Cut the a sheet of porous parting film (CoMat 02-169) making sure
C. Cut the breather fabric (CoMat 08-057) into sheets the same size as
the porous parting film. The number of pieces must equal the number
of plies used in the repair.
it has an equal overlap around the repair area. Put the layers

pieces of material have an overlap of 2.0in. (50,8 mm) around the

V2500 54-20-00 REPAIR No. 007

Page 209
Feb 1/09

rubber sheet.
(2) Put the two pieces of the breather cloth on to the repair
area.
repair area.

to the repair area.
(CoMat 08-051).
tape.

(88oC).
V2500 54-20-00 REPAIR No. 007

Page 210
Feb 1/09
the repair area.

NECESSARY.


(CoMat 05-021). The contours of the repair area must be smooth and
there must not be an edge between the repair area and the outer
skin of the cowl.
cleaner.
B. Clean the repair area with methylethylketone (CoMat 01-076) and a

V2500 54-20-00 REPAIR No. 007

Page 211
Feb 1/09

(Ref. SPPM TASK 70-38-07-380-501).

(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-20-00 REPAIR No. 007

Page 212
Feb 1/09

Fig. 201
V2500 54-20-00 REPAIR No. 007

Page 213
Feb 1/09
Surface Damage Buildup Repair

Fig. 202
V2500 54-20-00 REPAIR No. 007

Page 214
Feb 1/09

Fig. 203
V2500 54-20-00 REPAIR No. 007

Page 215
Feb 1/09
V2500 54-20-00 REPAIR No. 007

Page 216
Feb 1/09
REPAIR NO. 008

LEFT FAN COWL OIL FILLER AND CHIP DETECTOR ACCESS DOOR LAND REPAIR
VRS2868
1. General.
A. This procedure may be used to repair damage to the interface land

on the left fan cowl composite sandwich oil filler and chip
detector access doors. To repair damage to the laminate oil filler
access door, refer to REPAIR No. 035 (VRS7501).
filler plies, a carbon fibre patch and a fiberglass sanding ply.
C. This repair can only be done in the areas indicated, and must not
be more than 1.0 in. (25,4 mm) wide and 1.6 in. (40,6 mm) long. The
damage must be a sufficient distance from the fittings, brackets,
hinges and flanges to install all the repair plies and the sanding
ply on the outer surface. Only one repair for each land is
permitted. Refer to Figures 201 and 202.
D. This repair must be done in a room with a controlled temperature of

between 68o - 77oF (20o - 25oC). The humidity must be kept at 50
percent or less.

to Goodrich.

(VRS7501)
(SPPM)
(SPPM)
V2500 54-20-00 REPAIR No. 008

Page 201
Feb 1/09
Heat Blanket, 32o - 248oF (0o - 120oC)

Heat Lamp, 32o - 212oF (0o - 100oC)
Suction Cleaner
Standard Workshop Tools and Equipment
B. Special Tools
C. Consumable Materials (Ref. Overhaul Processes and

Consumables Index)

CoMat 07-085 Epoxy varnish
D. Repair parts
None
V2500 54-20-00 REPAIR No. 008

Page 202
Feb 1/09
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Oil filler panel Composite sandwich structure
Chip detector panel Composite structure
4. Disassemble the access door (if necessary).
A. Remove the latch(es) from the access door

(Ref. AMM TASK 71-13-14-000-010).
A. Clean around the damaged area with methylethylketone (CoMat 01-

076) and lint-free cloth (CoMat 02-099). Wipe the repair area dry.
A. Mark the centre of the damaged area.
B. Mask around the repair area with 2.0 in. (50,8 mm) wide strips of
must be from the damage as follows:
door land.
(2) On the external surface, measure 4.85 in. (123,2 mm) from the
door edge.

V2500 54-20-00 REPAIR No. 008

Page 203
Feb 1/09

DO THIS TASK. BEFORE YOU USE PPE,READ, UNDERSTAND AND OBEY
NECESSARY.
C. Remove the surface protective treatment from the repair area with
waterproof abrasive paper (CoMat 05-021). Make the edges of the
area smooth.
D. Measure the damage cut-out area.
(1) Find the centre of the damaged area, measure 0.5 in.
(12,7 mm) each side along the door land and make a mark.
(2) Measure 1.6 in. (40,6 mm) from the door edge and make a mark
to show the door land area.
(3) Make the two corners of the repair area to a radius of

0.25 in. (6,3 mm).

NECESSARY.


(CoMat 05-021).
A. Let the repair area dry for 6 hours at 176oF (80oC) using heat
lamps.
V2500 54-20-00 REPAIR No. 008

Page 204
Feb 1/09
NOTE: The repair materials must be applied at the end of the 6

hours.
9. Cut the filler and repair plies (Ref. Fig. 202).

NECESSARY.
A. Prepare eight filler plies.
(1) Wear lint-free gloves (CoMat 02-097) and cut eight pieces of
larger all around (except at the door edge) than the cut-out
repair area.
NOTE: To prevent fraying, the plies may be cut to the

finished dimensions after soaking in adhesive.
(50,8 mm) larger all around (except at the door edge) than

C. Prepare the seven subsequent repair plies.
dry carbon fibre fabric (CoMat 08-059), each piece 0.25 in.
(6,3 mm) larger all around (except at the door edge) than the
previous piece.

V2500 54-20-00 REPAIR No. 008

Page 205
Feb 1/09
fiberglass fabric (CoMat 02-167) so it is 0.75 in. (19,0 mm)
larger all around (except at the door edge) than the largest
ply.

(2) Wrap a piece of non-porous parting film (CoMat 02-367) around

the backing plate.

side of the door land and align it with the door edge.
door land and a good overlap of the cut-out area.

NOTE: The weight of adhesive necessary, will be approximately the

same as the weight of the carbon and the fiberglass fabric.
After the plies are soaked, the remaining adhesive is used on
the repair area.
B. Soak the fiberglass and the carbon plies with the adhesive.

(CoMat 02-367).
V2500 54-20-00 REPAIR No. 008

Page 206
Feb 1/09
(2) Apply the adhesive to the two sides of each ply with the
brush (CoMat 02-087) and put a second sheet of non-porous
parting film on each ply.
thoroughly.
C. Cut the eight filler plies to their finished dimensions.

NECESSARY.
(1) Cut each filler ply to the same dimensions as the cut-out
area.
of 0.25 in. (6,3 mm).
D. Cut the eight repair plies to their finished dimensions.

NECESSARY.
(except at the door edge) than the cut-out repair area.
0.25 in. (6,3 mm) wider.
45 degrees.
V2500 54-20-00 REPAIR No. 008

Page 207
Feb 1/09

NECESSARY.
around (except at the door edge) than the last repair ply.
(2) Find a long side and cut two corners approximately 1.0 in.
(25,4 mm) from the end at an angle of 45 degrees.

cleaner.

13. Install the filler plies (Ref. Fig. 202).
A. Apply an equal level of the adhesive mix to the cut-out area and
the edges using a brush (CoMat 02-087).
V2500 54-20-00 REPAIR No. 008

Page 208
Feb 1/09
ply.
(2) Put the first filler ply, with the adhesive side down, in the
cut-out area, and align it with the edge of the door land.
metal spatula.
(4) Remove the remaining parting film from the first filler ply.
C. Apply the seven subsequent filler plies.
(1) Repeat step B. for each filler ply.
A. Apply an equal layer of adhesive to the repair area using a brush

(CoMat 02-087).
B. Put the first carbon repair ply on to the repair area.
(1) Remove the non-porous parting film (CoMat 02-367) from one
side of the first repair ply.
the repair area and align it with the door edge, making sure
that it has an equal 1.0 in. (25,4 mm) overlap around the
repair area.
(3) Use the roller to remove air which is trapped in the

adhesive.
repair ply.
V2500 54-20-00 REPAIR No. 008

Page 209
Feb 1/09
C. Put the seven subsequent carbon repair plies on to the repair area.
(1) Repeat step B. above for the remaining repair plies, making
(6,3 mm) overlap around the previous one.
D. Put the fiberglass ply on to the repair area.
(1) Repeat step B. above for the fiberglass ply, making sure that
the ply has an equal overlap of 0.75 in. (19,0 mm) around the
top repair ply.
(2) Make sure that the fiberglass ply is adjacent to, but not on,
the teflon tape.
E. Remove the unwanted adhesive from the teflon tape with a clean
metal spatula.
area.
3.0 in. (76.2 m) around the fiberglass ply.
fiberglass ply on the repair area. Make sure that the breather
fabric has the same dimensions as the porous parting film.

V2500 54-20-00 REPAIR No. 008

Page 210
Feb 1/09


adhesive cures.

rubber sheet.
repair area.
I. Put at least two temperature probes on the teflon tape, adjacent to

the repair area.
(CoMat 08-051).
larger than the door.
2.00 in. (50.8 mm) around the breather cloth.
(5) Attach and seal the bagging film to the cowl with the sealant
V2500 54-20-00 REPAIR No. 008

Page 211
Feb 1/09
area, making sure it gives an indication of at least 25.0 in.
(635.0 mm) of mercury while the adhesive cures.

(88oC).

from the repair.
18. Prepare the access door (Ref. Fig. 202).

NECESSARY.
CAUTION: DO NOT CAUSE DAMAGE TO THE REPAIR PLIES OR CARBON PLIES OF

THE DOOR.
A. If necessary, chamfer the door edge at the hinge area.
(1) Measure between 0.12 - 0.16 in. (3,0 - 4,0 mm) from the
internal surface and make a mark.
(2) Chamfer the hinge area along the edge of the internal surface
at an angle of 45 degrees.
B. If necessary, drill the latch fastener hole(s).
(1) Use the latch as a template and make a mark for the fastener
hole(s).
V2500 54-20-00 REPAIR No. 008

Page 212
Feb 1/09

tools.
(3) Countersink the holes on the external surface to an angle of

100 degrees.
C. If necessary, make sure the latch opening is clear.
(1) Use the latch as a template and make a mark for the latch
opening.
(2) Remove the material from the latch opening as necessary

using standard workshop tools.
(1) Measure approximately 0.35 in. (8,9 mm) from the door edge
E. Make the fiberglass sanding ply smooth with waterproof abrasive

paper (CoMat 05-021), making sure there is no edge between the
repair area and the outer surface.
F. Prepare the door land.
(1) Make the door land to the original contour.
(2) Close the access door, and make sure that the aerodynamic
contour on the external surface is correct and the hinge area
does not catch.
19. Apply surface protection to the cut edges.
A. Use a brush (CoMat 02-087) and apply epoxy varnish (CoMat 07-085)
to the cut and chamfered edges, and let the varnish dry.
20. Assemble the access door (if necessary).
A. Install the latch(es) on the access door

(Ref. AMM TASK 71-13-14-400-010).
NOTE: Use longer fasteners if necessary, and make sure that they
are properly secured.
V2500 54-20-00 REPAIR No. 008

Page 213
Feb 1/09
cleaner.



(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-20-00 REPAIR No. 008

Page 214
Feb 1/09
View on the inside surface of

the Composite Sandwich Oil Filler Access Door
Fig 201
V2500 54-20-00 REPAIR No. 008

Page 215
Feb 1/09
Composite Sandwich Oil Filler Door, Repair Land Area

Fig 202
V2500 54-20-00 REPAIR No. 008

Page 216
Feb 1/09
Aug 1/06

Fig 203
V2500 54-20-00 REPAIR No. 008

Page 217
Feb 1/09
V2500 54-20-00 REPAIR No. 008

Page 218
Feb 1/09
REPAIR NO. 009

FAN COWL ACCESS PANEL INTERFACE LAND REPAIR
VRS2837/2924
1. General
A. This procedure may be used to repair damage to the access panel

closing land on the left and right fan cowls.
NOTE: For applicable repair area refer to Figure 201.
fill-in and repair plies.
C. Only one repair is permitted for each land.

(SPPM)

Steel Roller, 2.0 in. (50.8mm) diameter, 2.0 in. (50.8mm) long
Suction Cleaner
B. Consumable Materials (Ref. Overhaul Processes and

Consumables Index)

V2500 54-20-00 REPAIR No. 009

Page 201
Feb 1/09

A. Component Material
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Fan Cowl Composite structure
4. Clean the fan cowl.
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMI-
CALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY
INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES INSTRUCTIONS ON
HOW YOU MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY USE,
KEEP AND DISCARD CHEMICALS.

5. Examine the repair area

TASK 71-13-11-300-022 (VRS2748) when you do this repair.
6. Prepare the damaged area for repair (Ref Fig 201).
follows:
(1) Measure a minimum of 2.25 in. (57.2 mm) each side along the
panel land.
(2) On the inner surface, measure 2.4 in. (60.9 mm) from the edge
of the panel land.
V2500 54-20-00 REPAIR No. 009

Page 202
Feb 1/09
(3) Measure along the skin contour, and make the two corners of
the marked area to an angle of 45 degrees and a length of
approximately 1.5 in. (38.1 mm).
(4) Use the marking pen (CoMat 06-131) to apply temporary marks
to the measured repair area.

NECESSARY.
C. Remove the surface protective treatment from the repair area with
area smooth, and also rub the external surface side of the panel
land.
(12.7 mm) each side along the panel land and make a mark in
line with the edge of the external surface.

0.25 in. (6.3 mm).
7. Remove the damaged material (Ref Fig 201).

ESSARY.

V2500 54-20-00 REPAIR No. 009

Page 203
Feb 1/09

(CoMat 05-021).
A. Use heat lamps to dry the repair area. Keep the temperature at 80oC
(176oF) for 6 hours. The repair materials must be applied
immediately at the end of the 6 hours.
9. Prepare the fill-in and repair plies (Ref Fig 201).

SARY.
A. Prepare four fill-in plies.
(1) Wear lint-free gloves (CoMat 02-097) and cut four pieces of
dry carbon fibre fabric (CoMat 08-059) 1.0 in. (25.4 mm)
repair area.
C. Prepare the second, third and fourth repair plies.
(2) Wear lint-free gloves (CoMat 02-097) and cut three pieces of
the previous piece.
10. Prepare the repair area (Ref Fig 201).
(1) Make the backing plate to the outer-skin surface contour.

the backing plate.
V2500 54-20-00 REPAIR No. 009

Page 204
Feb 1/09
(3) Temporarily attach the backing plate to the outer-skin side

of the panel land and make sure it touches the outer-skin
edge.

manufacturer’s instructions. The weight of adhesive required will
fabric.
B. Soak the carbon fibre plies with the mixed adhesive.

(CoMat 02-168).
(2) Apply adhesive to each ply with the brush (CoMat 02-087) and
cover each ply with another sheet of non-porous parting
film.
(3) Use the roller to force the adhesive into each ply thor-
oughly.
C. Cut the fill-in and repair plies to their finished dimensions.
(1) Cut each fill-in ply to the same dimensions as the cut-out
area.
(2) Find a long side on each fill-in ply and cut two corners to a
radius of 0.25 in. (6.3 mm).
(3) Cut the first repair ply so that it extends 1.0 in. (25.4 mm)
from the three edges of the cut-out area.
V2500 54-20-00 REPAIR No. 009

Page 205
Feb 1/09
(12.7 m) from the end at an angle of 45 degrees.
(5) Cut each subsequent repair ply 0.5 in. (12.7 mm) longer and
0.25 in. (6.3 mm) wider.
approximately 0.5 in. (12.7 mm) from the end at an angle of
45 degrees.

cleaner.

13. Fill the cut-out area (Ref Fig 201).
ply.
V2500 54-20-00 REPAIR No. 009

Page 206
Feb 1/09
(2) Put the first fill-in, with the adhesive side down, in the
cut-out area, and align it with the inner skin edge.
metal spatula.
ply.
C. Apply the remaining fill-in plies.

repair ply.
the repair area and align it with the inner skin edge, making
sure that it has an equal overlap around the repair cut-out.
ply.
repair ply.
C. Apply the remaining repair plies.
(1) Repeat step B above for the remaining repair plies. Make sure
that the fourth (top) repair ply is adjacent to, but not on,
the teflon tape.
V2500 54-20-00 REPAIR No. 009

Page 207
Feb 1/09
D. Remove unwanted adhesive from the teflon tape with a clean metal
spatula.
15. Prepare to cure the adhesive (Ref Fig 202).
A. Get a heat blanket, which must be a minimum of 3.0 in. (76 m) larger
all around than the repair area.
3.0 in. (76.2 m) around the top repair ply.
C. Cut four sheets of breather fabric (CoMat 08-057), making sure that
the breather fabric has the same dimensions as the porous parting
film.


in. (50.8 mm) larger on each side than the silicone rubber
sheet.
repair area.
V2500 54-20-00 REPAIR No. 009

Page 208
Feb 1/09
I. Put as least two temperature probes on the teflon tape adjacent to

the repair area.
(CoMat 08-051).
tape.
making sure it gives an indication of at least 25.0 in. (635.0 mm)

(90oC).
the repair.
V2500 54-20-00 REPAIR No. 009

Page 209
Feb 1/09
18. Prepare the access panel land (Ref Fig 201).

SARY.
OF THE COWL.

(CoMat 05-021).
(2) Close the access panel, and make sure that the aerodynamic
contour is correct.
cleaner.


V2500 54-20-00 REPAIR No. 009

Page 210
Feb 1/09
V2500 54-20-00 REPAIR No. 009

Page 211
Feb 1/09

Fig 201
V2500 54-20-00 REPAIR No. 009

Page 212
Feb 1/09

Fig 202
V2500 54-20-00 REPAIR No. 009

Page 213
Feb 1/09
V2500 54-20-00 REPAIR No. 009

Page 214
Feb 1/09
REPAIR NO. 010

LEFT FAN COWL ACCESS PANELS MAIN AREA SURFACE DAMAGE REPAIR
VRS2869
1. General.
A. This procedure may be used to repair surface damage to the main

area of the Chip Detector Door and Composite Sandwich Oil Filler
Door of the left fan cowl. To repair damage to the laminate oil
filler access door, refer to REPAIR No. 036 (VRS2795).
C. The damage must be a sufficient distance from the edge of the panel
to install all the repair plies and sanding ply. Refer to Para. 6A
and Fig. 201 and 202. The damage can be nearer to the edge if less
plies are damaged. There must be a minimum of 10.0 in. (254,0 mm)
between damaged areas. The damage on the Chip Detector door must
not go through more than 4 composite plies. The damage on the Oil
Filler door must not go through 2 plies on the outer surface or 4
plies on the inner surface.
D. The orientation of the carbon fibre repair plies are as follows:

(1) Chip Detector door (0-90)/(±45)/(±45)/(0-90)
(2) Oil Filler door (inner surface) (0-90)/(±45)/(0-90)/(±45)
(3) Oil Filler door (outer surface) (0-90)/(±45).

percent or less.

to Goodrich.

(VRS2795)
(SPPM)
(SPPM)
V2500 54-20-00 REPAIR No. 010

Page 201
Feb 1/09

Suction cleaner
B. Special Tools

Index).

D. Repair parts
None
V2500 54-20-00 REPAIR No. 010

Page 202
Feb 1/09
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Left fan cowl Composite structure
chip detector door
Left fan cowl Composite sandwich structure
oil filler door
DEPTH OF DAMAGE NO. OF REPAIR PLIES
Up to 0.015in. (0,38 mm) 1+ fiberglass ply (Sanding)

0.016 to 0.030in. (0,41 to 0,76 mm) 2+ fiberglass ply (Sanding)
More than 0.046in. (1,17 mm) 4+ fiberglass ply (Sanding)
for this example. If the damage goes through the panel, or goes
into the honeycomb of the panel, refer to manufacturer.

V2500 54-20-00 REPAIR No. 010

Page 203
Feb 1/09
follows:
each ply of the panel (ref. step 4.), and add 0.75 in.
(CoMat 02-167).

in. (25,4 mm).

NECESSARY.
edges from the damage with the abrasive paper (CoMat 05-021).
V2500 54-20-00 REPAIR No. 010

Page 204
Feb 1/09

ESSARY.
the finished dimensions after soaking in adhesive (Ref. steps 1.D
and 9.C).
repair ply for each ply of the panel which is damaged and these
after soaking in adhesive (Ref. steps 1.D and 9.C).
V2500 54-20-00 REPAIR No. 010

Page 205
Feb 1/09

NOTE: After the plies are soaked, the remaining adhesive is used on
the repair area (Ref. step 12.).

V2500 54-20-00 REPAIR No. 010

Page 206
Feb 1/09


metal spatula. The filled damage must be level with the top carbon
fibre ply of the panel.
V2500 54-20-00 REPAIR No. 010

Page 207
Feb 1/09

film.
in step 1.D.
in step 1.D.
spatula.
V2500 54-20-00 REPAIR No. 010

Page 208
Feb 1/09

D. above.
parting film.

to the repair area.
V2500 54-20-00 REPAIR No. 010

Page 209
Feb 1/09
the repair area.

SARY.

(CoMat 05-021).
V2500 54-20-00 REPAIR No. 010

Page 210
Feb 1/09


(Ref. SPPM TASK 70-38-07-380-501).
A. Ident the component/log book with the REPAIR no.VRS2869

(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-20-00 REPAIR No. 010

Page 211
Feb 1/09

Fig. 201 Sheet 1
V2500 54-20-00 REPAIR No. 010

Page 212
Feb 1/09

Fig. 201 Sheet 2
V2500 54-20-00 REPAIR No. 010

Page 213
Feb 1/09

Fig. 202
V2500 54-20-00 REPAIR No. 010

Page 214
Feb 1/09

Fig. 203
V2500 54-20-00 REPAIR No. 010

Page 215
Feb 1/09
THIS PAGE IS INTENTIONALLY LEFT BLANK
V2500 54-20-00 REPAIR No. 010

Page 216
Feb 1/09
REPAIR NO. 012

FAN COWL DOOR EDGE DELAMINATION REPAIR
VRS2834/2877
1. General.
A. This repair may be used to repair edge delamination on the left or

right fan cowl.
B. The damage must not be in the 12.0 in. (304,8 mm) overheat zone on
the forward edge. The damage must not be more than 0.50 in.
(12,7 mm) in the forward and aft direction by maximum length of
1.25 in. (31,8 mm) circumferentially. There must be a minimum of
10.0 in. (254,0 mm) between damaged areas. Refer to Fig. 201.

percent or less.

to Goodrich.

(VRS2748/2749)
(SPPM)

V2500 54-20-00 REPAIR No. 012

Page 201
Feb 1/09

Index).

C. Special Tools

D. Repair parts
None.
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
PROCEDURE.

V2500 54-20-00 REPAIR No. 012

Page 202
Feb 1/09

6. Examine the fan cowl edges (Ref. Fig. 201).

the area using a marking pen (CoMat 06-131). If the damage is more
than
1.25 in. (31,8 mm) in length and more than 0.5 in. (12,7 mm) in the
forward and aft direction, refer to Goodrich.
B. If lightning strike protection wire mesh is present and the loss of

REPAIR No. 031 (VRS2748/2749) when you do this repair.
V2500 54-20-00 REPAIR No. 012

Page 203
Feb 1/09

adhesive.
C. Slowly inject the adhesive with the syringe into the delaminated
area until the adhesive begins to flow out from the edges of the
plies.


V2500 54-20-00 REPAIR No. 012

Page 204
Feb 1/09


(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-20-00 REPAIR No. 012

Page 205
Feb 1/09
Fan Cowl Edge Delamination Repair

Fig. 201
V2500 54-20-00 REPAIR No. 012

Page 206
Feb 1/09
REPAIR NO. 013

FAN COWL DOOR DELAMINATION REPAIR
VRS2829/2874
1. General.

delamination in the plies of the left or right fan cowl. It applies
only where no actual rupture (discontinuity) of the plies is found.
B. The damage must be confined to an area of 2.0 in. (50,8 mm)

diameter or less in the main panel area (Zone C). The damage in all
other applicable areas must be confined to 3.0 in. (76,2 mm)
diameter or less. The damage must not be in the overheat zone of
the Inlet T.A.I. Exhuast (Zone K1). If the damage is near to the
edge of the panel, refer to REPAIR No. 012 (VRS2834/2877). Refer to
Fig. 201.
C. This repair can only be done in the areas indicated, Ref. Fig. 201.

percent or less.
E. If the damage or repair patch overlaps two zones refer to Goodrich.

to Goodrich.

(VRS2834/2877)
(SPPM)

V2500 54-20-00 REPAIR No. 013

Page 201
Feb 1/09

Index).

C. Special Tools

D. Repair parts
None.
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
PROCEDURE.

V2500 54-20-00 REPAIR No. 013

Page 202
Feb 1/09

6. Examine the fan cowl (Ref. Figs. 201 and 202).

the area using a marking pen (CoMat 06-131).
B. At the two farthest points make a mark for drilling. Use a marking
pen (CoMat 06-131).
7. Prepare the fan cowl for repair (Ref. Fig. 202).
A. Use a hand drill with a 0.062 in. (1,58 mm) drill to drill two
holes to the depth of delamination.
B. Remove unwanted material from the repair area with a suction

cleaner.
V2500 54-20-00 REPAIR No. 013

Page 203
Feb 1/09

adhesive.
C. Put the syringe into one of the drilled holes and slowly inject the
adhesive until it starts to come through the other drilled hole.


V2500 54-20-00 REPAIR No. 013

Page 204
Feb 1/09

A. Ident the component/log book with the repair no. VRS2829/2874

(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-20-00 REPAIR No. 013

Page 205
Feb 1/09
Location of Repair Area (Left Fan Cowl)

Fig. 201 Sheet 1
V2500 54-20-00 REPAIR No. 013

Page 206
Feb 1/09

Fig. 201 Sheet 2
V2500 54-20-00 REPAIR No. 013

Page 207
Feb 1/09

Fig. 201 Sheet 3
V2500 54-20-00 REPAIR No. 013

Page 208
Feb 1/09

Fig. 201 Sheet 4
V2500 54-20-00 REPAIR No. 013

Page 209
Feb 1/09
Location of Repair Area (Right Fan Cowl)

Fig. 201 Sheet 5
V2500 54-20-00 REPAIR No. 013

Page 210
Feb 1/09

Fig. 201 Sheet 6
V2500 54-20-00 REPAIR No. 013

Page 211
Feb 1/09

Fig. 201 Sheet 7
V2500 54-20-00 REPAIR No. 013

Page 212
Feb 1/09

Fig. 201 Sheet 8
V2500 54-20-00 REPAIR No. 013

Page 213
Feb 1/09

Fig. 201 Sheet 9
V2500 54-20-00 REPAIR No. 013

Page 214
Feb 1/09
Fan Cowl Delamination Repair

Fig. 202
V2500 54-20-00 REPAIR No. 013

Page 215
Feb 1/09
V2500 54-20-00 REPAIR No. 013

Page 216
Feb 1/09
REPAIR NO. 014

FAN COWL DOOR LANDS SURFACE DAMAGE REPAIR
VRS2830/2876
1. General.
A. This procedure may be used to repair surface damage to the forward

and aft door lands of the left or right fan cowls.
C. There must be enough distance to install all the repair plies and
sanding ply and not be within the interface area of the land, refer
to Para. 4A and 6A and Fig. 202. The damage must not go through all
the composite plies.
(0-90)/(0-90)/(±45)/(±45)/(0-90)/(0-90)/(0-90)/(0-90).

percent or less.

(VRS2748/2749)
(SPPM)
(SPPM)
V2500 54-20-00 REPAIR No. 014

Page 201
Feb 1/09

Suction cleaner
B. Special Tools

Index).

--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Right fan cowl Composite structure
V2500 54-20-00 REPAIR No. 014

Page 202
Feb 1/09
A. Examine the damaged area to assess the amount of damage and, using
the standard workshop tools, measure the depth of the damage. Do
this in several places where the extent of the damage permits. From
this information the number of repair plies should be calculated as
follows:

If in doubt over the depth of the damage, i.e. deciding between

0.045 in. (1,14 mm) and 0.046 in. (1,17 mm), assume the larger
figure as the criteria for selecting the number of repair plies to
use. That is, 4 plies rather than 3, for this example.

V2500 54-20-00 REPAIR No. 014

Page 203
Feb 1/09
A. Mask around the repair area with 2.0 in. (50,8 mm) wide strips of
each damaged ply of the cowl (ref. step 4.).

1.0 in. (25,4 mm).

NECESSARY.
B. Remove the sharp edges from the damage and make the surface of the
repair area rough with the abrasive paper (CoMat 05-021).

NECESSARY.
carbon fabric (CoMat 08-059) so that it has a 2.0 in. (50,8 mm)
overlap around the damage.
in step 1.D.
V2500 54-20-00 REPAIR No. 014

Page 204
Feb 1/09
B. Wear lint-free gloves (CoMat 02-097) and cut each subsequent

repair ply from dry carbon fabric (CoMat 08-059) 2.0 in. (50,8 mm)
larger all around than the previous piece. Cut one repair ply for
each ply of the cowl which is damaged.
in step 1.D.
C. Wear lint-free gloves (CoMat 02-097) and cut one piece of

fiberglass fabric (CoMat 02-167) so that it has a 1.0 in. (25,4 mm)
overlap around the area identified by the teflon tape.


manufacturer’s instructions. The weight of the adhesive needed
will be approximately the same as the weight of the dry carbon
fibre fabric (CoMat 08-059) and the fiberglass fabric (CoMat 02-
167).

(CoMat 02-168).
V2500 54-20-00 REPAIR No. 014

Page 205
Feb 1/09
and put a second sheet of non-porous parting film on each
ply.
(3) Use the roller force the adhesive into each ply thoroughly.

NECESSARY.
plies.
around the damage.

0.5 in. (12,7 mm).
area defined by the teflon tape.

V2500 54-20-00 REPAIR No. 014

Page 206
Feb 1/09

ply of the cowl.

(1) Remove the non-porous parting (CoMat 02-168) film from one
NOTE: Make sure that the ply fibres follow the orientation
as given in step 1.D.
V2500 54-20-00 REPAIR No. 014

Page 207
Feb 1/09
ply.
repair ply.
repair ply.
NOTE: Make sure that the ply fibres follow the orientation as
given in step 1.D.
ply.
repair ply.
D. Install the subsequent repair plies.
E. Install the fiberglass sanding ply.
(1) Repeat step C. above for the fiberglass sanding ply, making
sure that it has an equal overlap around the last carbon
fibre repair ply, and is touching the teflon tape.
spatula.
area.
B. Cut the a sheet of porous parting film (CoMat 02-169) making sure
the porous parting film. The number of pieces must equal the number
of plies used in the repair.
V2500 54-20-00 REPAIR No. 014

Page 208
Feb 1/09
it has an equal overlap around the repair area. Put the layers



adhesive cures.

rubber sheet.
area.
repair area.

to the repair area.
(CoMat 08-051).
V2500 54-20-00 REPAIR No. 014

Page 209
Feb 1/09

(88oC).
the repair area.

NECESSARY.

A. Make all contours of the repair area smooth with waterproof

abrasive paper (CoMat 05-021), making sure that there is no edge
between the repair area and the outer skin of the cowl.
V2500 54-20-00 REPAIR No. 014

Page 210
Feb 1/09
cleaner.
B. Clean the repair area with methylethylketone (CoMat 01-076) and a


(Ref. SPPM TASK 70-38-07-380-501).

(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-20-00 REPAIR No. 014

Page 211
Feb 1/09

Fig. 201
V2500 54-20-00 REPAIR No. 014

Page 212
Feb 1/09
Surface Damage Build-Up Repair

Fig. 202
V2500 54-20-00 REPAIR No. 014

Page 213
Feb 1/09

Fig. 203
V2500 54-20-00 REPAIR No. 014

Page 214
Feb 1/09
REPAIR NO. 015

FAN COWL ACCESS PANEL LANDS SURFACE DAMAGE REPAIR
VRS2832
1. General.
A. This procedure may be used to repair surface damage on the lands of

the Air Starter/Blow-Off Door, Chip Detector Door and Composite
Sandwich Oil Filler Door. To repair damage to the laminate oil
filler access door, refer to REPAIR No. 037 (VRS7502).
NOTE: For applicable repair area refer to Figures 203, 204 and 205.
B. Damage which penetrates or goes to the edge of the panel is not

within the limits of this repair and must be referred to Goodrich.
C. Only one repair is permitted for each land.

percent or less.

to Goodrich.

(VRS7502)
(SPPM)
(SPPM)
V2500 54-20-00 REPAIR No. 015

Page 201
Feb 1/09

Heat Lamp, 176o - 194oF (80o - 90oC)
Steel Roller, 2.0 in. (50,8mm) diameter, 2.0 in. (50,8mm) long
Suction Cleaner
B. Special Tools

Consumables Index)

CoMat 02-097 lint-free gloves
CoMat 02-099 lint-free cloth
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Oil filler door Composite sandwich structure
Chip detector door Composite structure
Air starter door Composite structure
V2500 54-20-00 REPAIR No. 015

Page 202
Feb 1/09
this in several places where the extent of the damage permits.
From this information the number of repair plies should be
calculated as follows:
-------------------------------------------------------------
DEPTH OF DAMAGE NO. OF PLIES
-------------------------------------------------------------
Up to 0.013 in. (0,33 mm) 1

0.014 in. (0,35 mm) to 0.026 in. (0,66 mm) 2
0.027 in. (0,68 mm) to 0.039 in. (0,99 mm) 3
0.040 in. (1,01 mm) to 0.052 in. (1,32 mm) 4
0.053 in. (1,34 mm) to 0.065 in. (1,65 mm) 5
0.066 in. (1,67 mm) to 0.078 in. (1,98 mm) 6
0.079 in. (2,00 mm) to 0.091 in. (2,31 mm) 7
0.092 in. (2,33 mm) to 0.104 in. (2,64 mm) 8
More than 0.104 in. (2,64 mm) 9
If in doubt over the depth of the damage, ie., deciding between

0.039 in. (0,99 m) and 0.040 in. (1,01 mm), assume the larger
A. Clean around the damaged area with methylethylketone (CoMat 01-076)

and lint-free cloth (CoMat 02-099). Wipe the repair area dry.
V2500 54-20-00 REPAIR No. 015

Page 203
Feb 1/09

1.0 in. (25,4 mm).

NECESSARY.
B. Remove the sharp edges from the damage and make the surface of the
repair area rough with waterproof abrasive paper (CoMat 05-021).
7. Cut the repair plies.

NECESSARY.
(50,8 mm) overlap around the damaged area.
NOTE: If only one ply is needed to do the repair use fiberglass

fabric (CoMat 02-167), the sanding ply.
V2500 54-20-00 REPAIR No. 015

Page 204
Feb 1/09
B. Wear lint-free gloves (CoMat 02-097) and cut each subsequent repair
ply from dry carbon fibre fabric (CoMat 08-059) 2.0 in. (50,8 mm)
larger all around than the previous piece. Cut one repair ply for
C. Wear lint-free gloves (CoMat 02-097) and cut one piece of

fiberglass fabric (CoMat 02-167) so that it has a 1.0 in. (25,4 mm)
overlap around the area which the teflon tape (CoMat 02-007)
identifies.
lamps.

hours.

the repair area.


(CoMat 02-367).
thoroughly.
V2500 54-20-00 REPAIR No. 015

Page 205
Feb 1/09

NECESSARY.
repair plies. Make sure that the first repair ply has a
1.0 in. (25,4 mm) overlap around the damage, and each
subsequent repair ply has a 1.0 in. (25,4 mm) overlap around
the repair ply below it. Trim the corners of the repair plies
to 45 degrees by 0.5 in. (12,7 m). Cut the fiberglass ply so
that it is the same shape as the area identified by the

V2500 54-20-00 REPAIR No. 015

Page 206
Feb 1/09

thickness.
B. Apply the adhesive mix to the damaged area of the cowl with a clean
metal spatula. Make sure the adhesive is level with the top carbon
ply of the cowl.

(CoMat 02-087).
the repair area, making sure that the damaged area is in the
center of the repair ply.

adhesive.
V2500 54-20-00 REPAIR No. 015

Page 207
Feb 1/09
(4) Remove the remaining non-porous parting film from the repair
ply.
C. Put the second carbon repair ply on to the repair area.
(1) Remove the non-porous parting film from one side of the
repair ply.
(2) Put the first repair ply, with the adhesive side down, on to
and equal overlap around the first repair ply.

adhesive.
ply.
D. Put the remaining carbon repair plies on to the repair area, repeat
step C above.
E. Put the fiberglass ply on to the repair area.
fiberglass ply.
(2) Put the fiberglass ply, with the adhesive side down, on to
the repair area making sure that fiberglass ply has an equal
overlap around the last carbon repair ply to the teflon mask
area.
(3) Use the roller to remove air which is trapped in the adhesive
and to make the fiberglass ply smooth.
(4) Remove the unwanted adhesive from the teflon tape with a

fiberglass ply.
area.
3.0 in. (76,2 m) around the fiberglass ply.
V2500 54-20-00 REPAIR No. 015

Page 208
Feb 1/09



rubber sheet.
repair area.
I. Put as least two temperature probes on the teflon tape, adjacent to

the repair area.
(1) Cover the repair area with the nylon bagging film
(CoMat 02-163) that must have a minimum overlap of 2.00 in.
(50,8 mm) around the breather cloth.
V2500 54-20-00 REPAIR No. 015

Page 209
Feb 1/09

(90oC).
the repair.

NECESSARY.

V2500 54-20-00 REPAIR No. 015

Page 210
Feb 1/09
cleaner.



(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-20-00 REPAIR No. 015

Page 211
Feb 1/09

Fig 201
V2500 54-20-00 REPAIR No. 015

Page 212
Feb 1/09

Fig 202
V2500 54-20-00 REPAIR No. 015

Page 213
Feb 1/09

the Air Starter/Blow-Off Door
Fig 203
V2500 54-20-00 REPAIR No. 015

Page 214
Feb 1/09

the Chip Detector Door
Fig 204
V2500 54-20-00 REPAIR No. 015

Page 215
Feb 1/09

the Honeycomb Composite Oil Filler Door
Fig 205
V2500 54-20-00 REPAIR No. 015

Page 216
Feb 1/09
CANCELLATION NOTICE

V2500 54-20-00 REPAIR No. 016

Page 201
Feb 1/09
V2500 54-20-00 REPAIR No. 016

Page 202
Feb 1/09
CANCELLATION NOTICE
REPAIR No. 017 VRS2831/2878

V2500 54-20-00 REPAIR No. 017

Page 201
Feb 1/09
V2500 54-20-00 REPAIR No. 017

Page 202
Feb 1/09
REPAIR NO. 018

FAN COWL AFT DOOR LANDS REPAIR
VRS2833/2875
1. General.
A. This procedure may be used to repair damage to the aft door lands
on the left and right fan cowls.
fill-in and repair plies, a fiberglass sanding ply, and replaces
the door rubbing strip.
C. This repair is to be done on door lands which have damage less than
1.0 in. (25,4 mm) long. If the damage exceeds this limit, refer to
Goodrich.
D. There must be a minimum of 10.0 in. (254,0 mm) between damaged

areas.

(VRS2748/2749)
(SPPM)
(SPPM)

Heat lamp, 32o to 248oF (0o - 120oC)
Suction cleaner
B. Special Tools
V2500 54-20-00 REPAIR No. 018

Page 201
Feb 1/09

Index).

Comat 08-051 Sealant tape
CoMat 08-073 Aerodynamic smoothing compound
D. Repair Parts
--------------------------------------------
PART NO. PART IDENT
--------------------------------------------
CSR904B-4-5 Rivet
CSR904B-4-6 Rivet
740-4001-015 Nylon strip (left fan cowl - top)
740-4001-017 Nylon strip (left fan cowl - bottom)
740-4002-015 Nylon strip (right fan cowl - top)
740-4002-017 Nylon strip (left fan cowl - bottom)
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------

REPAIR 031 (VRS2748/2749) when you do this repair.
V2500 54-20-00 REPAIR No. 018

Page 202
Feb 1/09

6. Remove the rubbing strip from the door land. (Ref. Fig. 201).

NECESSARY.
A. Make a 90 degree cut 0.31 in. (7,88 mm) from a rivet and a minimum
of 5.0 in. (126 mm) from each side of the damaged area.
B. Drill out the rivets that attach the part of the rubbing strip to
be removed, and make a note of the position of the rivet holes.
C. Use a thin-bladed knife to break the bond between the rubbing strip
and the door land.

NECESSARY.
A. Use standard workshop tools to carefully remove all damaged

material from the door land.
B. Make the two corners of the cut-out to a radius of 0.25 in.

(6,3 mm) using a 0.25 in. (6,3 mm) router bit.
V2500 54-20-00 REPAIR No. 018

Page 203
Feb 1/09
C. Make the repair area smooth with waterproof abrasive paper

(CoMat 05-021), and chamfer the edges of the damaged area to an
angle of 45 degrees.
A. Apply teflon tape (CoMat 02-161) to the outer skin, 2.5 in.
(63,5 mm) from and all around the damaged area.

NECESSARY.
B. Remove the surface protective treatment from the repair area with
waterproof abrasive paper (CoMat 05-021). Lightly abrade the
exposed graphite fiber surface of the outer skin top ply.
C. Remove the rubbing strip adhesive from the inner surface of the
door land with waterproof adhesive paper (CoMat 05-021).
D. Make an aluminium backing plate to overlap the damaged area.
(1) Make a backing plate from 0.032 in. (0,81 mm) thick
aluminium, and bend it to the same contour as the door land.

the backing plate.
(3) Attach the backing plate to the door land with clamps or
adhesive tape.
V2500 54-20-00 REPAIR No. 018

Page 204
Feb 1/09
A. Clean the outer skin surfaces and the door land of the repair area
with methylethylketone (CoMat 01-076) and lint free cloth (CoMat
02-099). Wipe the area dry.
be applied immediately at the end of the six hours.
11. Prepare the fill-in and repair and sanding plies (Ref. Fig. 202).

NECESSARY.
A. Prepare the fill-in plies.
(1) Wear lint-free gloves (CoMat 02-097) and cut the fill-in
plies from dry carbon fibre fabric (CoMat 08-059), a minimum
of 1.0 in. (25,4 mm) larger all around than the damaged area.
carbon fibre fabric (CoMat 08-059) a minimum of 2.0 in. (50,8
mm) larger all around the damaged area.
C. Prepare the second, third and fourth repair plies.
(1) Wear lint-free gloves (CoMat 02-097) and cut three pieces of
(6,3 mm) larger all around than the previous piece.
V2500 54-20-00 REPAIR No. 018

Page 205
Feb 1/09
fiberglass fabric (CoMat 02-167) 0.75 in. (19,0 mm) larger
all around than the largest repair ply.

NOTE: The weight of adhesive required will be approximately the

same as the weight of the dry carbon fibre fabric and
fiberglass fabric.
(1) Put each ply on a sheet of the non-porous parting film

(CoMat 02-168).
(2) Apply adhesive to each ply with the brush (CoMat 02-087) and
cover each ply with another sheet of non-porous parting film.
(3) Use a roller to force the adhesive into each ply thoroughly.
C. Cut the fill-in, repair and sanding plies to their finished

dimensions.
(1) Cut each fill-in ply to the same dimensions as the as the
cut-out area.
(2) Cut 1.0 in. (25,4 mm) from the edge of each repair ply
(2.0 in. (50,8 mm) at the door edge).
V2500 54-20-00 REPAIR No. 018

Page 206
Feb 1/09
(3) Cut the corners of each repair ply approximately 0.5 in.
(4) Cut 1.0 in. (25,4 mm) from the edge of the fiberglass sanding
ply (2.0 in. (50,8 mm) at the door edge).
(5) Cut the corners of the fiberglass sanding ply approximately

1.0 in. (25,4 mm) from the end at an angle of 45 degrees.


the outer skin of the repair area.
ply.
the damaged area.
(3) Remove any creases and air from the ply with a steel roller.
(4) Remove the remaining parting film from the first fill-in ply.
V2500 54-20-00 REPAIR No. 018

Page 207
Feb 1/09
15. Install the repair plies and fiberglass sanding ply (Ref. Fig. 202).

the outer skin of the repair area.
repair ply.
that it has a 1.0 in. (25,4 mm) overlap around the cut-out.
(3) Use the roller to remove any creases and air from the ply.
repair ply.
(1) Repeat step B above for the remaining repair plies.

(2) Put the fiberglass sanding ply, with the adhesive side down,
on the repair area and align it with the door edge, making
sure that it has a 0.75 in. (19,0 mm) overlap around the last
carbon repair ply.
(3) Use the roller to remove any creases and air from the ply.
V2500 54-20-00 REPAIR No. 018

Page 208
Feb 1/09

E. Remove any unwanted adhesive from the teflon tape with a clean
metal spatula.
16. Prepare to cure the adhesive.
A. Get a heat blanket, which must be a minimum of 3.0 in. (76,2 mm)
larger all around than the repair area.
B. Cut a sheet of porous parting film (CoMat 02-169), making sure that
3.0 in. (76,2 mm) around the top repair area.
C. Cut five sheets of breather fabric (CoMat 08-057), making sure that
the breather fabric has the same size dimensions as the porous
parting film.


four positions around the repair.
G. Put the non-porous parting film onto the repair area, making sure
in. (50,8 mm) larger on each side than the silicone rubber
sheet.
(2) Put the two sheets of the breather cloth on to the repair
area.
V2500 54-20-00 REPAIR No. 018

Page 209
Feb 1/09
repair area.

to the repair area.
(CoMat 08-051).
(4) Attach and seal the vacuum bag with the sealant tape.
18. Remove the repair equipment (Ref. Fig. 203).
the repair.
V2500 54-20-00 REPAIR No. 018

Page 210
Feb 1/09
19. Make the repair area smooth (Ref. Fig. 202).

NECESSARY.

A. Make the door edge smooth with waterproof abrasive paper

(CoMat 05-021). Chamfer the edge of the repair and sanding plies.
(1) The maximum depth of the chamfer should be equal to four

repair plies.
(2) The maximum width of the chamfer should equal to four times
the depth of the chamfer.
B. Make the sanding ply smooth with waterproof abrasive paper

(CoMat 05-021). Make a feather edge around the all the edges.
C. Remove all unwanted material from the area with a suction cleaner.
D. Use a brush (CoMat 02-087) and apply epoxy varnish (CoMat 07-085)
E. Clean the repair area with methylethylketone (CoMat 01-076) and

V2500 54-20-00 REPAIR No. 018

Page 211
Feb 1/09
21. Prepare the door land and the replacement rubbing strip (Ref. Fig. 201).
A. Make the replacement rubbing strip.
(1) Cut a length from the applicable nylon strip (Ref. 3.D. -
Repair parts) to give a maximum gap of 0.032 in. (0,81 mm) at
each end.

NECESSARY.
B. Drill the rivet holes (Ref. step 6.B.) in the door land using a
0.128 mm (3,25 mm) diameter drill.
C. Abrade the door land and nylon rubbing strip mating surfaces using
waterproof abrasive paper (CoMat 05-021).
D. Remove all unwanted material from the area with a suction cleaner.
E. Clean the mating surfaces with methylethylketone (CoMat 01-076) and

a lint-free cloth (CoMat 02-099). Wipe the surface dry.
V2500 54-20-00 REPAIR No. 018

Page 212
Feb 1/09
22. Bond the replacement nylon rubbing strip to the door land.

B. Attach the rubbing strip.
(1) Use a brush (CoMat 02-087) to apply an equal layer of

adhesive to the mating surfaces of the rubbing strip and the
door land.
(2) Position the rubbing strip on the door land, making sure that
the edges are aligned, and the centerline of the rubbing
strip is aligned with the center of the rivet holes.
(3) Put a strip of non-porous parting film (CoMat 02-168) over

the rubbing strip.
(4) Temporarily attach the rubbing strip to the door land with
clamps.
C. Cure the adhesive.
(1) Use the heat blanket and a temperature probe to keep the
temperature of the repair area at 140oF (60oC) for 180
minutes, or 212oF (100oC) for 20 mins.
23. Rivet the rubbing strip to the door land (Ref. Fig. 201).

NECESSARY.
A. Drill the rivet holes in the replacement rubbing strip.
V2500 54-20-00 REPAIR No. 018

Page 213
Feb 1/09
(1) Drill through the holes in the door land, along the
centerline of the rubbing strip, using a 0.128 in. (3,25 mm)
diameter drill.
(2) Drill one hole 0.31 in (8,8 mm) from each end and a second
hole 0.50 in. (12,7 mm) from the first.
B. Drill the rivet holes in the remaining rubbing strip.
(1) Drill along the centerline of the rubbing strip using a

0.128 in. (3,25 mm) diameter drill.
(2) Drill one hole 0.50 in. (12,7 mm) from the rivet at each end
of the remaining rubbing strip.
C. Countersink the rivet holes in the rubbing strip and the outer skin
using a 100 degree countersink bit.
D. Install the rivets.
(1) Use CSR904B-4-5 or CSR904B-4-6 rivets as necessary.
(2) Apply jointing compound (CoMat 04-005) to the rivets and

install them while the jointing compound is still wet.
(3) Remove the unwanted jointing compound.
E. Grind the rivet heads level with the rubbing strip using a
applicable grinder.
24. Fill the rivet countersinks.
A. Mix the aerodynamic smoothing compound (CoMat 08-073) in accordance

with the manufacturer’s instructions.
V2500 54-20-00 REPAIR No. 018

Page 214
Feb 1/09
B. Clean the rivet countersinks on the tapered surfaces of the

repaired area with methylethylketone (CoMat 01-076) and a lint-
free cloth (CoMat 02-099). Wipe the countersinks dry.
C. Fill the rivet countersinks on the outer skin.
(1) Apply the aerodynamic smoothing compound with a spatula,

taking care to avoid air bubbles.
(2) Make the aerodynamic smoothing compound level with the

tapered outer skin.
D. Cure the aerodynamic smoothing compound.
(1) Use a heat lamp to keep the temperature of the door land area
at 113oF (45oC) for 270 minutes.

A. Ident the component/log book with the REAPIR no. VRS2833/2875

(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-20-00 REPAIR No. 018

Page 215
Feb 1/09
Repair Details and Dimensions

Fig. 201
V2500 54-20-00 REPAIR No. 018

Page 216
Feb 1/09
Backing Plate, Fill-In Ply and Repair Ply Installation

Fig. 202
V2500 54-20-00 REPAIR No. 018

Page 217
Feb 1/09

Fig. 203
V2500 54-20-00 REPAIR No. 018

Page 218
Feb 1/09
CANCELLATION NOTICE

V2500 54-20-00 REPAIR No. 019

Page 201
Feb 1/09
V2500 54-20-00 REPAIR No. 019

Page 202
Feb 1/09
REPAIR NO. 020

FAN COWL PART PENETRATION REPAIR
VRS2712/2713
1. General.
A. This procedure may be used to repair damage to the fan cowl door
sandwich (Ref. Fig. 201 for applicable regions) (including cracks)
which must be more than 0.5 in. (12,7 mm) from the fittings,
brackets, hinges and flanges. The damage must be confined to an
area of 2.0 in. (50,8 mm) diameter or less. If the damage is beyond
these limits refer to Goodrich.
B. This type of damage may be repaired by the removal of the damaged

area, replacement of the honeycomb core with potting compound and
the application of a carbon fibre patch with adhesive.
C. The damage must be a sufficient distance from the edge of the

repair plies and a sanding ply. Refer to step 5.B. and Fig. 203.
D. This repair can only be done in the areas indicated, Ref. Fig. 201.
Zone A - Hinge area (0-90)/(0-90)/(±45)/(±45)/(0-90)/(±45)

Zone B - Latch area (0-90)/(0-90)/(±45)/(±45)/(0-90)/(±45)
Zone D - Access panel area (0-90)/(0-90)/(±45)/(±45)/(0-90)
Zone K - Forward & aft edge sandwich area (0-90)/(0-90)/(±45)/
(±45)

percent or less.
G. Damage which is not within the limits of these repairs must be

V2500 54-20-00 REPAIR No. 020

Page 201
Feb 1/09

(VRS2748/2749)
(SPPM)
(SPPM)
Heat lamp, 113o - 131oF (45o - 55oC)

Suction cleaner

Index).

V2500 54-20-00 REPAIR No. 020

Page 202
Feb 1/09
C. Special Tools
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
A. The damage (which includes cracks) must be more than 0.5 in.
(12,7 mm) from the fittings, brackets, hinges and flanges. It must
be confined to an area of 2.0 in. (50,8 mm) diameter or less.

REPAIR 031 (VRS2748/2749) when you do this repair.
A. Mark around the damage with a marking pen (CoMat 06-131), making
sure to include cracks and areas of delamination.
B. Mask around the repair area with 2.0 in (50,8 mm) wide strips of
must be from the area identified in step A as follows:
each of the outer plies.
(3) Make sure the corners of the strip of tape have a radius of
at least 0.5 in. (12,7 mm).
V2500 54-20-00 REPAIR No. 020

Page 203
Feb 1/09

NECESSARY.
C. Make the surface of the repair area rough with waterproof abrasive
D. Remove the outer plies and the honeycomb.
(1) Use a high-speed rotary cutter to remove the plies and

honeycomb identified in step A.
(2) Do not cause delamination of the plies.
(3) Make the surface of the inner plies smooth so that the
surface is continuous.
(4) Do not penetrate the adhesive that bonds the honeycomb to the
inner plies.

cleaner.
B. Clean the repair with methylethylketone (CoMat 01-076) and lint-

free cloth (CoMat 02-099). Wipe the repair area dry with a clean
V2500 54-20-00 REPAIR No. 020

Page 204
Feb 1/09
7. Prepare the honeycomb plug.

NECESSARY.
A. Cut the aluminium honeycomb core plug.
(1) Wear lint-free gloves (CoMat 02-097) and cut the aluminium
honeycomb core (CoMat 08-066) so that it is a good fit in the
repair hole.
(2) Make sure that the ribbons of the honeycomb plug are in the
same direction as that of the undamaged honeycomb.

A. Mix the potting compound (CoMat 08-072) for the honeycomb plug in
accordance with the manufacturer’s instructions.
V2500 54-20-00 REPAIR No. 020

Page 205
Feb 1/09
B. Install the honeycomb plug into the hole.
(1) Install the honeycomb plug into the hole, making sure that it
is flat on the inner plies of the cowl.
(2) Make sure that the ribbon direction of the honeycomb is

correct.
(3) Fill with the potting compound until it is level with the
honeycomb plug.
C. Cure the potting compound.
(1) USe heat lamps to cure the potting compound for 1 to 2 hours
between 113o - 131oF (45o - 55oC).
(2) The heat-up rate must not be greater than 5.5oF (3oC) in each
minute.
10. Prepare the cap ply, the fiberglass ply, the filler plies and
the repair plies (Ref. Fig. 202 and 203).

NECESSARY.
A. Wear lint-free gloves (CoMat 02-097) and cut the filler plies
(Ref. step 1.E.).
(1) There must be a filler ply for each of the plies in the
related outer skin.
(2) Cut the dry carbon fibre fabric (CoMat 08-059) until it has
an 1.0 in. (25,4 mm) overlap around the repair cut-out.
in step 1.E.
B. Wear lint-free gloves (CoMat 02-097) and cut a cap ply.
(1) Cut one piece of fiberglass fabric (CoMat 02-167) until it

has an 1.0 in. (25,4 mm) overlap around the repair cut-out.
V2500 54-20-00 REPAIR No. 020

Page 206
Feb 1/09
C. Wear lint-free gloves (CoMat 02-097) and cut the first repair ply.
(1) Cut one piece of dry carbon fibre fabric (CoMat 08-059) until
it has an 2.0 in. (50,8 mm) overlap around the honeycomb
plug.
given in step 1.E.
D. Wear lint-free gloves (CoMat 02-097) and cut the remaining repair
plies.
(1) There must be a repair ply for each of the outer cowl plies.
(2) Cut one piece of dry carbon fibre fabric (CoMat 08-059) for
each subsequent repair ply until it has an 2.0 in. (50,8 mm)
overlap around the repair ply below.
given in step 1.E.
E. Wear lint-free gloves (CoMat 02-097) and cut the fiberglass ply.
(1) Cut one piece of fiberglass fabric (CoMat 02-167) until it

has an 2.0 in. (50,8 mm) overlap around the honeycomb plug.
F. Mix the EA9390 adhesive (CoMat 08-050) in accordance with the

manufacturers’s instructions.

repair area.
V2500 54-20-00 REPAIR No. 020

Page 207
Feb 1/09
G. Soak the fiberglass and the dry carbon fibre fabric plies with
EA9390 adhesive (CoMat 08-050).
(1) Put each ply on a separate sheet of non-porous parting film

(CoMat 02-168).
brush (CoMat 02-087) and cover with a second sheet of non-
thoroughly. Make sure that each ply is fully soaked.
H. Cut the cap ply and the filler plies to their finished dimensions.
(1) Let the two pieces of the non-porous parting film stay on
each ply until the installation procedure.
(2) Cut each filler ply and the cap ply until it does not have an
overlap on the sides of the repair cut-out.
I. Cut the repair plies to their finished dimensions.
repair plies.
(3) Make sure the first repair ply has an 1.0 in. (25,4 mm)
overlap around the honeycomb plug. Each subsequent repair ply
must have a 1.0 in. (25,4 mm) overlap around the repair ply
below it.
J. Cut the fiberglass ply until it is the same shape as the area
V2500 54-20-00 REPAIR No. 020

Page 208
Feb 1/09

free cloth (CoMat 02-099). Wipe the repair area dry with a clean
12. Install the cap ply, the filler plies and the repair plies
(Ref. Fig. 205).
A. Use a brush (CoMat 02-087) to apply an equal layer of EA9390

adhesive (CoMat 08-050) to the repair area and the repair cut-out.
B. Put the cap ply and the first filler ply into the repair cut-out.
(1) Install the fiberglass cap ply.
side of the first filler ply.
(3) Put the first filler ply, with the adhesive side down, into
the repair cut-out, making sure that the filler ply is flat.
(4) Use a roller to remove air that is caught in the adhesive.
V2500 54-20-00 REPAIR No. 020

Page 209
Feb 1/09
(5) Remove the remaining non-porous parting film from the filler
ply and, using a clean metal spatula, make sure the filler
ply is flat and in the correct position.
in step 1.E.
C. Put the remaining filler plies into the repair cut-out.
(1) For the other filler plies, repeat step B. above.
in step 1.E.
D. Put the first repair ply on to the repair area.
side of the repair ply.
(2) Put the repair ply, with the adhesive side down, on to the
repair area, making sure that the repair cut-out is in the
ply.
in step 1.E.
E. Put the second repair ply on to the repair area.
side of the repair ply.
(2) Put the repair ply, with the adhesive side down, on to the
repair area, making sure that the second repair ply has an
equal overlap around the first repair ply.
ply.
in step 1.E.
V2500 54-20-00 REPAIR No. 020

Page 210
Feb 1/09
F. Put the remaining repair plies on to the repair area (if it is

necessary).
(1) If more repair plies are necessary, repeat step E. above.
in step 1.E.
G. Put the fiberglass ply on to the repair area.
side of the fiberglass ply.
the repair area, making sure that the fiberglass ply has an
equal overlap around the first repair ply and touches the
teflon tape.
(3) Use a roller to remove air that is caught in the adhesive and
to make the fiberglass ply smooth.
(4) Remove unwanted adhesive from the teflon tape with a clean
metal spatula.

fiberglass ply.
area.
B. Cut a sheet of porous parting film (CoMat 02-169). Making sure that
3.0 in. (76,2 mm) around the fiberglass ply.
parting film.
V2500 54-20-00 REPAIR No. 020

Page 211
Feb 1/09
E. Cut the sheet of non-porous parting film (CoMat 02-168) and



adhesive cures.
G. Put the non-porous parting film onto the repair area, making sure

rubber sheet.
repair area.

the repair area.
(CoMat 08-051).
V2500 54-20-00 REPAIR No. 020

Page 212
Feb 1/09

R
R

R
(88oC).
repair.

NECESSARY.


cleaner.
V2500 54-20-00 REPAIR No. 020

Page 213
Feb 1/09

lint-free cloth before the solvent evaporates.


(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-20-00 REPAIR No. 020

Page 214
Feb 1/09

Fig. 201 Sheet 1
V2500 54-20-00 REPAIR No. 020

Page 215
Feb 1/09

Fig. 201 Sheet 2
V2500 54-20-00 REPAIR No. 020

Page 216
Feb 1/09

Fig. 201 Sheet 3
V2500 54-20-00 REPAIR No. 020

Page 217
Feb 1/09

Fig. 201 Sheet 4
V2500 54-20-00 REPAIR No. 020

Page 218
Feb 1/09

Fig. 201 Sheet 5
V2500 54-20-00 REPAIR No. 020

Page 219
Feb 1/09

Fig. 201 Sheet 6
V2500 54-20-00 REPAIR No. 020

Page 220
Feb 1/09

Fig. 201 Sheet 7
V2500 54-20-00 REPAIR No. 020

Page 221
Feb 1/09

Fig. 201 Sheet 8
V2500 54-20-00 REPAIR No. 020

Page 222
Feb 1/09

Fig. 201 Sheet 9
V2500 54-20-00 REPAIR No. 020

Page 223
Feb 1/09
Damage cut-out dimensions

Fig. 202
V2500 54-20-00 REPAIR No. 020

Page 224
Feb 1/09

Fig. 203
V2500 54-20-00 REPAIR No. 020

Page 225
Feb 1/09

Fig. 204
V2500 54-20-00 REPAIR No. 020

Page 226
Feb 1/09
REPAIR 021
FAN COWL EXTERNAL PAINT DAMAGE REPAIR
(VRS2743/2744)
1. General
A. This procedure may be used to repair the external repair on the

outer surfaces of the left and right fan cowl.
B. Repairs to the external paint are made by the application of a

filler material followed by a primer coat of paint followed by
a top coat of paint.
2. Referenced Information - None
A. Standard Tools
Heat lamp, 0º - 212ºF (0º - 100ºC)

Paint spray equipment

Consumable Index)
CoMat 01-076 Methylethylketone Alt 01-438 Solvent

CoMat 02-178 Masking tape, No. 250
CoMat 07-156 Primer base 513x384
CoMat 07-157 Primer converter 910x456
CoMat 07-158 Thinner 020x364
CoMat 08-144 Polystop LP Sikkens Stopper
V2500 54-20-00 REPAIR 021

Page 201
Feb 1/09
4. Clean the Damaged Area
A. Make the surface of the repair area rough with waterproof

silicon carbide abrasive paper (CoMat 05-019).
B. Clean the repair area with Methylethylketone (CoMat 01-076) and

a lint-free cloth (CoMat 02-099). Wipe the area dry with a
clean piece of lint-free cloth before the solvent evaporates.
5. Apply the Filler
A. Fix small irregularities with Sikkens Stopper (CoMat 08-144).

Mixing ratio of knifing stopper should be 30 parts base to 1
part hardener.
B. Apply and smooth with a clean spatula, using firm hand

pressure. Discard mixed material after 7-15 minutes.
C. Abrade the original profile using waterproof silicone carbide

D. Remove sanding residue by wiping with clean cloths.
V2500 54-20-00 REPAIR 021

Page 202
Feb 1/09
6. Apply the Primer
A. Mask around the repair area with the masking tape

(CoMat 02-178) to prevent overspray.
B. Mix the primer base (CoMat 07-156), the primer converter (CoMat
07-157), and the thinner (CoMat 07-158) in accordance with the
manufacturers instructions. Let the mixture set for 30 minutes
before you use it.
C. Apply the primer to the damaged area within the masking tape
with either the spray equipment or a brush.
CAUTION: ALLOW THE PAINT TO DRY FOR 15 MINUTES BEFORE THE HEAT IS
APPLIED.
D. Cure the primer for one hour at 180º - 200ºF (82º - 93ºC) with
an explosion proof heat lamp.
7. Make an Inspection of the Primer Coat
A. Apply a 1.0 in. (25.4 mm) wide strip of (CoMat 02-178) masking
tape to the primed surface. Pull the tape from the primed
surface in one abrupt motion. If any of the primer is removed by
the tape, reject the primer coat and do step 4 followed by 6 and
7 again.
V2500 54-20-00 REPAIR 021

Page 203
Feb 1/09
8. Apply the Top Coat of Paint
A. Mix the topcoat of paint in accordance with the manufacturer’s

instructions.
B. Use the airline specifications to select the color and apply

the external top coat of paint over the primed surface which is
within the masked area.
C. Cure the paint in accordance with the manufacturer’s

instructions.
D. When the paint is cured, remove the masking tape from around
the repair area.
9. Make an Inspection of the Exterior Paint
A. Apply a 1.0 in. (25,4 mm) wide strip of masking tape to the
painted surface. Pull the tape from the painted surface in one
abrupt motion. If any of the paint is removed by the tape,
reject the paint coat and do step 4, followed by steps 6 through
9 again.
V2500 54-20-00 REPAIR 021

Page 204
Feb 1/09
REPAIR 022
FAN COWL DRAINS MAST WALL DAMAGE REPAIR
(VRS2957)
1. General
A. This procedure may be used to repair minor surface damage on

the wall of the drains mast.
B. This repair blends out the damaged area until it is smooth with
the rest of the drains mast.

TASK 71-71-42-200-501 V2500 Engine Manual
A. Standard Tools

Consumable Index)

C. Component Material
PART IDENT MATERIAL

Drains mast/Collector plate Stainless Steel
assembly
V2500 54-20-00 REPAIR 022

Page 201
Feb 1/09
4. Examine the Repair Area
A. Examine the damaged area and, using the standard workshop

tools, measure the depth of the damage. Mark the repair area
which must measure a minimum of 10 times the depth of the
damage, using the marking pen (CoMat 06-131).
5. Repair the Damaged Area
A. Repair the damage area in accordance with hand polish and blend
procedure (Ref. SPPM Task 70-35-03-300-501).
B. Make sure that the maximum depth of the repair is not greater
than the maximum depth of the damage.
C. Make sure that the depth of the repair is zero at the edge of
the marked area.

a lint-free cloth (CoMat 02-099). Wipe the area with a clean
piece of lint-free cloth before the area dries.
A. Inspect the repair area (Ref. Task 71-71-42-200-002).
B. Make sure the repair area is smooth with no scratches and no

sudden changes of thickness.
V2500 54-20-00 REPAIR 022

Page 202
Feb 1/09
REPAIR 023
LEFT FAN COWL LATCH BEARING PLATE REPLACE
(VRS2740)
1. General
A. This repair may be used to replace the latch plate on the left
fan cowl oil filler and chip detector access panel.
A. Standard Tools

Consumable Index)

CoMat 04-005 Jointing Compound
C. Repair Parts
PART NO. PART IDENT

HL11VF-5-5 Hi-Lok pin
HL97V-5 Hi-Lok Collar
AN960-08 Washer
740-4003-039 Laminated shim
740-4048-501 Bearing plate
V2500 54-20-00 REPAIR 023

Page 201
Feb 1/09
PART IDENT MATERIAL

Fan cowl door Composite structure
4. Remove the Damaged Bearing Plate
A. Remove the Hi-Lok collars and pins.
(2) Make a note of the sequence of removal of the Hi-Lok pins

and washers as they must be installed in the same
sequence.
(3) Put an Allen key into the pin to hold it stationary and
remove the collar with pliers.
(4) Make sure the holes in the fan cowl doors are not damaged.
B. Remove the damaged bearing plate.
(1) Make sure that the Hi-Lok pins and the washers are not
damaged or put out of shape.
(2) Keep the Hi-Lok pins and the washers. Discard the Hi-Lok
collars.

repair area.
V2500 54-20-00 REPAIR 023

Page 202
Feb 1/09
B. Clean the new bearing plate and the repair area with
(CoMat 02-099). Wipe the area with a clean piece of lint-free
A. Examine the Hi-Lok bolt holes in the fan cowl door.
(1) The diameter of the holes must be between 0.164 in.

(4.17 mm) and 0.167 in. (4.24 mm).
(2) If the diameter of the holes are not within the limits
given, or if the holes are damaged, oversize fasteners
must be used.
7. Install the New Bearing Plate
A. Move the new bearing plate into position making sure that the
laminated shim is between the plate and the fan cowl door.
B. Remove layers of the laminated shim until the access panel

closes with its external surface aligned to the outer surface
of the fan cowl door.
C. Apply jointing compound (CoMat 04-005) to the mating faces of

the laminated shim and the bearing plate.
D. Attach the new bearing plate to the fan cowl door.
(1) Use standard workshop tools to install the pins and

washers in the same sequence as they were removed.
(2) Install the new collars by hand.
V2500 54-20-00 REPAIR 023

Page 203
Feb 1/09
(3) Use an Allen key to hold the pin stationary while

tightening the collar with a spanner until the hexagon
head drops off.
(4) Use a plastic spatula to remove any unwanted jointing

compound.
A. Examine the repair area to make sure that the bearing plate and
the fasteners are correctly installed. If the repair is
unsatisfactory, repeat the repair.
V2500 54-20-00 REPAIR 023

Page 204
Feb 1/09
Bearing Plate Replacement

Figure 201
V2500 54-20-00 REPAIR 023

Page 205
Feb 1/09
V2500 54-20-00 REPAIR 023

Page 206
Feb 1/09
REPAIR NO. 024

AIR-START BLOW-OFF DOOR INTERFACE-LAND REPAIR
VRS2722
1. General.
A. This repair may be used to repair damage to the closing land on the
air start blow off door.
fill-in and repair plies.
C. Only one repair for each access panel land is permitted.
TASK 71-13-00, Disassembly Fan Cowls CMM (CMM-FC-V2500-1IA)

TASK 71-13-00, Assembly Fan Cowls CMM (CMM-FC-V2500-1IA)
(SPPM)
(SPPM)

Heat lamp, 32o to 212oF (0o - 100oC)
Suction cleaner
V2500 54-20-00 REPAIR No. 024

Page 201
Feb 1/09

Index).

Comat 08-051 Sealant tape
C. Special Tools
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Air-start/blow-off door Composite structure
4. Remove the door latches.
A. If necessary, remove the door latches adjacent to the repair area

(Ref. Component Maintenance Manual 71-13-00, Disassembly).
V2500 54-20-00 REPAIR No. 024

Page 202
Feb 1/09

B. Mask round the repair area with teflon tape (CoMat 02-007).
follows:
panel land.
(2) On the inner surface, measure 4.2 in. (106,7 mm) from the
edge of the panel land.
(3) Measure along the outer skin contour, and make the two
corners of the marked area to an angle of 45 degrees and a
length of approximately 1.5 in. (38,1 mm).
(4) Use the marking pen (CoMat 06-131) to apply temporary marks
to the measured repair area.
V2500 54-20-00 REPAIR No. 024

Page 203
Feb 1/09

NECESSARY.
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE PANEL. DO NOT
C. Remove the surface protection treatment from the repair area with
repair area smooth, and also rub the external surface side of the
panel land.
(12,7 mm) each side along the panel land and make a mark.
(2) Measure 0.7 in. (17,8 mm) from the panel edge and make a mark

0.25 in. (6,3 mm).

NECESSARY.
A. Use standard workshop tools to carefully remove all damaged

B. Make the area smooth with waterproof abrasive paper (CoMat 05-021).
V2500 54-20-00 REPAIR No. 024

Page 204
Feb 1/09
A. Clean the surfaces of the repair area with methylethylketone

(CoMat 01-076) and lint free cloth (CoMat 02-099). Wipe the area
dry.
10. Prepare the fill-in and repair plies (Ref. Fig. 201).

NECESSARY.
A. Prepare eight fill-in plies.
repair area.
V2500 54-20-00 REPAIR No. 024

Page 205
Feb 1/09
the previous piece.
fiberglass fabric (CoMat 02-167) 0.75 in. (19,0 mm) larger
all around (except at the panel edge) than the largest repair
ply.
A. Install the aluminium backing plate.
(1) Make the backing plate to the inner-skin surface contour.

the backing plate.
(3) Temporarily attach the backing plate to the internal-surface

side of the panel land and make sure it touches the outer-
skin edge.
V2500 54-20-00 REPAIR No. 024

Page 206
Feb 1/09

NOTE: The weight of adhesive required will be approximately the

same as the weight of the dry carbon fibre fabric and
fiberglass fabric.
B. Soak the fiberglass and carbon fibre plies with the mixed adhesive.
(1) Put each ply on a sheet of the non-porous parting film

(CoMat 02-168).
(2) Apply adhesive to the two sides of each ply with the brush
(CoMat 02-087) and cover each ply with another sheet of non-
(3) Use a roller to force the adhesive into each ply thoroughly.
C. Cut the fill-in ply and repair plies to their finished dimensions.
(1) Cut each fill-in ply to the same dimensions as the as the
cut-out area.
(2) Find a long side on each fill-in ply and cut two corners to a
radius of 0.25 in. (6,3 mm).
(3) Cut the first repair ply so that it extends 1.0 in. (25,4 mm)
from the three edges of the cut-out area.
0.25 in. (6,3 mm) wider.
V2500 54-20-00 REPAIR No. 024

Page 207
Feb 1/09
45 degrees.
(7) Cut the fiberglass sanding ply so that it extends 0.75 in.
(19,0 mm) from the three edges of the largest repair ply.


cleaner.

using a brush (CoMat 02-087)
V2500 54-20-00 REPAIR No. 024

Page 208
Feb 1/09
ply.
the cut-out area. Align it with the edge of the panel land.
(3) Remove any unwanted adhesive and air from the ply with a
metal spatula.
ply.
15. Install the repair plies and fiberglass sanding ply (Ref. Fig. 201).

the repair area.
repair ply.
(2) Put the first repair ply, with the adhesive side down, on the
repair area and align it with the panel edge, making sure
that it has a 1.0 in. (25,4 mm) overlap around the cut-out.
ply.
repair ply.
V2500 54-20-00 REPAIR No. 024

Page 209
Feb 1/09
(1) Repeat step B above for the remaining repair plies.

(2) Put the fiberglass sanding ply, with the adhesive side down,
on the repair area and align it with the panel edge, making
sure that it has a 0.75 in. (19,0 mm) overlap around the last
carbon repair ply and adjacent to, but not on, the teflon
tape.
(4) Remove any unwanted adhesive from the teflon tape with a

fiberglass ply.
A. Get a heat blanket, which must be a minimum of 3.0 in. (76,2 mm)
larger all around than the repair area.
C. Cut nine sheets of the breather fabric (CoMat 08-057) into pieces
the same size as the porous parting film (Ref step B. above).
D. Put the porous parting film on to the repair area, making sure it
has an equal overlap around the repair area. Put the breather

D. above.
V2500 54-20-00 REPAIR No. 024

Page 210
Feb 1/09
parting film.

to the repair area.
the cowl with the sealant tape (CoMat 08-051).
(88oC).
18. Remove the repair equipment (Ref. Fig. 202).
the repair.
V2500 54-20-00 REPAIR No. 024

Page 211
Feb 1/09
19. Prepare the access panel (Ref. Fig. 201).

NECESSARY.

A. If necessary, chamfer the panel at the hinge area.
(2) Chamfer along the edge of the internal surface, in the hinge
area, at an angle of 45 degrees.
B. If necessary, drill the door latch fastener holes (Ref. Component

Maintenance Manual 71-13-00, Assembly).
(1) Use the latch as a template and make a mark for each fastener
hole.
(2) Countersink each hole on the external surface using a

100 degree countersink bit.
C. Make the door edge smooth with waterproof abrasive paper

(CoMat 05-021). Radius chamfer the repair plies and sanding ply.
(1) The width of the chamfer should be approximately 0.6 in.

(15,3 mm) from the panel edge.
D. Make the sanding ply smooth with waterproof abrasive paper

(CoMat 005-021). Make a feather edge around all the edges.
E. Prepare the panel land.
(1) Make the panel to the original contour.
(2) Temporarily close the access panel, and make sure that the
aerodynamic contour on the external surface is correct and
that the hinge area does not catch.
V2500 54-20-00 REPAIR No. 024

Page 212
Feb 1/09
(3) Make sure that the aerodynamic clearances are correct

(Ref. Component Maintenance Manual 71-13-00, Assembly).
F. Remove all unwanted material from the area with a suction cleaner.
G. Use a brush (CoMat 02-087) and apply epoxy varnish (CoMat 07-085)
20. Assemble the access panel.
A. If necessary, install the door latches adjacent to the repair area

(Ref. Component Maintenance Manual 71-13-00, Assembly).
(1) Use longer fasteners if necessary.
(2) Make sure that the fasteners are locked in safety.


V2500 54-20-00 REPAIR No. 024

Page 213
Feb 1/09

(Ref. SPM TASK 70-09-00-400-501).
V2500 54-20-00 REPAIR No. 024

Page 214
Feb 1/09

Fig. 201
V2500 54-20-00 REPAIR No. 024

Page 215
Feb 1/09

Fig. 202
V2500 54-20-00 REPAIR No. 024

Page 216
Feb 1/09
REPAIR NO. 025

RIGHT FAN COWL ACCESS PANELS MAIN AREA SURFACE DAMAGE REPAIR
VRS2880
1. General.
A. This repair may be used to repair surface damage to the main area
of the access panels of the right fan cowl.
between damaged areas. The damage must not go through more than 5
composite plies.
sequence:
(0-90)/(±45)/(±45)/(0-90)/(0-90)/(±45)/
(±45)/(0-90)/(0-90)/(±45)/(±45)/(0-90).

F. Damage which is not within the limits of these repairs must be


(SPPM)
(SPPM)
V2500 54-20-00 REPAIR No. 025

Page 201
Feb 1/09

Heat lamp, 176o - 194oF (80o - 90oC)
Suction cleaner
B. Special Tools

(PCI)).

CoMat 02-097 lint-free gloves
CoMat 02-099 lint-free cloth
D. Repair parts
None.
V2500 54-20-00 REPAIR No. 025

Page 202
Feb 1/09
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Right fan cowl
access panels Composite structure
A. Using standard workshop tools, measure the depth of the damage.
B. Make a note of the depth of the damage, and calculate the number of
plies necessary to repair the damage as follows:

If in doubt on the depth of the damage, install one more repair ply
(for example - if you are not sure if the depth is 0.030 in.
(0,76 mm) or 0.031 in. (0,79 mm), use three repair plies).

V2500 54-20-00 REPAIR No. 025

Page 203
Feb 1/09
follows:
each ply of the panel which is damaged, and add 0.75 in.
(CoMat 02-167).
(3) Make the corners of the strip at an angle of approximately 45

degrees with a length of approximately 1.0 in. (25,4 mm).

NECESSARY.
B. Make the surface of the repair area rough with waterproof abrasive
paper (CoMat 05-021), making sure to remove the sharp edges of the
damage.
V2500 54-20-00 REPAIR No. 025

Page 204
Feb 1/09
7. Cut the repair plies (Ref. Fig. 201 and 202).

NECESSARY.
A. Cut the first repair ply.
(50,8 mm) overlap around the damage (Ref. step 1.D.).

dimensions after soaking in adhesive.
B. Cut the remaining repair plies (if they are required).
(1) Wear lint-free gloves (CoMat 02-097) and use dry carbon
fibre fabric (CoMat 08-059), and cut each subsequent repair
ply
2.0 in. (50,8 mm) longer and 2.0 in. (50,8 mm) wider. There
must be one repair ply for each ply of the panel which is
damaged (Ref. step 1.D.).
C. Cut the fiberglass ply.
fiberglass fabric so it has a 1.0 in. (25,4 mm) overlap
around the area identified by the teflon tape.

dimensions after they are soaked in adhesive (Ref steps 1.D.
and 9.C).
be applied immediately at the end of the six hours.
V2500 54-20-00 REPAIR No. 025

Page 205
Feb 1/09



(CoMat 02-168).
film.
thoroughly.
plies.
around the damage.

in. (12,7 mm).
area identified by the teflon tape (CoMat 02-007).
V2500 54-20-00 REPAIR No. 025

Page 206
Feb 1/09


B. Fill the damaged area of the panel with the adhesive using a clean
ply of the panel.
V2500 54-20-00 REPAIR No. 025

Page 207
Feb 1/09
A. Using a brush (CoMat 02-087) to apply an equal layer of EA9390

adhesive (Ref step 9.A.) to the repair area.
repair ply.
ply.
repair ply.
repair ply.
ply.
repair ply.
in step 1.D.
V2500 54-20-00 REPAIR No. 025

Page 208
Feb 1/09
D. Install the subsequent repair plies, if any.
E. Install the fiberglass ply.
(1) Repeat step C. above for the fiberglass ply, making sure that
it has an equal overlap around the last carbon fibre repair
ply, and is adjacent to, but not touching the teflon tape.
spatula.
area.
B. Cut a porous parting film (CoMat 02-169) making sure that it is

larger than the heat blanket and has an overlap of at least 3.0 in.
(76,2 mm) around the fiberglass ply.
the porous parting film (Ref step B. above). The number of sheets
of breather fabric must equal the number of plies used in the
repair.
D. Put the porous parting film onto the repair area, making sure that
breather fabric on top of the porous parting film. Use one layer of
breather fabric for each carbon ply used in the repair.


four positions around the repair.
V2500 54-20-00 REPAIR No. 025

Page 209
Feb 1/09
area first, making sure that it has an equal overlap around the
parting film.
(1) Cut two pieces of breather cloth (CoMat 02-166), at least

rubber sheet.
area.
repair area.

to the repair area.
(1) Use nylon bagging film (CoMat 02-163) and sealant tape (CoMat
08-051).
by 2.0 in. (50,8 mm) around the breather cloth.

(88oC).
V2500 54-20-00 REPAIR No. 025

Page 210
Feb 1/09
the repair.

NECESSARY.


(CoMat 05-021). The contours of the repair area must be smooth and
there must not be an edge or step between the repair area and the
outer skin of the panel.
cleaner.

V2500 54-20-00 REPAIR No. 025

Page 211
Feb 1/09

(Ref. SPPM TASK 70-38-07-380-501).

(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-20-00 REPAIR No. 025

Page 212
Feb 1/09

Fig. 201
V2500 54-20-00 REPAIR No. 025

Page 213
Feb 1/09
Surface Damage Build-up Repair (Typical)

Fig. 202
V2500 54-20-00 REPAIR No. 025

Page 214
Feb 1/09

Fig. 203
V2500 54-20-00 REPAIR No. 025

Page 215
Feb 1/09
V2500 54-20-00 REPAIR No. 025

Page 216
Feb 1/09
REPAIR 026
RIGHT FAN COWL ACCESS PANELS INSTALL OVERSIZE FASTENERS
(VRS2721)
1. General
A. This procedure may be used to replace the fasteners in the air

start door and the hinge with oversize fasteners.
B. This repair can only be done with the repair for replacing the
hinges. (Ref Engine Manual TASK 71-13-17-300-004).
A. Standard Tools
One-shot drills
Suction cleaner

Consumable Index)

C. Repair Parts
PART NO. PART IDENT

HL11VF-8-4 Hi-Lok bolt
HL11Vf-8-6 Hi-Lok bolt
V2500 54-20-00 REPAIR 026

Page 201
Feb 1/09
PART IDENT MATERIAL

Air start/blow off door Composite structure
Hinge Steel
4. Remove the Access Panel from the Fan Cowl
A. Remove the access panel from the fan cowl

(Ref. AMM Task 71-13-17-000-010).
5. Examine the Air Start Door and the Hinge (Ref Figure 201)
A. Using standard workshop tools, measure the diameter of the

holes in the air start door and the hinge.
(1) The diameter of the holes must not be greater than 0.253
in. (6.43 mm).
(2) If the diameter of the holes is not in this limit do not

do this repair.
B. Use a marking pen (Comat 06-131) to make a mark beside each hole
that has a diameter between 0.193 to 0.253 in. (4.90 to 6.43
mm).
6. Increase the Hole Sizes for Oversize Hi-Lok Bolts
A. Increase the diameter of the holes in the hinge.
(1) Use standard workshop tools and a drill to increase the

diameter of the holes that were marked in paragraph 5.B.
(2) Make sure that the diameter of the holes is between 0.250
to 0.253 in. (6.35 to 6.43 mm).
B. Use temporary fasteners to hold the air start door and the
hinge together in the correct position.
V2500 54-20-00 REPAIR 026

Page 202
Feb 1/09
C. Increase the diameter of the holes in the air start door.
(1) Remove the temporary fasteners in sequence and drill

through the existing holes marked in paragraph 5.B.

diameter of the holes to the dimensions given in step A.
D. Disassemble the air start door and the hinge.
(1) Remove all of the temporary fasteners carefully to avoid

causing damage to the carbon plies.
(2) Use standard tools to remove all burrs and sharp edges.
A. Clean the interfaces between the air start door and the hinge
with methylethylketone (coMat 01-076) and lint-free cloth
(Comat 02-099). Wipe the area dry.
8. Install the Replacement Hinge (Ref Figure 201)
V2500 54-20-00 REPAIR 026

Page 203
Feb 1/09
A. Apply the jointing compound.

the interfaces of the air start door and the hinge.
are assembled.
B. Align the holes in the hinge with the holes in the air start
door.
C. Install the four hi-lok bolts.
(1) Make sure that each bolt is installed into the correct
diameter of hole.
(2) Put the collars onto the bolts.
D. Tighten the bolts and the collars.
(1) Use a ring wrench to turn the collars and an allen key to
hold the bolts.
(2) First, tighten each of the collars equally, to pull the

hinge and the air start door together.
(3) Second, tighten each of the collars until the hexagon nut
breaks off of the collar.
NOTE: The procedure is the same for the upper and the lower
hinge.
V2500 54-20-00 REPAIR 026

Page 204
Feb 1/09
9. Clean the Area Around the Hinge
A. Clean the hinge and the air start door with methylethylketone
area dry.
11. Install the Access Panel
A. Install the access panel on the fan cowl

(Ref AMM Task 71-13-17-400-010).
V2500 54-20-00 REPAIR 026

Page 205
Feb 1/09
RIGHT FAN UPPER

COWL HI-LOK/HI-LITE
HINGE BOLT
HI-LOK/HI-LITE COLLAR
AIR START DOOR
LOWER HI-LOK/HI-LITE
HINGE BOLT
sh00014297B
Access Panel, Install Oversize Fasteners

Figure 201
V2500 54-20-00 REPAIR 026

Page 206
Feb 1/09
REPAIR 028
AIR-START BLOW-OFF DOOR HINGE REPAIR
(VRS2950)
1. General
A. This procedure may be used to replace the hinge on the air start
blow off door.
A. Standard Tools

Consumable Index)

C. Repair Parts
PART NO. PART IDENT

740-4042-503 Hinge
740-4042-504 Hinge
HL11VF-6-4 Hi-Lok Bolt
HL11VF-6-6 Hi-Lok Bolt
V2500 54-20-00 REPAIR 028

Page 201
Feb 1/09
PART IDENT MATERIAL

Air start/blow off door Composite structure
Hinge Steel

(Ref. AMM Task 71-13-17-000-010).
5. Remove the Damaged Hinge
A. Remove the Hi-Lok collars, pins and washers if fitted.
(3) Remove the washer if fitted from the pin. Push the pin out
of the air start door.
(4) Discard the pins, the washers if fitted, the collars and
the hinge.

repair area.
V2500 54-20-00 REPAIR 028

Page 202
Feb 1/09
B. Clean the interfaces between the air start door and the hinge
with methylethylketone (CoMat 01-076) and lint-free cloth
7. Examine the Air Start door and the Hinge (Ref Figure 201)

holes in the air start door and the hinge.
(1) The diameter of the holes must be between 0.190 to 0.193

in. (4.82 to 4.90 mm).
must be used (Ref. SRM REPAIR 026).

the interfaces of the air start door and the hinge.
are assembled.
B. Align the holes in the hinge with the holes in the air start
door.
C. Install the four hi-lok bolts.
(1) Make sure that the correct length of bolt is installed

into each hole.
V2500 54-20-00 REPAIR 028

Page 203
Feb 1/09
(1) Use a ring wrench to turn the collars and an Allen key to
hold the bolts.

hinge and the air start door together.
hinge.
A. Clean the hinge and the air start door with methylethylketone
area dry.

(Ref AMM Task 71-13-17-400-010).
V2500 54-20-00 REPAIR 028

Page 204
Feb 1/09
RIGHT FAN UPPER

COWL HI-LOK/HI-LITE
HINGE BOLT
AIR START DOOR
LOWER HI-LOK/HI-LITE
HINGE BOLT
sh00014297B
Air-Start Blow-off Door Hinge Repair

Figure 201
V2500 54-20-00 REPAIR 028

Page 205
Feb 1/09
V2500 54-20-00 REPAIR 028

Page 206
Feb 1/09
REPAIR 029
LEFT FAN COWL ACCESS PANELS INSTALL OVERSIZE FASTENERS
(VRS2741)
1. General
A. This procedure may be used to replace the fasteners in the oil

filler door and the hinge with oversize fasteners.
B. This repair can only be done with the repair for replacing the
hinges. (Ref Engine Manual TASK 71-13-14-300-002).
A. Standard Tools
One-shot drills
Suction cleaner

Consumable Index)

C. Repair Parts
PART NO. PART IDENT

HL97-6 Hi-Lok collar
AN960-C10L Washer
V2500 54-20-00 REPAIR 029

Page 201
Feb 1/09
PART IDENT MATERIAL

Oil filler access door Composite structure
Hinge Steel

(Ref. AMM TASK 71-13-14-000-010).
5. Examine the Oil Filler Door and the Hinge (Ref Figure 201)

holes in the oil filler door and the hinge.
(1) The diameter of the holes must not be greater than 0.206
in. (5.23 mm).
(2) If the diameter of the holes is not in this limit do not

do this repair.
B. Use a marking pen (CoMat 06-131) to make a mark beside each hole
that has a diameter between 0.200 to 0.206 in. (5.08 to 5.23
mm).
6. Increase the Hole Sizes for Oversize Hi-Lok Bolts
A. Increase the diameter of the holes in the hinge.

diameter of the holes that were marked in paragraph 5.B.
(2) Make sure that the diameter of the holes is between 0.202
to 0.206 in. (5.13 to 5.23 mm).
B. Use temporary fasteners to hold the oil filler door and the
hinge together in the correct position.
V2500 54-20-00 REPAIR 029

Page 202
Feb 1/09
C. Increase the diameter of the holes in the oil filler door.
(1) Remove the temporary fasteners in sequence and drill

through the existing holes marked in paragraph 5.B.

diameter of the holes to the dimensions given in step A.
D. Disassemble the oil filler door and the hinge.
(1) Remove all of the temporary fasteners carefully to avoid

causing damage to the carbon plies.
(2) Use standard tools to remove all burrs and sharp edges.
A. Clean the interfaces between the oil filler door and the hinge
V2500 54-20-00 REPAIR 029

Page 203
Feb 1/09

the interfaces of the oil filler door and the hinge.
are assembled.
B. Align the holes in the hinge with the holes in the oil filler
door.
C. Install the six hi-lok bolts.
(1) Make sure that each bolt is installed into the correct
diameter of hole.
(2) Put the collars and the washers onto the bolts.
hold the bolts.

hinge and the oil filler door together.
hinge.
V2500 54-20-00 REPAIR 029

Page 204
Feb 1/09
A. Clean the hinge and the oil filler door with methylethylketone
area dry.

(Ref AMM Task 71-13-17-400-010).
V2500 54-20-00 REPAIR 029

Page 205
Feb 1/09
Access Panel, Install Oversize Fasteners

Figure 201
V2500 54-20-00 REPAIR 029

Page 206
Feb 1/09
REPAIR 030
OIL FILLER DOOR HINGE REPAIR
(VRS2849)
1. General
A. This procedure may be used to replace the hinge on the oil

filler door.
A. Standard Tools

Consumable Index)

C. Repair Parts
PART NO. PART IDENT

740-4086-503 Hinge
HL97V-6 Hi-Lok collar
AN960-C10L Washer
V2500 54-20-00 REPAIR 030

Page 201
Feb 1/09
PART IDENT MATERIAL

Oil filler door Composite structure
Hinge Steel

(Ref. AMM TASK 71-13-14-000-010).
5. Remove the Damaged Hinge
A. Remove the Hi-Lok collars, pins and washers if fitted.
(3) Remove the washer if fitted from the pin. Push the pin out
of the oil filler door.
(4) Discard the pins, the washers if fitted, the collars and
the hinge.

repair area.
V2500 54-20-00 REPAIR 030

Page 202
Feb 1/09
B. Clean the interfaces between the oil filler door and the hinge
7. Examine the Oil Filler Door and the Hinge (Ref Figure 201)

holes in the oil filler door and the hinge.
(1) The diameter of the holes must be between 0.190 to 0.193

in. (4.82 to 4.90 mm).
must be used (Ref. SRM REPAIR 029).

the interfaces of the oil filler door and the hinge.
are assembled.
B. Align the holes in the hinge with the holes in the oil filler
door.
C. Install the six hi-lok bolts.
(1) Make sure that the correct length of bolt is installed

into each hole.
V2500 54-20-00 REPAIR 030

Page 203
Feb 1/09
hold the bolts.

hinge and the oil filler door together.
E. Attach the hinge to the left fan cowl.
(1) Do again steps A. thru D. Where you see oil filler door
read left fan cowl.
A. Clean the hinge and the oil filler door with methylethylketone
area dry.

(Ref AMM Task 71-13-14-400-010).
V2500 54-20-00 REPAIR 030

Page 204
Feb 1/09
Oil Filler Door Hinge Repair

Figure 201
V2500 54-20-00 REPAIR 030

Page 205
Feb 1/09
V2500 54-20-00 REPAIR 030

Page 206
Feb 1/09
REPAIR 031
FAN COWLS-LIGHTNING STRIKE PROTECTION REPAIR
(VRS2748/2749)
1. General
A. This repair must be done in a room with a controlled

temperature of between 68ºand 77ºF (20º and 25ºC). The humidity
must be kept at 50 percent or less.
B. This procedure may be used to repair a rupture (discontinuity)

to the lightning strike protection of the fan cowl doors.
C. This repair removes the layer of resin around the damaged area
and installs a wire-mesh patch.
D. Damage which is not within the limits of the repair, refer to

Bombardier Aerospace, Shorts for an alternative repair scheme.
TASK 70-38-07-380-501
A. Standard Tools
Heat lamp, range 113º-131ºF (45º-55ºC)

Heat blanket, range 32º-248ºF (0º-120ºC)
Vacuum suction pump, range 0-30 in. (0-762 mm) of mercury
Temperature probes, range 32º-248ºF (0º-120ºC).
Steel roller, 2.0 in. (50.8 mm) long
Suction cleaner

Consumable Index)

CoMat 01-457 Methylisobutylketone (alternative to
CoMat 01-076)
V2500 54-20-00 REPAIR 031

Page 201
Feb 1/09
CoMat 02-087 Brush

CoMat 02-168 Non porous parting film
CoMat 02-300 Expanded copper screen
CoMat 06-131 Marker pen
CoMat 08-050 EA9390 Resin
PART IDENT MATERIAL

4. Examine the Damaged Area (Ref Figure 201)
A. The damage must be less than 12.0 in. (304.8 mm) wide. Make sure
the damage is only to the lightning strike protection and not
the plies below.
B. If the damage goes through the lightning strike protection and

into the plies below, refer to Bombardier Aerospace, Shorts.
5. Prepare the Damaged Area for Repair (Ref Figure 201)
A. Use the CoMat 06-131 marking pen and make a mark, the smallest
symmetrical shape possible, around all the areas of damage.
B. Apply the CoMat 02-007 teflon tape in 2.0 inch (50.8 mm) wide
strips, approximately 1.25 in. (31.75 mm) from the mark around
the damaged area.
V2500 54-20-00 REPAIR 031

Page 202
Feb 1/09

PPE IS NECESSARY.

REMOVE ONLY THE RESIN FROM THE LIGHTNING STRIKE PROTECTION
MATERIAL. DO NOT USE A LIQUID WITH THE WATERPROOF SILICON
CARBIDE ABRASIVE PAPER.
C. Use CoMat 05-021 waterproof silicon carbide abrasive paper and

lightly rub the damaged area. Make sure the lightning strike
protection material is not removed or decreased in thickness.
A. Use a suction cleaner and remove any unwanted material from the
repair area.
V2500 54-20-00 REPAIR 031

Page 203
Feb 1/09
B. Clean the repair area with CoMat 01-076 methylethylketone and a

CoMat 02-099 lint free cloth. Wipe the area dry with a clean
piece of lint free cloth before the solvent dries.
7. Prepare the lightning Strike Protection Repair Patch

(Ref Figure 201)

PPE IS NECESSARY.
A. Cut the lightning-stroke protection repair patch.
(1) Use standard workshop tools and equipment.
(2) Use lightning strike protection material CoMat 02-300

expanded copper screen, and cut the repair patch 1.25 in.
(31.75 mm) larger all around than the damaged area.
B. Mix the CoMat 08-050 resin in accordance with the manufacturers

instructions.
NOTE: The weight of the resin necessary will be approximately

the same as the weight of the lightning-strike-
protection repair patch. After the plies are soaked,
the remaining resin (if it is kept cool) can be used on
the repair area.
V2500 54-20-00 REPAIR 031

Page 204
Feb 1/09
C. Soak the repair patch with CoMat 08-050 Resin.
(1) Put the repair patch on to a sheet of CoMat 02-168 non-

(2) Use the CoMat 02-087 brush and apply the resin to each
side of the repair patch.
(3) Put a second sheet of CoMat 02-168 non-porous parting film

on top of the repair patch.
(4) Put the repair patch on a hard flat surface.
(5) Use the roller to force the resin into the repair patch.
Make sure that the repair patch is fully soaked.
D. Cut the repair patch to the correct dimensions for

installations.
(1) Use standard workshop tools and equipment.
(2) Cut the repair patch until it is the same shape as the
area identified by the teflon tape.
A. Clean the repair area with CoMat 01-076 methylethylketone and a

CoMat 02-099 lint free cloth. Wipe the area dry with a clean
V2500 54-20-00 REPAIR 031

Page 205
Feb 1/09
9. Install the lightning Strike Protection Repair Patch

(Ref Figure 202)
A. Use the CoMat 02-087 brush and apply an equal layer of

CoMat 08-050 resin to the repair area.
B. Put the repair patch on the repair area.

repair patch.
(2) Put the repair patch, with the resin side down, on the
repair patch. Make sure the repair patch does not overlap
the Teflon tape.
(3) Use the roller to remove unwanted resin on air bubbles

which are caught in the resin.
(4) Remove the remaining sheet of non-porous parting film from

the repair patch.
(5) Remove the teflon tape from around the repair area.
10. Prepare to Cure the Resin (Ref Figure 202)
A. Get a heat blanket that is larger all around than the repair
area.
B. Put the temperature probes as close as possible to the repair

area.
(1) Use the CoMat 02-007 Teflon tape and attach not less than
two temperature probes.
V2500 54-20-00 REPAIR 031

Page 206
Feb 1/09
(2) Make sure the temperature probes do not touch the repair
patch.
(3) Make sure that the temperature probes are positioned so

that they will be fully below the heat blanket.
C. Put the porous parting film and the breather fabric on the
repair area.
(1) Cut a sheet of CoMat 02-169 porous parting film larger

than the heat blanket and with a minimum overlap of 3.0
in. (76.2 mm) around the repair patch.
(2) Cut a sheet of Comat 08-057 breather fabric to the same

dimensions as the sheet of porous parting film.
(3) Put the sheet of porous parting film on the repair patch
with an equal overlap all around.
(4) Put the sheet of breather fabric on top of the sheet of

D. Put the non-porous parting film, the silicone rubber sheet and
the breather cloth on the repair area.
(1) Cut a piece of CoMat 02-168 non-porous parting film

approximately 1.0 in. (25.4 mm) smaller all around than
the breather fabric.
(2) Cut a sheet of CoMat 02-170 silicone rubber to the same

dimensions as the sheet of non-porous parting film.
(3) Cut two sheets of CoMat 02-166 breather cloth

approximately 1.5 in. (38.1 mm) larger all around the
silicon rubber sheet.
(4) Put the sheet of CoMat 02-168 non-porous parting film on

the repair patch area with an equal overlap all around.
(5) Put the sheet of CoMat 02-170 silicone rubber on top of

the sheet of CoMat 02-168 non-porous parting film.
V2500 54-20-00 REPAIR 031

Page 207
Feb 1/09
(6) Put the two sheets of CoMat 02-166 breather cloth on top
of the sheet of silicone rubber with an equal overlap all
around.
E. Put the heat blanket on top of the two sheets of breather cloth
with an equal overlap all around.
F. Install the vacuum bag to the repair area.
(1) Cut the nylon bagging film CoMat 02-163 approximately 2.0
in. (50.8 mm) larger all around than the breather cloth.
(2) Install the suction hose, from the suction pump, through
the nylon bagging film and directly onto the breather
cloth.
(3) Use the sealant tape CoMat 08-051 and attach and seal the
nylon bagging film to the outer skin.
11. Cure the Resin
A. Use the vacuum suction pump and decrease the pressure in the
repair area.
NOTE: Make sure the pressure indication is not more than 25.0
in. (635.0 mm) of mercury during the resin cure
process.
B. Use the blanket to raise and keep the temperature of the repair
area between 194º and 200ºF (90º and 93ºC) for 220 minutes.
NOTE: The cure time starts when the temperature gets to 194ºF
(90ºC).
NOTE: Make sure the rate of temperature increase or

subsequent decrease is not more than 5.5ºF (3ºC) in
each minute.
12. Remove the Repair Materials
A. Remove all the repair materials from around the repair patch
when the cure process is completed.
V2500 54-20-00 REPAIR 031

Page 208
Feb 1/09
A. Use a suction cleaner and remove any unwanted material from the
repair area.
B. Clean the repair area with CoMat 01-076 methylethylkeytone and

the CoMat 02-099 lint free cloth. Wipe the area dry with a clean
14. Apply the Surface Protection

standard painting procedures (Ref SPPM Task 70-38-07-380-501).
A. Do a visual inspection to make sure that the repair has been

V2500 54-20-00 REPAIR 031

Page 209
Feb 1/09
Details of the Repair - Install the Repair Patch

Figure 201
V2500 54-20-00 REPAIR 031

Page 210
Feb 1/09
Cure the Repair Patch

Figure 202
V2500 54-20-00 REPAIR 031

Page 211
Feb 1/09
V2500 54-20-00 REPAIR 031

Page 212
Feb 1/09
REPAIR NO. 033

FAN COWL DOOR LATCH HANDLES PAINT REPAIR
VRS2789
1. General
A. This procedure may be used to repair the red/orange fluorescent

paint on the four latch handles on the right fan cowl.
B. This repair removes the damaged paint and then applies three layers
of paint followed by a layer of lacquer.
None

Index)

CoMat 01-457 Mehtylisobutylketone
CoMat 05-112 Emery paper
CoMat 07-152 Red fluorescent paint and clear lacquer
A. Put masking tape (CoMat 02-178) around the edges of each latch. Put
a piece of masking tape all around the latch handles 1.40 in.
(35 mm) from the end.
B. Make the surface of the repair area, on each latch handle, rough
with emery paper (CoMat 05-112). Make sure all loose paint is
removed.
V2500 54-20-00 REPAIR No. 033

Page 201
Feb 1/09
WARNING: KEEP FLAMES, AND ELECTRICAL EQUIPMENT THAT IS NOT

FLAMEPROOOF, AWAY FROM THE WORK AREA. THE SOLVENT IS
FLAMMABLE.
A. Clean the latch handles with methylethylketone (CoMat 01-076) or

mehtylisobutylketone (CoMat 01-457) and lint free cloth (CoMat
02-099). Rub the area dry with a clean piece of lint free cloth
6. Apply the paint (Ref Fig 201).
A. Position each latch at approximately 30o to the outer surface of

the door.
B. Apply the paint (CoMat 07-152) to each latch handle as follows:
(1) Use a brush and apply an equal layer of paint (CoMat 07-152)
to the repair area on the latch handle.
(2) Let the paint dry for 0.5 hours or until dry to touch.
(3) Apply two more layers of paint to the latch handle, refer to
steps (1) and (2).
V2500 54-20-00 REPAIR No. 033

Page 202
Feb 1/09
(4) Use a heat lamp and dry the paint at a temperature of 158oF
(70oC) for 1 hour. As an alternative, the paint can be dried
at room temperature in accordance with the manufacturer’s
instructions.
7. Apply the lacquer.
A. Apply the lacquer (CoMat 07-152) to each latch handle as follows:
(1) Use a brush and apply an equal layer of lacquer

(CoMat 07-152) to the painted area on the latch handle.
(2) Let the lacquer dry for 0.5 hours or until dry to touch.
(3) Use a heat lamp and dry the lacquer at a temperature of 158oF
(70oC) for 1 hour. As an alternative, the lacquer can be
dried at room temperature in accordance with the
B. When the lacquer has dried, remove the masking tape from around the
latches and latch handles.
V2500 54-20-00 REPAIR No. 033

Page 203
Feb 1/09
Paint Repair
Fig 201
V2500 54-20-00 REPAIR No. 033

Page 204
Feb 1/09
REPAIR NO. 034

FAN COWL DOOR LEADING EDGE EROSION REPAIR
VRS2774/2775
1. General
A. This procedure may be used to repair erosion to the leading edge of

the fan cowl door. The full leading edge of the door may be
repaired.

(VRS2743/2744)
(SPPM)
Heat lamp (explosion proof), 0o to 212oF (0o - 100oC)

Router/chamfer tool
B. Special Tools
IAE 1N20444 Sonic test equipment
C. Consumable Materials (Ref. Overhaul Processes and Consumables

Index)

CoMat 02-087 Brush
CoMat 08-021 Structural adhesive EA934NA
CoMat 08-028 Structural adhesive EA956
CoMat 08-075 Milled glass fibres
V2500 54-20-00 REPAIR No. 034

Page 201
Feb 1/09
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Left Fan Cowl Composite Structure
Right Fan Cowl Composite Structure
A. Put a strip of masking tape (CoMat 02-178) around the damaged area
and 1.5 in. (38.1 mm) rearward of the leading edge.
B. Lightly rub the damaged area with waterproof silicon carbide

abrasive paper (CoMat 05-019) to make the surface rough.
NOTE: Make sure that all the paint is removed from the repair area.
WARNING: KEEP FLAMES, AND ELECTRICAL EQUIPMENT THAT IS NOT FLAMEPROOF,

AWAY FROM THE WORK AREA. THE SOLVENT IS FLAMMABLE.

lint free cloth (CoMat 02-099). Rub the area dry with a clean piece
of lint free cloth before the solvent dries.
V2500 54-20-00 REPAIR No. 034

Page 202
Feb 1/09
A. Use a heat lamp and dry the repair area at a temperature of 140oF
(60oC) for 3 hours.
NOTE: Make sure that the structural adhesive is not applied until
the repair area is cool.
7. Prepare the structural adhesive.
A. Mix the EA956 structural adhesive (CoMat 08-028) in accordance

with the manufacturer’s instructions.
NOTE: Structural adhesive EA934NA (CoMat 08-021) can be used as an

alternative.
B. Add milled glass fibres (CoMat 08-075) to the structural adhesive.
NOTE: The milled glass fibres are not required if the alternative
structural adhesive EA934NA is used.
(1) Add 15% by weight of the milled glass fibres to the

structural adhesive.
(2) Mix the milled glass fibres into the structural adhesive
thoroughly.
V2500 54-20-00 REPAIR No. 034

Page 203
Feb 1/09
8. Apply the structural adhesive.
A. Use the brush (CoMat 02-087) and apply a 0.015 in. (0.38 mm) layer
of structural adhesive to the repair area.
NOTE: Make sure that the structural adhesive is smooth.
9. Cure the structural adhesive.
A. Cure the structural adhesive in accordance with the manufacturer’s

instructions.
NOTE: The time to cure the structural adhesive depends on the

temperature used. For example, the structural adhesive will
cure at a temperature of 199oF (93oC) in one hour.
A. Remove the damaged area from the leading edge as follows:
(1) Assemble the router guide and cutter in accordance with the
(2) Put the router guide in the correct position, against the
leading edge, to remove the damaged area.
(3) Remove an area of not more than 1.5 in. (38.1 mm) wide and
with a maximum taper of 0.020 in. (0.51 mm).
V2500 54-20-00 REPAIR No. 034

Page 204
Feb 1/09
11. Examine the forward edge of the repair area for damage.
A. The damage to the forward edge of the repair area must be less than
5 plies/0.075 in. (1.91 mm) thick.
B. If the damage is more, refer to Goodrich.
12. Repair the forward edge.
A. Repair the forward edge of the repair area, if necessary.
(1) Use waterproof silicon carbide abrasive paper (CoMat 05-019)

to remove the damaged area.
(2) Remove an area of not more than 0.25 in. (6.35 m) wide and
with a maximum taper of 5 plies/0.075 in. (1.91 mm).
WARNING: KEEP FLAMES, AND ELECTRICAL EQUIPMENT THAT IS NOT

FLAMEPROOF, AWAY FROM THE WORK AREA. THE SOLVENT IS
FLAMMABLE.

lint free cloth (CoMat 02-099). Rub the area dry with a clean piece
of lint free cloth before the solvent dries.
V2500 54-20-00 REPAIR No. 034

Page 205
Feb 1/09
14. Prepare the structural adhesive.
A. Mix the EA956 structural adhesive (CoMat 08-028) in accordance with

the manufacturer’s instructions.
NOTE: Structural adhesive EA934NA (CoMat 08-021) can be used as an

alternative.
15. Apply the structural adhesive.
A. Use the brush (CoMat 02-087) and apply a 0.005 in. (0.13 mm) layer
of structural adhesive to the repair area.
NOTE: Make sure that the structural adhesive is smooth.
V2500 54-20-00 REPAIR No. 034

Page 206
Feb 1/09
16. Cure the structural adhesive.
A. Cure the structural adhesive in accordance with the manufacturer’s

instructions.
NOTE: The time to cure the structural adhesive depends on the

temperature used. For example, the structural adhesive will
cure at a temperature of 199oF (93oC) in one hour.
17. Do a inspection of the repair area.
A. Using the sonic test equipment (1N20444) and the tap test method,
SRM 54-01-00 Composite Structure Tap Test, examine the repair and
make sure that the structural adhesive has bonded correctly.
B. If the structural adhesive has not bonded correctly, do steps 14

thru 16 again.
18. Paint the repair area.
A. Paint the repair area, refer to REPAIR No. 021 (VRS2743/2744),

Structural Repair Manual (SRM).
A. Ident the component/log book with the REPAIR no.VRS2774/2775

(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-20-00 REPAIR No. 034

Page 207
Feb 1/09
Fan Cowl Door, Repair Leading Edge

Fig 201
V2500 54-20-00 REPAIR No. 034

Page 208
Feb 1/09
REPAIR NO. 035

LEFT FAN COWL LAMINATE OIL FILLER ACCESS DOOR LAND REPAIR
VRS7501
1. General.
A. This procedure may be used to repair damage to the interface land

on the left fan cowl laminate oil filler access door, not covered
by the hinge or latches. To repair damage to the composite sandwich
oil filler access door, refer to REPAIR No. 008 (VRS2868).
filler plies, a carbon fibre patch and a fiberglass sanding ply.
C. This repair can only be done in the areas indicated, and must not
be more than 1.0 in. (25,4 mm) wide. The damage on the hinged edge
must not be more than 0.5 in. (12,7 mm), and 0.6 in. (15,2 mm) long
on the other edges. The damage must be a sufficient distance from
the edge of the panel, fittings, brackets, hinges and flanges to
install all the repair plies and the sanding ply on the outer
surface. Only one repair for each land is permitted. Refer to
Figures 201 and 202.
D. Examine the fan cowl lands for signs of damage. If the fan cowl is
damaged, refer to REPAIR No. 007 (VRS2839/VRS2923).
Filler Plies - (0-90)/(±45)/(±45)/(0-90)/(0-90)/(±45)/(±45)/(0-90)
Repair Plies - (0-90)/(±45)/(±45)/(0-90)/(0-90)/(±45)/(±45)/(0-90)
Ply orientation is given from the outermost ply to the inner.

percent or less.
G. Damage which is not in the limits of this repair must be referred

to Goodrich.
V2500 54-20-00 REPAIR No. 035

Page 201
Feb 1/09

(VRS2839/VRS2923)
(VRS2868)
(SPPM)
(SPPM)

Suction Cleaner
B. Special Tools
V2500 54-20-00 REPAIR No. 035

Page 202
Feb 1/09

Consumables Index)

D. Repair parts
None
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
A. Examine the damaged area to assess the amount of damage.
B. To repair the lightning strike protection refer to

5. Disassemble the access door (if necessary).
A. Remove the latch(es) from the access door

(Ref. AMM TASK 71-13-14-000-010).
V2500 54-20-00 REPAIR No. 035

Page 203
Feb 1/09

A. Mark the centre of the damaged area.
B. Mask around the repair area with 2.0 in. (50,8 mm) wide strips of
door land.
(2) On the external surface, measure 8.75 in. (222,3 mm), plus
the damage length (0.5 in. (12,7 mm) or 0.6 in. (15,2 mm)
maximum) from the door edge.

V2500 54-20-00 REPAIR No. 035

Page 204
Feb 1/09

NECESSARY.
C. Remove the surface protective treatment and lightning protection

mesh from the repair area with waterproof abrasive paper
(CoMat 05-021). Make the edges of the area smooth.
(1) Find the centre of the damaged area, measure 0.5 in.
(12,7 mm) each side along the door land and make a mark.
(2) Measure 0.6 in. (15,2 mm) from the door edge and make a mark
to show the door land area. On the hinged area, measure
0.5 in. (12,7 mm).
(3) Make the two corners of the repair area to a radius of

0.25 in. (6,3 mm).

NECESSARY.


(CoMat 05-021).
V2500 54-20-00 REPAIR No. 035

Page 205
Feb 1/09
lamps.

hours.
10. Cut the filler and repair plies (Ref. Fig. 202).

NECESSARY.
A. Prepare eight filler plies.
larger all around (except at the door edge) than the cut-out
repair area.
given in step 1.D.

given in step 1.D.

V2500 54-20-00 REPAIR No. 035

Page 206
Feb 1/09
the previous piece.
given in step 1.D.

fiberglass fabric (CoMat 02-167) so it is 0.75 in. (19,0 mm)
larger all around (except at the door edge) than the largest
ply.


the backing plate.

side of the door land and align it with the door edge.
door land and a good overlap of the cut-out area.
V2500 54-20-00 REPAIR No. 035

Page 207
Feb 1/09


the repair area.

(CoMat 02-367).
thoroughly.
C. Cut the eight filler plies to their finished dimensions.

NECESSARY.
(1) Cut each filler ply to the same dimensions as the cut-out
area.
of 0.25 in. (6,3 mm).
V2500 54-20-00 REPAIR No. 035

Page 208
Feb 1/09
D. Cut the eight repair plies to their finished dimensions.

NECESSARY.
(except at the door edge) than the cut-out repair area.
(2) Find a long side on the first repair ply and cut two corners
45 degrees.
1.0 in. (25,4 mm) wider.
45 degrees.

NECESSARY.
around (except at the door edge) than the last repair ply, so
that it has the same shape as the area identified by the
teflon tape.
V2500 54-20-00 REPAIR No. 035

Page 209
Feb 1/09

cleaner.

14. Install the filler plies (Ref. Fig. 202).
A. Apply an equal level of the adhesive mix to the cut-out area and
the edges using a brush (CoMat 02-087).
ply.
(2) Put the first filler ply, with the adhesive side down, in the
cut-out area, and align it with the edge of the door land.
given in step 1.D.
metal spatula.
(4) Remove the remaining parting film from the first filler ply.
V2500 54-20-00 REPAIR No. 035

Page 210
Feb 1/09
C. Apply the seven subsequent filler plies.
(1) Repeat step B. for each filler ply.

(CoMat 02-087).
that it has an equal 1.0 in. (25,4 mm) overlap around the
repair area.
given in step 1.D.

adhesive.
repair ply.
C. Put the seven subsequent carbon repair plies on to the repair area.
(1) Repeat step B. above for the remaining repair plies, making
(25,4 mm) overlap around the previous one.
fiberglass ply.
V2500 54-20-00 REPAIR No. 035

Page 211
Feb 1/09
overlap of 0.75 in. (19,0 mm) around the last carbon repair
ply and touches the teflon tape.
(3) Use the roller to remove air which is caught in the trapped

fiberglass ply.
area.



adhesive cures.
V2500 54-20-00 REPAIR No. 035

Page 212
Feb 1/09

rubber sheet.
repair area.
I. Put at least two temperature probes on the teflon tape, adjacent to

the repair area.
(CoMat 08-051).
larger than the door.

V2500 54-20-00 REPAIR No. 035

Page 213
Feb 1/09
(88oC).

from the repair.
19. Prepare the access door (Ref. Fig. 202).

NECESSARY.
CAUTION: DO NOT CAUSE DAMAGE TO THE REPAIR PLIES OR CARBON PLIES OF

THE DOOR.
A. If necessary, chamfer the door edge at the hinge area.
(2) Chamfer the hinge area along the edge of the internal surface
at an angle of 45 degrees.
B. If necessary, drill the latch fastener hole(s).
(1) Use the latch as a template and make a mark for the fastener
hole(s).
(2) Drill the hole(s) as necessary using standard workshop tools.
(3) Countersink the holes on the external surface to an angle of

100 degrees.
C. If necessary, make sure the latch opening is clear.
(1) Use the latch as a template and make a mark for the latch
opening.
(2) Remove the material from the latch opening as necessary using
standard workshop tools.
V2500 54-20-00 REPAIR No. 035

Page 214
Feb 1/09
(1) Measure approximately 0.35 in. (8,9 mm) from the door edge
E. Make the fiberglass sanding ply smooth with waterproof abrasive

paper (CoMat 05-021), making sure there is no edge between the
repair area and the outer surface.
F. Prepare the door land.
(1) Make the door land to the original contour.
(2) Close the access door, and make sure that the aerodynamic
contour on the external surface is correct and the hinge area
does not catch.
20. Apply surface protection to the cut edges.
A. Use a brush (CoMat 02-087) and apply epoxy varnish (CoMat 07-085)
21. Assemble the access door (if necessary).
A. Install the latch(es) on the access door

(Ref. AMM TASK 71-13-14-400-010).
NOTE: Use longer fasteners if necessary, and make sure that they
are properly secured.
V2500 54-20-00 REPAIR No. 035

Page 215
Feb 1/09
cleaner.



(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-20-00 REPAIR No. 035

Page 216
Feb 1/09

the Laminate Oil Filler Access Door
Fig 201
V2500 54-20-00 REPAIR No. 035

Page 217
Feb 1/09
Laminate Oil Filler Door, Repair Land Area

Fig 202
V2500 54-20-00 REPAIR No. 035

Page 218
Feb 1/09

Fig 203
V2500 54-20-00 REPAIR No. 035

Page 219
Feb 1/09
V2500 54-20-00 REPAIR No. 035

Page 220
Feb 1/09
REPAIR NO. 036

LEFT FAN COWL LAMINATE OIL FILLER ACCESS DOOR MAIN AREA SURFACE DAMAGE REPAIR
VRS2795
1. General.
A. This procedure may be used to repair surface damage to the main

area of the laminate oil filler access door of the left fan cowl.
For the composite sandwich oil filler access door refer to VRS2869.
between damaged areas. The damage on the Oil Filler Door must not
go through more than 3 plies on the outer and the inner surfaces.
The damage must be a sufficient distance from the edge of the
repair plies and the sanding ply.
Oil Filler door (inner and outer surfaces) (0-90)/(±45)/(±45)
Ply orientation is given from the outermost ply to the inner.

percent or less.
V2500 54-20-00 REPAIR No. 036

Page 201
Feb 1/09

54-20-00 REPAIR No. 010 Structural repair Manual (SRM)
(VRS2869)
54-20-00 REPAIR No. 031 Structural repair Manual (SRM)
(VRS2748/VRS2749)
(SPPM)
(SPPM)

Suction cleaner
B. Special Tools
V2500 54-20-00 REPAIR No. 036

Page 202
Feb 1/09

Index).

D. Repair parts
None.
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
oil filler door
V2500 54-20-00 REPAIR No. 036

Page 203
Feb 1/09
DEPTH OF DAMAGE NO. OF REPAIR PLIES
Up to 0.015in. (0,38 mm) 1+ fiberglass ply (Sanding)

for this example. If the damage goes through the panel, refer to
Goodrich.

V2500 54-20-00 REPAIR No. 036

Page 204
Feb 1/09
A. Apply the teflon tape (CoMat 02-007) to the repair area. Calculate
the distance that the tape must be from the damage as follows:
each ply of the panel (ref. step 4.), and add 0.75 in.
(CoMat 02-167).

in. (25,4 mm).

NECESSARY.
edges from the damage with the abrasive paper (CoMat 05-021).

NECESSARY.
the finished dimensions after soaking in adhesive (Ref. steps 1.D
and 9.C).
V2500 54-20-00 REPAIR No. 036

Page 205
Feb 1/09
repair ply for each ply of the panel which is damaged and these
after soaking in adhesive (Ref. steps 1.D and 9.C).

NOTE: After the plies are soaked, the remaining adhesive is used on
the repair area (Ref. step 12.).

V2500 54-20-00 REPAIR No. 036

Page 206
Feb 1/09


metal spatula. The filled damage must be level with the top carbon
fibre ply of the panel.
V2500 54-20-00 REPAIR No. 036

Page 207
Feb 1/09

film.
in step 1.D.
in step 1.D.
spatula.
V2500 54-20-00 REPAIR No. 036

Page 208
Feb 1/09

D. above.
parting film.

to the repair area.
V2500 54-20-00 REPAIR No. 036

Page 209
Feb 1/09
the repair area.

NECESSARY.

area and the outer skin of the door. Use the abrasive paper
(CoMat 05-021).
V2500 54-20-00 REPAIR No. 036

Page 210
Feb 1/09


(Ref. SPPM TASK 70-38-07-380-501).
A. Ident tPhe component/log book with the REPAIR no. VRS2795

(Ref. SPM TASK 70-09-00-400-501).
V2500 54-20-00 REPAIR No. 036

Page 211
Feb 1/09

Fig. 201
V2500 54-20-00 REPAIR No. 036

Page 212
Feb 1/09

Fig. 202
V2500 54-20-00 REPAIR No. 036

Page 213
Feb 1/09

Fig. 203
V2500 54-20-00 REPAIR No. 036

Page 214
Feb 1/09
REPAIR NO. 037

LEFT FAN COWL LAMINATE OIL FILLER ACCESS DOOR LANDS SURFACE DAMAGE REPAIR
VRS7502
1. General
A. This procedure may be used to repair surface damage to the lands of

the laminate oil filler access door on the left fan cowl. For the
composite sandwich oil filler access door refer to VRS2832.
NOTE: For applicable repair area refer to Figure 201.
microballoons and installs carbon fiber repair plies and a
C. The maximum depth of damage that can be repaired is 2 plies (up to

0.030 in. (0,76 mm)).
D. Damage which goes to the edge, penetrates or is not within the

limits of this repair can possibly be repaired REPAIR No. 035
(VRS7501).The damage must be a sufficient distance from the edge of
the panel, fittings, brackets, hinges and flanges to install all
the repair plies and the sanding ply.
E. The orientation of the carbon fibre repair plies are as follows:

Oil Filler Door (inner and outer surface) (0-90)/(±45)
F. Only one repair is permitted for each land.
G. This repair must be done in a room with a controlled temperature of

percent or less.
H. When damage is beyond the scope of this repair refer to Goodrich.
V2500 54-20-00 REPAIR No. 037

Page 201
Feb 1/09

(VRS2832)
(VRS7501)
(SPPM)
(SPPM)

Heat Lamp, 176o - 194oF (80o - 90oC)
Steel Roller, 2.0 in. (50.8mm) diameter, 2.0 in. (50.8mm) long
Suction Cleaner

Index)

V2500 54-20-00 REPAIR No. 037

Page 202
Feb 1/09
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Left Fan Cowl
this in several places where the extent of the damage permits.
From this information the number of repair plies should be
calculated as follows:
Up to 0.015 in. (0,38 mm) 1 + fiberglass ply (Sanding)

More than 0.015 in. (0,38 mm) 2 + fiberglass ply (Sanding)
If in doubt over the depth of the damage, ie., deciding between

0.015 in. (0,38 m) and 0.016 in. (0,41 mm), assume the larger
B. To repair the lightning strike protection refer to


V2500 54-20-00 REPAIR No. 037

Page 203
Feb 1/09
A. Mask around the repair area with 2.0 in. (50.8 mm) wide strips of
(1) Measure 1.0 in. (25.4 mm) from the edge of the damage for
(2) Add 0.75 in. (19.05 mm) for an outer layer of fiberglass

1.0 in. (25.4 mm).

NECESSARY.
B. Remove the sharp edges from the damage and the lightning strike
protection over the repair area. Make the surface of the repair
area rough with waterproof abrasive paper (CoMat 05-021).
7. Cut the repair plies.

NECESSARY.
(50.8 mm) overlap around the damaged area.
V2500 54-20-00 REPAIR No. 037

Page 204
Feb 1/09
B. Wear lint free gloves (CoMat 02-097) and cut the second repair ply
(if necessary) from dry carbon fibre fabric (CoMat 08-059) 2.0 in.
(50.8 mm)larger all around than the previous piece. Cut one repair
ply for each ply of the cowl which is damaged.
C. Wear lint free gloves (CoMat 02-097) and cut one piece of
fiberglass fabric (CoMat 02-167) so that it has a 1.0 in. (25.4 mm)
overlap around the area which the teflon tape (CoMat 02-007)
identifies.
lamps.

hours.


the repair area. Refer to step 12.

(CoMat 02-367).
thoroughly.
V2500 54-20-00 REPAIR No. 037

Page 205
Feb 1/09

NECESSARY.
(1) Cut approximately 1.0 in. (25.4 mm) off each edge of the
repair plies. Make sure that the first repair ply has a 1.0
in. (25.4 mm) overlap around the damage, and the second
repair (if necessary) ply has a 1.0 in. (25.4 mm) overlap
around the repair ply below it. Trim the corners of the
repair plies to 45 degrees by 0.5 in. (12.7 m). Cut the
fiberglass ply so that it is the same shape as the area
identified by the teflon tape (CoMat 02-007).

V2500 54-20-00 REPAIR No. 037

Page 206
Feb 1/09

thickness.
B. Apply the adhesive mix to the damaged area of the cowl with a clean
metal spatula. Make sure the adhesive is level with the top carbon
ply of the door.

(CoMat 02-087).
the repair area, making sure that the damaged area is in the
as given in step 1.E.
V2500 54-20-00 REPAIR No. 037

Page 207
Feb 1/09

adhesive.
ply.
C. Put the second carbon repair (if necessary) ply on to the repair
area.
second repair ply.
(2) Put the second repair ply, with the adhesive side down, on to
an equal overlap around the first repair ply.
given in step 1.E.

adhesive.
ply.
fiberglass ply.
area.

fiberglass ply.
area.
V2500 54-20-00 REPAIR No. 037

Page 208
Feb 1/09

in. (50.8 mm) larger on each side than the silicone rubber
sheet.
repair area.

the repair area.
(50.8 mm) around the breather cloth.
V2500 54-20-00 REPAIR No. 037

Page 209
Feb 1/09

(88oC).
the repair.

NECESSARY.

V2500 54-20-00 REPAIR No. 037

Page 210
Feb 1/09
cleaner.



(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-20-00 REPAIR No. 037

Page 211
Feb 1/09
May 1/07

the Laminate Oil Filler Door Access Panel
Fig 201
V2500 54-20-00 REPAIR No. 037

Page 212
Feb 1/09

Fig 202
V2500 54-20-00 REPAIR No. 037

Page 213
Feb 1/09

Fig 203
V2500 54-20-00 REPAIR No. 037

Page 214
Feb 1/09
REPAIR NO. 038

FAN COWL MAIN AREA DISBOND REPAIR
VRS7500
1. General
A. This repair is only applicable to the main area left and right fan
cowl. The main area is the area where skin thickness is 2 plies of
8HSW only. Refer to Figures 201 and 202.
B. This repair removes the disbonded plies, ‘core closing’ of the

honeycomb core and installs epoxy adhesive, a fiberglass cap ply,
carbon fiber repair plies and a fiberglass sanding ply.
C. The damage must be more than 2.75 in (69,9 mm) from the fittings,
brackets, hinges and flanges. The damage must not be more than
4.0 in. (101,6 mm) wide and 4.0 in. (101,6 mm) long. There must be
a minimum of 20.0 in. (508,0 mm) between the edge of each repair
area. Only four repairs are permited on each door.

Main Panel Body (outer surface) (0-90)/(0-90)
Main Panel Body (inner surface) (0-90)/(0-90)

percent or less.
G. For replacement of honeycomb core refer to 54-02-00 REPAIR No. 009

(VRS2372).

(VRS 2372)
(VRS 2748/2749)
(SPPM)
(SPPM)
V2500 54-20-00 REPAIR No. 038

Page 201
Feb 1/09

Heat Lamp, 176o - 212oF (80o - 100oC)
Suction Cleaner

Index)

C. Special Tools
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
V2500 54-20-00 REPAIR No. 038

Page 202
Feb 1/09
4. Examine the damaged area (Ref. Figs. 201 and 202).
A. Determine the extent of the disbond using the sonic test equipment
(1N20444) and the tap test method, SRM 54-01-00 Composite
using a marking pen (CoMat 06-131).

wire mesh (after repair) occurs, refer to REPAIR No. 031
(VRS 2748/2749) when you do this repair.
A. Clean around the damaged area with methylethylketone (CoMat 01-

076) and lint-free cloth (CoMat 02-099). Wipe the repair area dry.
(1) Measure 2.0 in. (50,7 mm) from the edge of the damage,
1.0 in. (25,4 mm) for each ply of the cowl which is damaged.

0.5 in. (12,7 mm).
V2500 54-20-00 REPAIR No. 038

Page 203
Feb 1/09

NECESSARY.
B. Remove the disbonded plies.
(1) Use a high speed rotary cutter to remove the plies from the
damaged area in step 4A.
(2) Do not cause further disbond or disbonding of the plies.
cleaner.

lamps.

hours.
V2500 54-20-00 REPAIR No. 038

Page 204
Feb 1/09
9. Apply the epoxy paste adhesive to the honeycomb core (Ref. Fig. 203).
A. Mix the epoxy paste adhesive (CoMat 08-021) for the honeycomb core
in accordance with the manufacturer’s instructions.
B. Cut a piece of non-porous parting film (CoMat 02-367) 4.0 in.

(101,6 mm) larger than the area of honeycomb to be filled.
C. Use a marking pen (CoMat 06-131) to mark the contour of the repair
area on the non-porous parting film.
D. Place the non-porous parting film on a flat surface, and use

sealant tape (CoMat 08-051) to attach.
E. Apply the epoxy paste adhesive (CoMat 08-021) to the non-porous

parting film with a clean metal spatula within the marked area.
Apply sufficient material to get a maximum uniform thickness of
0.2 in. (5,1 mm). Use an edge fence to get the necessary thickness.
F. Position the non-porous parting film over the area to be closed,

with prepared compound surface towards the honeycomb cells. Push
the compound into the cells by lightly pushing on the non-porous
parting film.
G. Slowly ease the non-porous parting film away from the cells, take
care not to remove the compound from the cells. Use a knife, if
necessary, to help remove the compound from the non-porous parting
film.
H. Use a clean metal spatula to smooth the compound level with the
upper surface of the honeycomb cells.
NOTE: Use a spatula to add more compound to any cells that are not
fully closed.
I. Use a clean cloth to remove any compound from the skin around the
repair area.
J. Cure the epoxy paste adhesive.
V2500 54-20-00 REPAIR No. 038

Page 205
Feb 1/09
(1) Use heat lamps to cure the epoxy paste adhesive for 1 hour
between 190o - 210oF (88o - 99oC)


NECESSARY.
K. When the adhesive has cured, make the adhesive flush with the upper
surface of the honeycomb cells upper surface. Use abrasive paper
(CoMat 05-021).
10. Prepare the cap ply, the fiberglass ply, the filler plies and the repair
plies

NECESSARY.
A. Wear lint-free gloves (CoMat 02-097) and cut two filler plies.
(1) Cut the dry carbon fibre fabric (CoMat 08-059) so that it has
a 1.0 in. (25,4 mm) overlap around the repair cut-out.
given in step 1.E.
B. Wear lint-free gloves (CoMat 02-097) and cut a cap ply.
(1) Cut one piece of fiberglass fabric (Comat 02-167) so that it

has a 1.0 in. (25,4 mm) overlap around the repair cut-out.
C. Wear lint-free gloves (CoMat 02-097) and cut the first repair ply.
(1) Cut one piece of dry carbon fibre fabric (CoMat 08-059) so
that it has a 2.0 in. (50,8 mm) overlap around the potted
core.
V2500 54-20-00 REPAIR No. 038

Page 206
Feb 1/09
D. Wear lint-free gloves (CoMat 02-097) and cut the second repair ply.
(1) Cut another piece of dry carbon fibre fabric (CoMat 08-059)
for the second repair ply, so that it has a 1.0 in. (25,4 mm)
overlap repair ply below.
E. Wear lint-free gloves (CoMat 02-097) and cut the fiberglass ply.
(1) Cut one piece of fiberglass fabric (CoMat 02-167) so that it

has a 0.75 in. (19,1 mm) overlap around the second repair
ply.
F. Mix the EA9390 epoxy paste adhesive (CoMat 08-050) for the
fiberglass and carbon plies in accordance with the manufacturer’s
instructions.

G. Soak the fiberglass and the carbon plies with the adhesive.

(CoMat 02-367).
thoroughly.
V2500 54-20-00 REPAIR No. 038

Page 207
Feb 1/09
H. Cut the cap ply and the filler plies to their finished dimensions.
(2) Cut each filler ply and the cap ply until it does not have an
overlap on the sides of the repair cut-out.
I. Cut the repair plies to their finished dimensions.
(2) Cut approximately 1.0 in. (25,4 mm) off each of the repair
plies.
(3) Make sure the first repair ply has a 1.0 in. (25,4 mm)
overlap around the potted core. The second repair ply must
have an 1.0 in. (25,4 mm) overlap around the repair ply below
it.
J. Cut the fiberglass ply until it is the same shape as the area

V2500 54-20-00 REPAIR No. 038

Page 208
Feb 1/09
12. Install the cap ply, the filler plies and the repair plies
(Ref. Fig. 203).
A. Use a brush (CoMat 02-087) to apply an equal layer of EA9390 epoxy

paste adhesive (CoMat 08-050) to the repair area.
B. Put the cap ply and first filler ply into the repair cut-out.
side of the cap ply.
(2) Install the fiberglass cap ply, with the adhesive side down,
into the repair cut-out. Make sure that the cap ply is flat
and in the correct position.

adhesive.
(4) Remove the remaining non-porous parting film from the cap
ply.
(5) Remove the non-porous parting film from the first filler
ply.
(6) Install the first filler ply, with the adhesive side down,
into the repair cut-out. Make sure that the filler ply is
flat.

adhesive.
ply. Use a clean metal spatula to make sure the filler ply is
V2500 54-20-00 REPAIR No. 038

Page 209
Feb 1/09
C. Put the second filler ply on to the repair area.
second filler ply.
(2) Put the second filler ply, with the adhesive side down, on to
the repair area. Make sure that the second filler ply has an
equal overlap around the first filler ply.
given in step 1.E.

adhesive.
ply.
D. Put the first repair ply on to the repair area.
repair ply.
the repair area. Make sure that the repair cut-out is in the
given in step 1.E.

adhesive.
ply.
E. Put the second repair ply on to the repair area.
repair ply.
the repair area. Make sure that the second repair ply has an
given in step 1.E.
V2500 54-20-00 REPAIR No. 038

Page 210
Feb 1/09

adhesive.
ply.
F. Put the fiberglass ply on to the repair area.
fiberglass ply.
area.

fiberglass ply.
area.
B. Cut a sheet of porous parting film (CoMat 02-334) and make sure
least 3.0 in. (76.2 m) around the fiberglass ply.
D. Put the porous parting film on to the repair area. Make sure that

of material have an overlap of 2.0 in. (50.8 mm) around the
V2500 54-20-00 REPAIR No. 038

Page 211
Feb 1/09
G. Put the non-porous parting film on to the repair area. Make sure

rubber sheet.
area.

the repair area.
area. Making sure it gives an indication of at least 25.0 in.

V2500 54-20-00 REPAIR No. 038

Page 212
Feb 1/09
(88oC).
the repair.


abrasive paper (CoMat 05-021). Make sure that there is no edge
between the repair area and the fan cowl.
cleaner.

V2500 54-20-00 REPAIR No. 038

Page 213
Feb 1/09


(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-20-00 REPAIR No. 038

Page 214
Feb 1/09

V2500 54-20-00 REPAIR No. 038

Page 215
Feb 1/09

V2500 54-20-00 REPAIR No. 038

Page 216
Feb 1/09

V2500 54-20-00 REPAIR No. 038

Page 217
Feb 1/09

V2500 54-20-00 REPAIR No. 038

Page 218
Feb 1/09
Structure Repair Details

Figure 202
V2500 54-20-00 REPAIR No. 038

Page 219
Feb 1/09

Figure 203
V2500 54-20-00 REPAIR No. 038

Page 220
Feb 1/09

Figure 204
V2500 54-20-00 REPAIR No. 038

Page 221
Feb 1/09
V2500 54-20-00 REPAIR No. 038

Page 222
Feb 1/09
REPAIR NO. 039

FAN COWLS - REPLACE THE CORNER PLATES
VRS2790
1. General
A. This procedure may be used to replace any of the four corner plates
on each fan cowl doors.
B. This repair removes the damaged corner plate and installs a new
one.
C. Damage which is not within the limits of this repair must be


(SPPM)
(SPPM)
Drill 0.118 in. (3.00 mm)

B. Consumable Materials (Ref. Overhaul Processes and

Consumable Index)

C. Special Tools
None.
V2500 54-20-00 REPAIR No. 039

Page 201
Feb 1/09
D. Repair Parts
--------------------------------------------
PART NO. PART IDENT
--------------------------------------------
CSR904B-4-5 Rivet
740-4019-511 Corner plate
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
Corner plate Nylon
4. Remove the corner plate (Ref Fig 201).

NECESSARY.
CAUTION: WHEN REMOVING RIVETS DO NOT INCREASE THE RIVET HOLE SIZE. DO
NOT DRILL THROUGH THE RIVET. DAMAGE TO THE INTERNAL PARTS MAY
OCCUR.
A. Remove the rivets which attach the corner plate to the door.
(1) Use a 0.118 in. (3.00 mm) diameter drill to remove the rivet
heads.
(2) Use a punch and remove the rivets from the holes.
(3) Remove the corner plate from the door.
B. Use the waterproof silicon carbide abrasive paper (CoMat 05-019)

and remove any burrs.
V2500 54-20-00 REPAIR No. 039

Page 202
Feb 1/09
5. Clean the repair area and the replacement corner plate.
A. Clean the repair area and the replacement corner plate with
methylethylketone (CoMat 01-076) and a lint free cloth
(CoMat 02-099). Rub the repair area and the replacement corner
plate clean before the methylethylketone becomes dry.
6. Install the replacement corner plate.
A. Put the replacement corner plate in the correct position for

installation.
B. Install the rivets.
(1) Apply a thin layer of sealant (CoMat 08-125) to the rivets

CSR904B-4-5 before installation.
(2) Install the rivets before the sealant dries.
V2500 54-20-00 REPAIR No. 039

Page 203
Feb 1/09
A. Clean the repair area with methylethylketone (CoMat 01-076) and a

lint free cloth (CoMat 02-099). Rub the repair area clean before
the methylethylketone becomes dry.
8. Examine the repair area.

(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-20-00 REPAIR No. 039

Page 204
Feb 1/09
Replace the Corner Plates

Fig 201
V2500 54-20-00 REPAIR No. 039

Page 205
Feb 1/09
V2500 54-20-00 REPAIR No. 039

Page 206
Feb 1/09
REPAIR NO. 055

FAN COWL MAIN AREA FILLER PLATE REPAIR
VRS7505
1. General
A. This repair is only applicable to the main area left and right fan
cowl. The main area is the area where skin thickness is 2 plies of
8HSW only. Refer to Zone C, Figure 201 (Sheets 1 and 2).
B. If disdond has occurred on outer skin, this repair removes the

disbonded plies, replaces the removed plies with a pre-cured
support plate and installs carbon fiber repair plies and a
C. If disdond has occurred on inner skin, this repair removes the

plies on the outer skin, replaces the honeycomb core, replaces the
removed plies with a pre-cured support plate and installs carbon
fiber repair plies and a fiberglass sanding ply.
D. The damage must be more than 10.00 in (254,0 mm) from the fittings,
brackets, hinges and flanges and must be more than 5.0 in.
(127,0 mm) from the edge of the of the 2-ply region. The damage
must not be more than 20.0 in. (508,0 mm) wide and 20.0 in.
long in the upper 2-ply region and not more than 14.0 in.
(355,6 mm) wide and 20.0 in. long in the lower 2-ply region. There
must be a minimum of 10.0 in. (254,0 mm) between the edge of each
repair area. Only two repairs are permitted on each door. Refer to
Figure 201.
E. The orientation of the carbon fibre repair plies are as follows:

Main Panel Body (outer surface) (0-90)/(0-90)
Main Panel Body (inner surface) (0-90)/(0-90)

percent or less.
G. When damage is beyond the scope of this repair refer to Goodrich.
H. This repair is not applicable to the monolithic fan cowl door.
I. For replacement of honeycomb core refer to 54-02-00 Repair No.9

(VRS2372).
V2500 54-20-00 REPAIR No. 055

Page 201
Feb 1/09

(VRS2372)
(VRS 2748/2749)
(SPPM)
(SPPM)

Suction Cleaner

Index)

CoMat 02-170A Silicon rubber sheet
CoMat 08-136 FM 300-2M film adhesive
CoMat 08-164 8H SW pre-preg carbon fibre fabric
V2500 54-20-00 REPAIR No. 055

Page 202
Feb 1/09
C. Special Tools
--------------------------------------------
--------------------------------------------
PART IDENT MATERIAL
PART IDENT MATERIAL
--------------------------------------------
--------------------------------------------
A. Determine the extent of the disbond using the sonic test equipment
(1N20444) and the tap test method, SRM 54-01-00 Composite
using a marking pen (CoMat 06-153).

wire mesh (after repair) occurs, refer to REPAIR 031
(VRS2748/2749) when you do this repair.
A. Clean around the damaged area with methylethylketone

(CoMat 01-076) and lint-free cloth (CoMat 02-099). Wipe the repair
area dry.
(1) Measure 2.0 in. (50,7 mm) from the edge of the damage,
1.0 in. (25,4 mm) for each ply of the cowl which is damaged.
V2500 54-20-00 REPAIR No. 055

Page 203
Feb 1/09

0.5 in. (12,7 mm).

B. Remove the disbonded plies.
(1) Use a high speed rotary cutter to remove the plies from the
damaged area in step 4A.
(2) Do not cause further disbond or disbonding of the plies.
NOTE: If disbond has occurred on inner skin or the honeycomb

core is damaged, replace the honeycomb core (Refer to
54-02-00, Repair No. 09 (VRS2372).
cleaner.

V2500 54-20-00 REPAIR No. 055

Page 204
Feb 1/09
lamps.

hours.
9. Manufacture the filler plate plies.
A. Wear lint-free gloves (CoMat 02-97) and cut two plies for the
filler plate.
B. Cut the 8H SW pre-preg carbon fibre fabric (CoMat08-164) so that it

is the same size as the repair cut-out.
10. Prepare the filler plate plies.
A. Cut each ply so it is the same size as the repair cut-out.
B. Put the two plies together to make the support plate on a sheet of
non-porous parting film (CoMat 02-367).
C. Align the plies and put them onto a hard, flat surface with the
same profile as the repair area.
D. Use the roller to push the plies together.
A. Get a heat blanket, which must be larger all around than the filler
plate.
least 3.0 in. (76.2 m) around the filler plate.
C. Cut one sheet of breather fabric (CoMat 08-057) for each pre-preg
carbon ply on the filler plate. Make sure that the breather fabric
has the same dimensions as the porous parting film.
D. Put the porous parting film on to the filler plate. Make sure that
it has an equal overlap around the filler plate. Put the layers of
V2500 54-20-00 REPAIR No. 055

Page 205
Feb 1/09

silicone rubber sheet (CoMat 02-170A). Make sure that the two
installed breather fabric.
F. Put four fiberglass tows onto the filler plate using one strand of
around the plate. Each of the strands must connect the breather
G. Put the non-porous parting film on to the filler plate. Make sure
that it has an equal overlap around the filler plate. Put the
H. Cut two sheets of breather cloth (CoMat 02-166), at least 2.0 in.
(50.8 mm) larger on each side than the silicone rubber sheet.
I. Put the two sheets of breather cloth on to the filler plate.
J. Put the heat blanket on top of the breather cloth. Make sure that
the heat blanket has an overlap all around the filler plate.
K. Put as least two temperature probes on the teflon tape, adjacent to

the filler plate.
L. Install the vacuum bag on to the filler plate.
M. Cover the filler plate with the nylon bagging film (CoMat 02-163)
that must have a minimum overlap of 2.0 in. (50,8 mm) around the
breather cloth.
N. Install the vacuum hose, from the suction pump, so that it goes
directly on to the breather cloth.
O. Attach and seal the bagging film to the cowl with the sealant tape
(CoMat 08-051).
A. Use the vacuum suction pump to decrease the pressure. Making sure
it gives an indication of at least 25.0 in. (635,0 mm) of mercury
while the adhesive cures.
345.2°F - 363.2°F (174° - 185°C) for 120 minutes.
V2500 54-20-00 REPAIR No. 055

Page 206
Feb 1/09

be greater than 2° - 4°F (0.8 - 2.5°C) in each minute.
D. Start to measure the cure time when the temperature reaches 345.2oF
(174°C).
E. When the cure process is completed, remove the layup materials from
the filler plate.
13. Prepare the repair plies

A. Wear lint-free gloves (CoMat 02-097) and cut the first repair ply.
(1) Cut one piece of dry carbon fibre fabric (CoMat 08-059) so
that it has a 2.0 in. (50,8 mm) overlap around the repair
cut-out core.
B. Wear lint-free gloves (CoMat 02-097) and cut the second repair ply.
(1) Cut another piece of dry carbon fibre fabric (CoMat 08-059)
for the second repair ply, so that it has a 1.0 in. (25,4 mm)
overlap repair ply below.
C. Wear lint-free gloves (CoMat 02-097) and cut the fiberglass ply.
(1) Cut one piece of fiberglass fabric (CoMat 02-167) so that it

has a 0.75 in. (19,1 mm) overlap around the second repair
ply.
V2500 54-20-00 REPAIR No. 055

Page 207
Feb 1/09
D. Mix the EA9390 epoxy paste adhesive (CoMat 08-050) for the
fiberglass and carbon plies in accordance with the manufacturer’s
instructions.

E. Soak the fiberglass and the carbon plies with the adhesive.

(CoMat 02-367).
thoroughly.
F. Cut the repair plies to their finished dimensions.
(2) Cut approximately 1.0 in. (25,4 mm) off each of the repair
plies.
(3) Make sure the first repair ply has a 1.0 in. (25,4 mm)
overlap around the potted core. The second repair ply must
have an 1.0 in. (25,4 mm) overlap around the repair ply below
it.
G. Cut the fiberglass ply until it is the same shape as the area
V2500 54-20-00 REPAIR No. 055

Page 208
Feb 1/09

15. Install the filler plate.
A. Cut two plies of FM 300-2 film adhesive (CoMat 08-136) the same
size as the repair cut-out.
B. Apply the two FM 300-2 film adhesive (CoMat 08-136) plies to the
repair area.
C. Install the filler plate into the repair cut-out. Make sure that
the filler plate is the same profile as the repair area.
16. Prepare to cure the film adhesive (Ref. Fig. 204).
area.
least 3.0 in. (76.2 m) around the repair area.

installed breather fabric.
V2500 54-20-00 REPAIR No. 055

Page 209
Feb 1/09
I. Cut two sheets of breather cloth (CoMat 02-166), at least 2.0 in.
(50.8 mm) larger on each side than the silicone rubber sheet.
J. Put the two sheets of breather cloth on to the repair area.
K. Put the heat blanket on top of the breather cloth. Make sure that
the heat blanket has an overlap all around the repair area.
L. Put as least two temperature probes on the teflon tape, adjacent to

the repair area.
M. Install the vacuum bag on to the repair area.
N. Cover the repair area with the nylon bagging film (CoMat 02-163)
that must have a minimum overlap of 2.0 in. (50,8 mm) around the
breather cloth.
O. Install the vacuum hose, from the suction pump, so that it goes
directly on to the breather cloth.
P. Attach and seal the bagging film to the cowl with the sealant tape
(CoMat 08-051).
257° - 275°F (125° - 135°C) for 120 minutes.

be greater than 5.4°F (3°C) in each minute.
V2500 54-20-00 REPAIR No. 055

Page 210
Feb 1/09
D. Start to measure the cure time when the temperature reaches 257°F
(125°C).
E. Remove the repair equipment.
F. When the cure process is completed, remove the layup materials from
the repair.
A. Put the first repair ply on to the repair area.
repair ply.
the repair area. Make sure that the repair cut-out is in the

adhesive.
ply.
B. Put the second repair ply on to the repair area.
repair ply.
the repair area. Make sure that the second repair ply has an
V2500 54-20-00 REPAIR No. 055

Page 211
Feb 1/09

adhesive.
ply.
C. Put the fiberglass ply on to the repair area.
fiberglass ply.
area.

fiberglass ply.
area.
least 3.0 in. (76.2 m) around the fiberglass ply.

V2500 54-20-00 REPAIR No. 055

Page 212
Feb 1/09

rubber sheet.
area.

the repair area.
V2500 54-20-00 REPAIR No. 055

Page 213
Feb 1/09

(88oC).
the repair.


abrasive paper (CoMat 05-021). Make sure that there is no edge
between the repair area and the fan cowl.
V2500 54-20-00 REPAIR No. 055

Page 214
Feb 1/09
cleaner.



(Ref. SPPM TASK 70-09-00-400-501).
V2500 54-20-00 REPAIR No. 055

Page 215
Feb 1/09
Location of 2-Ply Region

V2500 54-20-00 REPAIR No. 055

Page 216
Feb 1/09
Location of 2-Ply Region

V2500 54-20-00 REPAIR No. 055

Page 217
Feb 1/09
Repair the Fan Cowl Main Area

Figure 202
V2500 54-20-00 REPAIR No. 055

Page 218
Feb 1/09

Figure 203
V2500 54-20-00 REPAIR No. 055

Page 219
Feb 1/09

Figure 204
V2500 54-20-00 REPAIR No. 055

Page 220
Feb 1/09

Figure 205
V2500 54-20-00 REPAIR No. 055

Page 221
Feb 1/09

Figure 206
V2500 54-20-00 REPAIR No. 055

Page 222
Feb 1/09
STRUCTURE IDENTIFICATION - THRUST REVERSER
1. General
A. The thrust reverser assembly is mounted on the aft flange of

the fan frame. It is made up of two halves which form kidney
shaped bifurcation ducts. Each half is hinged to the aircraft
pylon at four places. The two halves are latched together at
the bottom.
B. Each half has five blocker doors, a translating sleeve, two

actuators, cascade vanes, a bifurcation duct and the necessary
attachments to mount each half.
2. Structure Description
The materials used in the thrust reverser construction are aluminum

alloy sheet, composite graphite fabric and aluminum honeycomb core.
3. Structure Identification

(Figures) and tables. The tables list the structural components used
in the thrust reverser except for fasteners. Each component is
identified by an item number in the table which corresponds to a number
in the illustration. The tables give the component’s description, gage
(thickness), and material from which it was made.
Figure and Table numbers ending with an “A” are for Translating Sleeve
serial numbers 5001001 and on.
A. Determine which parts should or should not attempt to

fabricate.
V2500 54-30-00 Page 1

Aug 1/09
13506
Thrust Reverser Assembly

V2500 54-30-00 Page 2

Aug 1/09
13507A
Translating Sleeve Outer Barrel Assembly

V2500 54-30-00 Page 3

Aug 1/09
DETAIL II
8
SEE
DETAIL II
10
12
11 14
16
13
18
15
17
6 8
7
SECTION B - B
SECTION A - A SEE DETAIL III
19
20
21
22
23 24
26 DETAIL III
25 27 28
13508

V2500 54-30-00 Page 4

Aug 1/09
8 5
SEE DETAIL IV SECTION C - C
29
30
31
DETAIL IV
32
5
33
34
13509
SECTION D - D

V2500 54-30-00 Page 5

Aug 1/09
46
47
46
48
DETAIL III
50
49
DETAIL IV
44 45
DETAIL V
44
13511

V2500 54-30-00 Page 6

Aug 1/09
ITEM DESCRIPTION GAGE MATERIAL

(INCH)
1 INTERCOSTAL MAKE FROM S700E1077
2 STIFFENER MAKE FROM S700E1077
3 ANGLE 0.080 2024 T3 CLAD ALUM SHEET
QQ-A-250/5
4 BLOCKER DOOR 2024 T351 ALUM PLATE,
QQ-A-250/5
5 CORE 5052 ALUM HONEYCOMB, 3/16 INCH
(4.76 MM), CLASS 2, TYPE 1,
3LBS/CU.ft (48.05 KG/M3)
(4.76 MM), CLASS 2, TYPE 1, 3
LBS/CU.ft (48.05 KG/M3
7.9 LBS/CU.ft (127.13 KG/M3)
8 OUTER SKIN
9 COMPOSITE 0.0145 GRAPHITE EPOXY FABRIC GROUP 1,
OUTER SKIN PLY TYPE 2, CLASS 1, GRADE 1 AT 0º
OUTER SKIN PLY TYPE 2, CLASS 1. GRADE 1 AT
-45º
OUTER SKIN PLY TYPE 2, CLASS 1, GRADE 1 AT
+45º


Table I (Sheet 1 of 3)
V2500 54-30-00 Page 7

Aug 1/09

(INCH)
OUTER SKIN PLY TYPE 2, CLASS 2, GRADE 1 AT
+45º
OUTER SKIN PLY TYPE 2, CLASS 1, GRADE 1 AT -
45º
17 COMPOSITE 0.0045 GLASS EPOXY FABRIC GROUP 1,
OUTER SKIN PLY TYPE 1, CLASS 1
18 COMOPSITE 0.0045 GLASS EPOXY FABRIC GROUP 1,
OUTER SKIN PLY TYPE 1, CLASS 1
19 COMPOSITE 0.0045 GLASS EPOXY FABRIC GROUP 1,
FRAME CAP PLY TYPE 1, CLASS 1
DOUBLER TYPE 1, CLASS 1, GRADE 1 AT 0º
24 DOUBLER 0.0055 GRAPHITE EPOXY FABRIC GROUP 1,
TYPE 1, CLASS 1, GRADE 1 AT 0º

V2500 54-30-00 Page 8

Aug 1/09

(INCH)
27 CLOSURE TEDLAR EPOXY FABRIC
28 COVER 0.0045 GLASS EPOXY FABRIC GROUP 1,
TYPE 1, CLASS 1
TYPE 1, CLASS 1, GRADE 1
7.9 LBS/CU.ft (127.13 KG/M3)
(4.76 MM), CLASS 2, TYPE 1, 3
LBS/CU.ft (48.05 KG/M3)
35 ACCESS PANEL 0.125 2024 T3 CLAD ALUM SHEET
QQ-A-250/5

V2500 54-30-00 Page 9

Aug 1/09

(INCH)
36 SEAL RETAINER 0.025 321 CRES, COMP T1, MIL-S-6721,
ANNEALED
37 SEAL ZZ-R-765 SILICONE RUBBER,
CLASS 2B, GRADE 50
Translating Sleeve Inner Barrel Pressure Panel Assembly

Table IIA
V2500 54-30-00 Page 10

Aug 1/09
SEE
3 10 9 8
DETAIL I
11
12 4
13
5
14
15
16
SEE 17
DETAIL III 18
19
2
20
21
22
23
24
25 26
27 7
6 DETAIL II
28
29 37
5 36
35
30 31 1 32 33 34
2 14 13 40 39 38
15
35 41 16
36 17
37 7 6
18
20 19
THRU 20
31
21
42 22
23
SEE 24
DETAIL II
43
SEE 25 26 27 28 29 30 31
4 SEE
DETAIL IV
DETAIL V 5 6
3
2
1
DETAIL I
7 13516

V2500 54-30-00 Page 11

Aug 1/09
46
47
46
48
DETAIL III
50
49
DETAIL IV
44 45
DETAIL V
44
13511

V2500 54-30-00 Page 12

Aug 1/09

(INCH)
1 CORE 5052 NON-PERFORATED ALUM
HONEYCOMB, 1/8 INCH (3.17 MM),
CLASS 2, TYPE 1, 3 LBS/CU.ft
(48.05 KG/M3)
(48.05 KG/M3)
(48.05 KG/M3)
(48.05 KG/M3)
(48.05 KG/M3)
(48.05 KG/M3)
(48.05 KG/M3)
8 CORE 0.0045 GLASS EPOXY FABRIC GROUP 1,
TYPE 1, CLASS 1
9 CORE TEDLAR

Table II (Sheet 1 of 4)
V2500 54-30-00 Page 13

Aug 1/09

(INCH)
10 OUTER SKIN PLY 0.0045 GLASS EPOXY FABRIC GROUP 1,
TYPE 1, CLASS 1
11 COMPOSITE 0.0145 GRAPHITE FABRIC GROUP 1, TYPE
OUTER SKIN PLY 2, CLASS 1, GRADE 1 AT 0º

V2500 54-30-00 Page 14

Aug 1/09

(INCH)
35 SKIN PLY 0.0045 GLASS EPOXY FABRIC GROUP 1,
TYPE 1, CLASS 1
36 BARRIER 0.0045 TEDLAR
TYPE 1, CLASS 1

V2500 54-30-00 Page 15

Aug 1/09

(INCH)
TYPE 1, CLASS 1
39 BARRIER TEDLAR
TYPE 1, CLASS 1
(48.05 KG/M3)
42 DOUBLER 0.0032 TI-6AL-4V TITANIUM, ANNEALED,
MIL-T-9046, TYPE 3, COMP. C
43 DOUBLER 0.0032 TI-6AL-4V TITANIUM, ANNEALED,
MIL-T-9046, TYPE 3, COMP. C
44 UPPER ISLAND 0.0050 2024-0 CLAD ALUM SHEET
QQ-A-250/5, HEAT TREAT TO T42
45 BRACKET 0.0063 2024-0 CLAD ALUM SHEET
46 MID-ISLAND 0.0050 2024-0 CLAD ALUM SHEET
47 CLIP 0.0080 2024-0 CLAD ALUM SHEET
48 LOWER ISLAND 0.0050 2024-0 CLAD ALUM SHEET
49 CLIP 0.0080 17-4 PH CRES, AMS 5604, HEAT
TREAT TO H925
50 BRACKET 0.0080 2024-0 CLAD ALUM SHEET

V2500 54-30-00 Page 16

Aug 1/09
B B
4
3
A
C C
2 5
8 6
D D
SECTION A-A 13937

Figure 2A (Sheet 1 of 2)
V2500 54-30-00 Page 17

Aug 1/09
2 1
SECTION B-B 5
7 4 (5 PLACES)
2
1
SECTION C-C 4 5
7 (4 PLACES)
2
1
VIEW D-D 9
13938

V2500 54-30-00 Page 18

Aug 1/09

(INCH)
1 SKIN OUTER 0.020 2024-T3 BARE ALUM SHEET
QQ-A-250/4
2 CORE 0.352 5052 ALUMINUM HONEYCOMB NON-
PERFORATED, 1/4 INCH (6.35 MM)
CLASS 2, TYPE 1, 6.0 LBS/CU FT
(96.11 KG/M3)
3 CLOSURE 0.020 2024-0 BARE ALUMINUM SHEET
CLASS 2, TYPE 1, 22.1 LBS/CU
FT (354.04 KG/M3)
5 SKIN, INNER 0.050 2024-0 BARE ALUMINUM SHEET
(CHEM MILLED TO 0.020 IN.)
(97.72 KG/M3)
7 DOUBLER 0.032 2024-T3 BARE ALUMINUM SHEET
QQ-A-250/4
(97.72 KG/M3)
9 DOUBLER 0.050 2024-T3 BARE ALUMINUM SHEET
QQ-A-250/4

Table IIA
V2500 54-30-00 Page 19

Aug 1/09
B D F 12
C H
A 5 E 10 G
6
8
3
1
2 13
7 9
1 4
11
31
1 32
28 30 14
16 15
29
20
22 31
32
24
22
14
109 16
22
22
18
17
27 19
23
21
26 25
A C E 20 G
H
21
B D F 13517
Translating Sleeve Inner Barrel Assembly

V2500 54-30-00 Page 20

Aug 1/09
6 33
34
35
1
36
22
21 22 36
34
26 35
SECTION A - A
13518

V2500 54-30-00 Page 21

Aug 1/09
33
2
37
2
6
38
1
39
40
36 21 22
38
41 26
42
SECTION B - B
13519

V2500 54-30-00 Page 22

Aug 1/09
43
38
6
36
1
2
4
5
29
36
22
24
22
25 SECTION C - C
21 22
36
38 13520

V2500 54-30-00 Page 23

Aug 1/09
46 30 44
47 45
48 38
49
16
7
36
30
38
8
49
49
31
16 32
16
20
22
SECTION D - D
36
21 22
38
41
42
13521

V2500 54-30-00 Page 24

Aug 1/09
50
51
7
16
49
36 16
31
32
20
22
36
22 SECTION E - E
21
38
13522
41
42

V2500 54-30-00 Page 25

Aug 1/09
10
52
51
9
14
14
36
19
16
22 49
31
54 53 20 32 36
38
55
49
SECTION F - F
13523

V2500 54-30-00 Page 26

Aug 1/09
56
14 12
36
57
36
12
14
36
14
17
57
58
59
60
SECTION G - G
VIEW LOOKING FORWARD
13524

V2500 54-30-00 Page 27

Aug 1/09
13
57
56
20
36
58
59
60 17 36 15
57
SECTION H - H
13525

V2500 54-30-00 Page 28

Aug 1/09

(INCH)
1 CORE TI-3AL-2.5V, 6-20 RDCB-N
TITANIUM HONEYCOMB
CLASS 2, TYPE 1, 3 LB/CU.ft
(48.05 KG/M3)
(48.05 KG/M3)
(48.05 KG/M3)
5 CORE TI-6AL-2.5N, 6-45 RDCB-N
TITANIUM HONEYCOMB
(48.05 KG/M3)
(48.05 KG/M3)
(48.05 KG/M3)
(48.05 KG/M3)

Table III (Sheet 1 of 6)
V2500 54-30-00 Page 29

Aug 1/09

(INCH)
(48.05 KG/M3)
(48.05 KG/M3)
(48.05 KG/M3)
(48.05 KG/M3)
TITANIUM HONEYCOMB
(48.05 KG/M3)
16 CORE TI-3AL-2.5V. 6-20 RDCB-N
TITANIUM HONEYCOMB
CLASS 2, TYPE 1, 22.1 LB/CU.ft
(10.02 KG/M3)
(48.05 KG/M3)

V2500 54-30-00 Page 30

Aug 1/09

(INCH)
(48.05 KG/M3)
TITANIUM HONEYCOMB
(48.05 KG/M3)
TITANIUM HONEYCOMB
TITANIUM HONEYCOMB
(48.05 KG/M3)
(48.05 KG/M3)
26 SPACER 0.600 PHENOLIC LAMINATE, MIL-P-3115
(48.05 KG/M3)
TITANIUM HONEYCOMB

V2500 54-30-00 Page 31

Aug 1/09

(INCH)
(48.05 KG/M3)
TITANIUM HONEYCOMB
31 SPLICE 0.0045 GLASS EPOXY FABRIC GROUP 1,
TYPE 1, CLASS 1
32 SPLICE 0.0045 GLASS EPOXY FABRIC GROUP 1,
TYPE 1, CLASS 1
33 DOUBLER 0.032 TI-6AL-4V TITANIUM, AMS 4911,
ANNEALED
34 SKIN PLY 0.0145 GRAPHITE EPOXY FABRIC GROUP 1,
36 ACOUSTIC SKIN 0.0435 ACOUSTIC WOVEN WIRE (CRES) AND
NPT GRAPHITE SKIN-PERFORATED*
37 SKIN 0.033 2 PLIES GRAPHITE FABRIC* - 1
PLY GLASS FABRIC*
38 DOUBLER 0.029 2 PLIES GRAPHITE FABRIC*

V2500 54-30-00 Page 32

Aug 1/09

(INCH)
ANNEALED
44 COMPOSITE SKIN 0.0045 GLASS EPOXY FABRIC GROUP 1,
PLY TYPE 1, CLASS 1
PLY TYPE 1, CLASS 1
PLY TYPE 1, CLASS 1
49 MID SKIN 0.029 2 PLIES GRAPHITE FABRIC*
ANNEALED
51 FILLER
ANNEALED
(48.05 KG/M3)
56 SKIN 0.2755 19 PLIES GRAPHITE FABRIC - 1
PLY GLASS FABRIC
57 AFT SKIN 0.029 2 PLIES GRAPHITE FABRIC *

V2500 54-30-00 Page 33

Aug 1/09

(INCH)
59 SKIN PLY TEDLAR
*SKIN IS REINFORCED IN OTHER

AREAS WITH ADDITIONAL PLIES OF
GRAPHITE FABRIC AND FIBERGLASS

V2500 54-30-00 Page 34

Aug 1/09
7
1
2 6
F 8 B
A
E
G H
3 4 J 7
9
H
2 J
E G
10
F
3
11
2
20 D D
12
2 SEE G-G
SEE F-F
SEE E-E H
2 H B
14
3 A 13
3
3 3
13939

V2500 54-30-00 Page 35

Aug 1/09
18
19
12
K
1
15
26
10
18
10
15
19 N
26
16
18 L 12
17
1 L
SECTION A-A
13940

V2500 54-30-00 Page 36

Aug 1/09
25
22
18
8
25
10
9
22
18
R
SECTION B-B 13941

V2500 54-30-00 Page 37

Aug 1/09
1
10
2
18
12
2
15
SECTION C-C 18
15
12
12
18
10
15
10
1
1
16
N M
13942

V2500 54-30-00 Page 38

Aug 1/09
14
7 9 8
10
SECTION D-D
18 18
19 19
24
22
23
3
3 10 18
1
1 1
21
10
20 5
18
12
10 12
SECTION G-G
21
SECTION E-E SECTION F-F

13943

V2500 54-30-00 Page 39

Aug 1/09
24
23 25
25
25
22
25 22
18 18
10
8
10
8
6
6
7
SECTION H-H SECTION I-I
10
18
22
SECTION J-J 13944

V2500 54-30-00 Page 40

Aug 1/09

(INCH)
1 SKIN 0.071 2024-0 BARE ALUM SHEET
QQ-A-250/4 HEAT TREAT TO T42
(CHEM MILLED TO 0.050/0.020 IN.)
2 CORE 0.900 5052 ALUMINUM HONEYCOMB
(36.85 KG/M3)
(86.51 KG/M3)
(97.72 KG/M3)
(86.51 KG/M3)
(86.51 KG/M3)
(36.85 KG/M3)
(CHEM MILLED TO 0.050/0.025 IN.)
(96.12 KG/M3)
10 SKIN 0.025 2024-T3 BARE ALUM SHEET
QQ-A-250/4 PERFORATED, HEAT
TREAT TO T42

Table IIIA (Sheet 1 of 3)
V2500 54-30-00 Page 41

Aug 1/09

(INCH)
(97.72 KG/M3)
(354.04 KG/M3)
(86.51 KG/M3)
(36.85 KG/M3)
(86.51 KG/M3)
(86.51 KG/M3)
(86.51 KG/M3)
18 DOUBLER 0.071 2024-0 BARE ALUM SHEET
(354.04 KG/M3)

V2500 54-30-00 Page 42

Aug 1/09

(INCH)
(129.76 KG/M3)
(354.04 KG/M3)
(354.04 KG/M3)
24 DOUBLER 0.080 2024-T3 BARE ALUM SHEET,
25 DOUBLER 0.050 2024-T3 BARE ALUM SHEET,
26 SPLICE 0.032 2024-T3 BARE ALUM SHEET,
QQ-A-250/4

V2500 54-30-00 Page 43

Aug 1/09
13534
Left Thrust Reverser C-Duct Inner Barrel

V2500 54-30-00 Page 44

Aug 1/09
13535

V2500 54-30-00 Page 45

Aug 1/09
13536

V2500 54-30-00 Page 46

Aug 1/09
13537

V2500 54-30-00 Page 47

Aug 1/09

V2500 54-30-00 Page 48

Aug 1/09

V2500 54-30-00 Page 49

Aug 1/09

V2500 54-30-00 Page 50

Aug 1/09

(INCH)
1 STRAP 0.062 2024-0 BARE ALUM SHEET
QQ-A-250/4
4 CORE 5052 ALUMINUM HONEYCOMB NON-
PERFORATED, 3/8 INCH (9.52 MM),
(48.05 KG/M3)
(91.31 KG/M3)
CLASS 2, TYPE 1, 4.4 LBS/CU.FT
(70.49 KG/M3)

Table IV (Sheet 1 of 7)
V2500 54-30-00 Page 51

Aug 1/09

(INCH)
(59.27 KG/M3)
16 ACOUSTIC SKIN PRE S/N 5001
16A SKIN 0.045 2024-T3 BARE ALUM PERFORATED
SHEET QQ-A-250/4, POST S/N 5001
SHEET QQ-A-250/4, POST S/N 5001
18 CORE 5052 ALUMINUM HONEYCOMB
CLASS 2, TYPE 1, 3.7 LBS/CU.ft
(59.27 KG/M3)
(70.49 KG/M3)

V2500 54-30-00 Page 52

Aug 1/09

(INCH)
(48.05 KG/M3)
(70.49 KG/M3)
SHEET, QQ-A-250/4, POST S/N
5001
(48.05 KG/M3)
(48.05 KG/M3)
SHEET, QQ-A-250/4, POST S/N
5001

V2500 54-30-00 Page 53

Aug 1/09

(INCH)
38 CLOSURE 0.032 2024-0 BARE ALUM SHEET
40 CORE 5052 ALUMINUM HONEYCOMB FLEX
CORE 8.0 LBS/CU.ft (126 KG/M3)
41 SUPPORT RING 2024-0 ALUM EXTRUSION,
43 STRAP 0.020 2024-0 BARE ALUM SHEET
(48.05 KG/M3)
(128.7 KG/M3)
47 FILLER 0.015 2024-0 BARE ALUMINUM SHEET
PERFORATED 1/8 INCH (3.17 MM),
(57.24 KG/M3)
49 DOUBLER 0.050 2024-0 BARE ALUMINUM SHEET
50 CLOSURE 0.040 CRES TYPE 321 SHEET, AMS 5510

V2500 54-30-00 Page 54

Aug 1/09

(INCH)
(128.7 KG/M3)
52 CLOSURE 0.040 CRES TYPE 321 SHEET, AMS 5510
56 STRAP 0.040 2024-0 BARE ALUMINUM SHEET
(128.7 KG/M3)
62 CORE 5052 ALUMINUM ALLOY HONEYCOMB
FLEX CORE, F80-.0025 HEXCEL,
8.0 LBS/CU.ft (126 KG/M3)
(24.1 KG/M3)

V2500 54-30-00 Page 55

Aug 1/09

(INCH)
64 SPLICE 0.071 2024-0 BARE ALUMINUM SHEET
65 CORE 5052 ALUMINUM HONEYCOMB, NON-
(352 KG/M3)
(352 KG/M3)
(70.49 KG/M3)
(352 KG/M3)
(352 KG/M3)
PERFORATED, 1/8 INCH
22 LBS/CU.ft (352 KG/M3)

V2500 54-30-00 Page 56

Aug 1/09

(INCH)
(129.76 KG/M3)
(104.13 KG/M3)
(129.76 KG/M3)
(59.2 KG/M3)
81 CORE 5052 ALUMINUM ALLOY. F80-.0025
HEXCEL, 8.0 LBS/CU.ft
(128.16 KG/M3)
82 CORE 5052 ALUMINUM ALLOY. F80-.0025
HEXCEL, 8.0 LBS/CU.ft
(128.16 KG/M3)

V2500 54-30-00 Page 57

Aug 1/09
Right Thrust Reverser C-Duct Inner Barrel

V2500 54-30-00 Page 58

Aug 1/09
C
D
13542B

V2500 54-30-00 Page 59

Aug 1/09
15
38
14
41 5
41
37
15
42
40
43
39
39
19
45
44
17
46
47
48
SECTION A-A
18
13543

V2500 54-30-00 Page 60

Aug 1/09
37
49
41 5
41
15 42
51 50
39
45
39
5
19
52
17
53
SECTION B-B
54
18
13544

V2500 54-30-00 Page 61

Aug 1/09
55 6
56
4
3
57
58
15 7
9
28
45
59
27
60 20 22
28 25 5
61
21
SECTION C-C
13545A

V2500 54-30-00 Page 62

Aug 1/09
4
2 3
57
58
64 7
67
33
69 65
34
70
24 63
71 59 66
73
30
62 7
75
15
76
67
72 15
74 77 68
78
5
15
79
24
80 29
75
81
82
25
28
27
SECTION D-D 13546A

V2500 54-30-00 Page 63

Aug 1/09

(INCH)
2 SKIN 0.032 2024-0 BARE ALUMINUM SHEET
(70.49 KG/M3)
5A SKIN 0.025 2024-T3 BARE ALUMINUM PERFORATED
SHEET, QQ-A-250/4, POST S/N 5001
(48.05 KG/M3)
10 SKIN 0.025 2024-T3 BARE ALUMINUM SHEET
(91.31 KG/M3)
12 SKIN 0.025 2024-T3 BARE ALUMINUM SHEET

Table V (Sheet 1 of 7)
V2500 54-30-00 Page 64

Aug 1/09

(INCH)
(48.06 KG/M3)
(48.06 KG/M3)
(70.49 KG/M3)
(48.06 KG/M3)
(59.27 KG/M3)

V2500 54-30-00 Page 65

Aug 1/09

(INCH)
(70.49 KG/M3)
(59.27 KG/M3)

V2500 54-30-00 Page 66

Aug 1/09

(INCH)
(59.27 KG/M3)
(48.06 KG/M3)
41 CLOSURE 0.090 6AL-4V TITANIUM SHEET, AMS 4911
(59.27 KG/M3)
43 CORE 5052 ALUMINUM HONEYCOMB, HEXCEL
FLEX CORE, 25 LBS/CU.ft
(400.5 KG/M3)
FLEX CORE, 8.0 LBS/CU.ft
(128.16 KG/M3)
46 DOUBLER 0.040 2024-0 BARE ALUMINUM SHEET,
(400.5 KG/M3)
(48.06 KG/M3)

V2500 54-30-00 Page 67

Aug 1/09

(INCH)
(59.27 KG/M3)
(400.5 KG/M3)
(400.5 KG/M3)
(352.44 KG/M3)
FLEX CORE, 8.0 LBS/CU.ft
(128.16 KG/M3)
(104.13 KG/M3)
(352.44 KG/M3)

V2500 54-30-00 Page 68

Aug 1/09

(INCH)
PERFORATED, 3.16 INCH (4.76 MM),
(70.49 KG/M3)
(352.44 KG/M3)
(129.76 KG/M3)
(129.76 KG/M3)
(129.76 KG/M3)

V2500 54-30-00 Page 69

Aug 1/09

(INCH)
(129.76 KG/M3)
(104.13 KG/M3)
(129.76 KG/M3)
79 CORE 5052 ALUMINUM HEXCEL FLEX CORE,
F80-.0025, 8.0 LBS/CU.ft
(128.16 KG/M3)
(129.76 KG/M3)
81 CORE 5052 ALUMINUM HEXCEL FLEX CORE,
F80-.0025, 8.0 LBS/CU.ft
(128.16 KG/M3)

V2500 54-30-00 Page 70

Aug 1/09
Thrust Reverser Torque Box Assembly

V2500 54-30-00 Page 71

Aug 1/09

V2500 54-30-00 Page 72

Aug 1/09
10
11 18
12 20
17 19
21
16
15
14
DETAIL I
13
17
18,19
22
23
20,21
24
DETAIL II
13549

V2500 54-30-00 Page 73

Aug 1/09

(INCH)
1 V = BLADE 2024-0 EXTRUDED ALUMINUM BAR,
2 SEAL SILICONE RUBBER, 22-R-765, CLASS
2b, GRADE 50
3 SEAL RETAINER MAKE FROM S700F0996-1
4 FRAME 0.032 TI-6AL-4V, TITANIUM SHEET, AMS
4911
5 INNER FAIRING SEE TABLE VIC
ASSEMBLY
4911
7 OUTER FAIRING GRAPHITE FABRIC MATERIAL, GROUP
ASSEMBLY 1, TYPE 2, CLASS 1, GRADE 1,
15 PLY
8 RUBSTRIP 0.040 2024-T3 CLAD ALUMINUM SHEET,
QQ-A-250/5
9 CONE ASSEMBLY GRAPHITE FABRIC MATERIAL, GROUP
1, TYPE 2, CLASS 1, GRADE 1,
33 PLY
25 SHIM .000 TO USE LIQUID SHIM
.030
.030 TO USE SOLID AND/OR LAMINATED SHIMS

.090 IN COMBINATION WITH LIQUID SHIM
LIMITED TO .030 MAX THICKNESS,
LAMINATED SHIM MIL-S-22499 COMP
I TYP III CLASS 2 SOLID SHIM
2024-T3 SHEET 00-A250/4
Thrust Reverser Torque Ring Fairing - Graphite Fiber

Table VI
V2500 54-30-00 Page 74

Aug 1/09

(INCH)
1 V = BLADE 2024-0 EXTRUDED BAR, AMS4165,
QQ-A-200/3, HEAT TREAT T62
ALTERNATE MATERIAL: 2024-0
ROLLED BAR PER QQ-A-225/6
2b, GRADE 50
4911
5-6 INNER FAIRING 0.05 2024-0 ALUMINUM ALLOY,
7 OUTER FAIRING GRAPHITE FABRIC MATERIAL, GROUP
ASSEMBLY 1, TYPE 2, CLASS 1, GRADE 1,
15 PLY
QQ-A-250/5
9 CONE ASSEMBLY GRAPHITE FABRIC MATERIAL, GROUP
1, TYPE 2, CLASS 1, GRADE 1,
33 PLY
.030

2024-T3 SHEET 00-A250/4
Thrust Reverser Torque Ring Fairing- One Piece Aluminum

Table VIA
V2500 54-30-00 Page 75

Aug 1/09

(INCH)
1 V = BLADE 2024-0 EXTRUDED BAR, AMS4165,
ALTERNATE MATERIAL: 2024-0
ROLLED BAR PER QQ-A-225/6
2b, GRADE 50
4911
5 INNER FAIRING 0.05 AMS-QQ-A-250/4, ALUMINUM ALLOY,
ASSEMBLY TEMPER 0, 2024-0 ALUMINUM SHEET,
6 FRAME 0.063 AMS-QQ-A-250/4, ALUMINUM ALLOY,
TEMPER 0, 2024-0 ALUMINUM SHEET,
7 OUTER FAIRING GLASS FABRIC MATERIAL, GROUP 1,
ASSEMBLY TYPE 1, CLASS 1, GRADE 1,
15 PLY
QQ-A-250/5
9 CONE ASSEMBLY GLASS FABRIC MATERIAL, GROUP 1,
TYPE 1, CLASS 1 AND CARBON
FABRIC, MATERIAL GROUP 1 TYPE 2,
CLASS 1

.030

2024-T3 SHEET 00-A250/4
Thrust Reverser Torque Ring Fairing- Two Piece Aluminum

Table VIB
V2500 54-30-00 Page 76

Aug 1/09

(INCH)
10 INNER FAIRING GRAPHITE FABRIC MATERIAL, GROUP
PLY 1, TYPE 2, CLASS 1, GRADE 1, +45º
PLY 1, TYPE 2, CLASS 1, GRADE 1, 0º
PLY 1, TYPE 2, CLASS 1, GRADE 1, -45º
17 CORE 0.040 SYNTACTIC CORE MATERIAL, TYPE 1,
GROUP 1, CLASS 40

Table VIC
V2500 54-30-00 Page 77

Aug 1/09
1 PRESSURE PANEL OUTER BARREL

ASSEMBLY ASSEMBLY
(SEE FIGURE 2) (SEE FIGURE 1)
3
2 4 5
A
C
B
INNER BARREL
D ASSEMBLY
A (SEE FIGURE 3)
6
13950
Translating Sleeve Assembly

V2500 54-30-00 Page 78

Aug 1/09
E
10
7
8
9
12
11
E 13
13 12
13
14
14
OUTER
BARREL
ASSEMBLY
13
14
12
13
15
14 13
12
INNER
BARREL 13
ASSEMBLY
14
14 13 13
G
12
13
10
12
8
9
16
11
G
13951
SECTION A-A

V2500 54-30-00 Page 79

Aug 1/09
17
9 PRESSURE
18 PANEL
ASSEMBLY
21 17
20
19 5
INNER BARREL
9 ASSEMBLY
SECTION B-B
17
INNER BARREL
ASSEMBLY 22
24
INNER BARREL
25 ASSEMBLY
23
SECTION C-C
26
20
27 28
SECTION D-D 13952

V2500 54-30-00 Page 80

Aug 1/09
OUTER BARREL
25 20 26 ASSEMBLY
19
30
29
7
34
33
32 8
31 INNER BARREL
ASSEMBLY
SECTION E-E
33
1
SECTION F-F
13953

V2500 54-30-00 Page 81

Aug 1/09
INNER BARREL PRESSURE PANEL

ASSEMBLY ASSEMBLY
35 8
25 26
1
H
16
29
20 26
OUTER BARREL
ASSEMBLY
SECTION G-G
36
37 38
39
45 37
43 44
40 41
41 41 42
42 42
H
(R. H. SIDE)
13954

V2500 54-30-00 Page 82

Aug 1/09

(INCH)
1 SEAL ZZ-R-765 SILICONE RUBBER CLASS
2, GRADE 50
2 ACCESS DOOR 0.125 2024-T3 BARE ALUMINUM SHEET,
QQ-A-250/4 (CHEM MILLED
0.045 IN.)
3 DOUBLER 0.080 2024-T3 CLAD ALUMINUM SHEET,
QQ-A-250/5
4 FRAME 0.071 2024-0 CLAD ALUMINUM SHEET,
QQ-A-250-5, HEAT TREAT TO T42
5 FAIRING 0.058 GRAPHITE FABRIC, 4 PLIES
6 PIN STOW 0.062 2024-0 CLAD ALUMINUM SHEET,
BRACKET QQ-A-250/5, HEAT TREAT TO T42
7 SLIDER, UPPER 2024-T8511 ALUMINUM EXTRUSION,
QQ-A-200/3
8 SEAL RETAINER 2024-0 ALUMINUM EXTRUSION,
9 SLIDER, INNER 2024-T3511 ALUMINUM EXTRUSION,
QQ-A-200/3
10 ACTUATOR 2014-T6 ALUMINUM FORGING,
FITTING AMS4134
11 0.032 2024-T3 CLAD ALUMINUM SHEET,
QQ-A-250/5
12 CLIP 0.080 2024-0 CLAD ALUMINUM SHEET,
13 HINGE 17-4PH CRES CASTING, AMS5343
14 ISLAND 0.050 2024-0 CLAD ALUMINUM SHEET,
15 LOCKOUT 2014-T652 ALUMINUM FORGING,
FITTING MIL-A-22771
16 SLIDER, LOWER 7075-T73 ALUMINUM FORGING,
MIL-A-22771
17 0.123 LAMINATED ALUMINUM, MIL-S-22499,
COMP 1, CLASS I, TYPE 2
18 SPACER L-P-513 PHENOLIC SHEET, TYPE PBE

Table VII (Sheet 1 of 3)
V2500 54-30-00 Page 83

Aug 1/09

(INCH)
19 INTERCOSTAL 0.063 2024-T3 CLAD ALUMINUM SHEET,
EXTENSION QQ-A-250/5
20 INTERCOSTAL 2024-T3511 ALUMINUM EXTRUSION,
QQ-A-200/3
22 DOUBLER GRAPHITE FABRIC
23 ANGLE 0.063 2024-0 CLAD ALUMINUM SHEET,
24 ZEE 0.071 2024-0 CLAD ALUMINUM SHEET,
25 ANGLE 0.080 2024-T3 CLAD ALUMINUM SHEET,
QQ-A-250/5
26 STIFFENER 2024-T3511 ALUMINUM EXTRUSION,
QQ-A-200/3
28 ANGLE 0.100 2024-0 CLAD ALUMINUM SHEET,
29 SHEAR PIN 0.880 718 INCONEL BAR, AMS5662,
HEAT TREAT COND II
31 SHEAR PIN FITTING 17-4PH CRES CASTING, AMS5343
32 BRACKET 0.100 2024-0 BARE ALUMINUM SHEET,
33 SEAL PLUG ZZ-4-765 SILICONE RUBBER,
CLASS 2A, GRADE 25
34 SPLICE 0.080 2024-T3 CLAD ALUMINUM SHEET,
QQ-A-250/5
35 SEAL RAMP 0.063 CP TITANIUM, AMS4900
36 LATCH KEEPER (RH) 17-4PH CRES CASTING, AMS5343
36 LATCH HOUSING 17-4PH CRES CASTING, AMS5343
(LH)

V2500 54-30-00 Page 84

Aug 1/09

(INCH)
37 PANEL 0.050 2219-0 CLAD ALUMINUM SHEET,
AMS4096, HEAT TREAT T62
38 SEAL RETAINER 0.025 321 CRES SHEET, COMP T1,
MIL-S-6721, ANNEALED
39 SEAL ZZ-4-765 SILICONE RUBBER,
CLASS 2, GRADE 50
40 DEFLECTOR 0.040 CP TITANIUM, AMS4096
41 PLATE 0.063 2024-T3 ALUMINUM CLAD SHEET,
00-A-250/5
COMP 1, TYPE II, CLASS 2
43 CHANNEL 0.032 2219-0 CLAD ALUMINUM SHEET,
AMS4096, HEAT TREAT TO T62
44 SUPPORT 0.032 2219-0 CLAD ALUMINUM SHEET,
45 CHANNEL 0.025 2219-0 CLAD ALUMINUM SHEET,

V2500 54-30-00 Page 85

Aug 1/09
OUTER BARREL
ASSEMBLY
PRESSURE PANEL (SEE FIGURE 1)
ASSEMBLY
(SEE FIGURE 2A)
A 1 2
INNER BARREL
ASSEMBLY
(SEE FIGURE 3A)
13945

V2500 54-30-00 Page 86

Aug 1/09
3 C
4 8
5 9
6
10
C
7 OUTER BARREL
ASSEMBLY
INNER BARREL
ASSEBMLY 6
D D
11
6
12
E
10
5 9
E
VIEW A-A 13946

V2500 54-30-00 Page 87

Aug 1/09
12 OUTER BARREL
ASSEMBLY
22 21
3
18 17 16 15 14 13
20 19 INNER BARREL 5 6
VIEW C-C ASSEMBLY
17
5
28
4
24 23
10
25
6
PRESSURE PANEL
29 ASSEMBLY
2 30
26
27
10 INNER BARREL
ASSEMBLY
27
OUTER BARREL
ASSEMBLY
VIEW D-D
VIEW B-B
13947

V2500 54-30-00 Page 88

Aug 1/09
36
34 F 37 INNER BARREL
38 4
18 17 ASSEMBLY
28
34
33 35 5
3
32
F 31
27
VIEW E-E
OUTER BARREL
ASSEMBLY
INNER BARREL
ASSEMBLY (RH)
35 34
35
39
35
40
35 34
INNER BARREL
ASSEMBLY (LH)
VIEW F-F 13948

V2500 54-30-00 Page 89

Aug 1/09

(INCH)
1 ACCESS DOOR 0.125 2024-T3 BARE ALUMINUM SHEET,
QQ-A-250/4
2 FAIRING 0.050 2024-0 BARE ALUMINUM SHEET,
QQ-A-250/4 HEAT TREAT T42
3 SLIDER, OUTER 2024-T3511 ALUMINUM EXTRUSION,
QQ-A-200/3
4 SEAL RETAINER 2024-T3511 ALUMINUM EXTRUSION,
QQ-A-200/3
5 SLIDER, INNER 2024-T3511 ALUMINUM EXTRUSION,
QQ-A-200/3
6 HINGE 17-4PH CRES CASTING, AMS5343,
H1000
7 CLOSURE 0.063 2024-0 BARE ALUMINUM SHEET,
8 CLOSEOUT 1.250 2024-T851 BARE ALUMINUM PLATE,
BRACKET QQ-A-250/4
9 ACTUATOR 2024-T6 ALUMINUM FORGING,
FITTING AMS4133
COMP 1, TYPE I, CLASS 1
11 LOCKOUT 2024-T652 ALUMINUM FORGING,
FITTING MIL-A-22771
12 0.063 LAMINATED ALUM, MIL-S-22499,
13 BRACKET 1.000 2024-T351 BARE ALUMINUM PLATE,
QQ-A-250/4
17 LONGERON 0.080 2024-0 CLAD ALUMINUM SHEET,

Table VIIA (Sheet 1 of 3)
V2500 54-30-00 Page 90

Aug 1/09

(INCH)
18 SEAL PLUG ZZ-R-765 SILICONE RUBBER, CLASS
2A, GRADE 25
19 SHEAR PIN 718 INCONEL BAR, AMS5662
20 SHEAR PIN 17-4PH CRES CASTING, AMS5343,
FITTING H1000
24 CLIP 0.063 2024-0 BARE ALUMINUM SHEET,
26 DOUBLER 0.125 2024-T3 BARE ALUMINUM SHEET,
QQ-A-250/4
27 FILLER L-P-00513 PHENOLIC SHEET,
TYPE PBE
28 SEAL ZZ-R-765 SILICONE RUBBER, CLASS
2, GRADE 50
30 CLOSURE 2024-0 ALUMINUM EXTRUSION,
31 DEFLECTOR 0.040 TI-CP-40 SHEET, AMS4902,
ANNEALED
32 LATCH HOUSING 15-5PH CRES CASTING, AMS5346
(LH) H925
32 LATCH KEEPER 15-5PH CRES CASTING, AMS5346
(RH) H925
33 SUPPORT 0.025 2219-0 ALUMINUM SHEET,
CHANNEL QQ-A-250/30, HEAT TREAT T62
34 SKIN 0.050 2219-0 ALUM SHEET, QQ-A-250/30,
HEAT TREAT T62

V2500 54-30-00 Page 91

Aug 1/09

(INCH)
35 SUPPORT 0.032 2219-0 ALUMINUM SHEET,
CHANNEL QQ-A-250/30, HEAT TREAT T62
36 0.186 LAMINATED ALUMINUM, MIL-S-22499
37 SHIM 0.063 2024-T3 BARE ALUMINUM SHEET,
38 SEAL RAMP 0.063 CP TITANIUM, AMS4900
39 SEAL RETAINER 0.025 321 CRES SHEET, COMP T1,
MIL-S-6721 ANNEALED
40 SEAL HI-TEMP SILICONE RUBBER ZZ-R-765
CLASS 2B GRADE 50

V2500 54-30-00 Page 92

Aug 1/09
2
3
13949
Blocker Door Assembly

Figure 8
V2500 54-30-00 Page 93

Aug 1/09

(INCH)
1 BLOCKER DOOR 2024-0 BARE ALUMINUM PLATE,
2 BUSHING A286 CRES, AMS5732
3 SPRING 0.050 718 INCONEL SHEET, AMS5596
HEAT TREAT COND II
Blocker Door Assembly

Table VIII
V2500 54-30-00 Page 94

Aug 1/09
THRUST REVERSER -ALLOWABLE DAMAGE
1. Introduction
This section contains the allowable damage limits for both sheet
metal and bonded panel structural components of the V2500 Thrust
Reverser. Any damage which is found to be more than the allowable
damage limits should be repaired in accordance with the procedures
found in 54-30-00, Repairs, Page block 201.
2. Zones
Each of the individual components is divided into zones. The zones

which are affected by the different types of allowable damage are
identified in the Figures and tables which follow.
The information in this section is given in three paragraphs.

Paragraph A gives general information about allowable damage,
structure material, and damage types. Paragraph B gives the allowable
damage limits for the Translating Sleeve. Paragraph C gives the
allowable damage limits for the C-Duct fixed structure.
A. General

may be returned to service without repair. Damage
permitted by these data will have no significant effect on
the strength or fatigue life of the structure, which will
still be able to fulfill its design function. The types of
allowable damage permitted are defined and brief
descriptions are given of the cleanup procedures needed to
either prevent damage propagation or improve the
aerodynamic smoothness of the damaged part.
V2500 54-30-00 Page 101

Aug 1/09
(2) Material Types - The basic material used in the

construction of the thrust reverser components is
aluminum. It makes up the bonded panel construction of the
thrust reverser translating sleeve and the sheet metal and
bonded panel construction of the C-duct inner barrel. In
addition, the outer skin of the translating sleeve is made
up of layered plies of graphite and fiberglass material.
(3) Damage - All damage limits assume that exposed edges do

not extend above the skin contour. Any such damage should
be reworked to remove or feather the extensions. Holes and
cracks in the pressure boundaries must be sealed with
applicable tape material. Allowable damage is classified
as either unlimited usage or time limited.
(a) Unlimited usage damage is defined as minor damage

which does not affect the structural integrity or
functional capability of the component and which needs
no repairs over the aircraft design life.

design life of the component. Therefore, damage must
be permanently repaired no later than the next
maintenance “C” check. The location and size of the
“A” check to make sure that the damage has not grown
beyond the time limited damage allowances.
(4) Damage types - the types of allowable damage permitted on

the thrust reverser components are define below. They
apply only to the parent material and do not include
damage to surface finishes such as paint.
(a) Abrasion - An abrasion is a damage area of any size

which results in a cross sectional area change because
the area was scuffed, rubbed, scraped, or had other
surface erosion. An abrasion usually appears rough and
irregular.
V2500 54-30-00 Page 102

Aug 1/09

results in a cross sectional area change. It is
usually caused by contact with a relatively sharp
object which produces a continuous, sharp or smooth
channel-like groove in the material.

Consider a series of nick in a line to be a gouge.

(e) Crack - A crack is a partial fracture or complete

break in the material and produces a most significant
cross sectional area change. It usually appears as an
irregular line.

(g) Rip/Tear (Woven Wire) - A rip or a tear in the woven

wire of an acoustic bonded panel is a sharp continuous
separation of the wire fibers.
(h) Hole - A hole is a complete penetration of the

material.
(i) Disbond - A disbond is a separation of the face sheet

(j) Delamination - A delamination is the separation of two

(k) Missing Rivet - Absence of rivet from fastener hole.
(l) Loose Rivet - Ineffective fastener.
V2500 54-30-00 Page 103

Aug 1/09
B. Translating Sleeve Composite Structure
(1) Allowable Damage - Configuration 1 (See Table 101)
NOTE: For configuration 2 see para (2)
The allowable damage zones for the Thrust Reverser

Translating Sleeve composite structures are:
TS1 - Area 5.0 in. (127 mm) or less from the upper or lower
sliders on the Outer Barrel and Fairing, Pressure Shelf and
Inner Barrel.
TS2 - Area 1.0 in. (25.4 mm) or less from the Pressure Shelf
fore and aft edges.
TS3 - 3.0 in. (76.2 mm) from forward and aft edges of the
Translating Sleeve.
TS4 - Inner Barrel perforated composite sheet (NPT) inner

skin surface of the titanium honeycomb sandwich.
TS5 - Solid laminate composite outer skin of the Outer

Barrel and Fairing.
TS6 - Composite skin and aluminum core frames of the Outer

Barrel.
TS7 - Inner Barrel composite outer skin surface of the

titanium honeycomb sandwich.
TS8 - Areas 2.0 in. (50.08 mm) or less from the Translating
Sleeve Inner and Outer Barrel joint.
TS9 - Areas 2.0 in. (50.08 mm) or less from the fitting
that attaches the actuator to the Translating Sleeve.
TS10 - Full depth composite skin/aluminum honeycomb

sandwich Pressure Shelf.
V2500 54-30-00 Page 104

Aug 1/09
Thrust Reverser Translating Sleeve Zones

Figure 101
V2500 54-30-00 Page 105

Aug 1/09
NOTE: See Figures 102 and 103 for limitations where damage is not
allowed
Abrasion All Damage allowed to Finishes only Operator
Zones surface resin only. option-
Unlimited use prevent
No fiber damage. growth
For TS7, See
Apply applicable Figure 102 where
sealing tape to damage is
protect damage area allowed.
from moisture.
Replace the tape if For TS10, See
it becomes peeled or Figure 103 where
damaged. damage is
allowed.
Crack TS5 No cracks within 3.0 in. (76.2 mm) Airplane
TS10 10.0 in. (254.0 mm) max. length “A”
of any other crack allowed. check
damage.
For TS10, See
Maximum of 5 cracks Figure 103 where
per barrel half. damage is
allowed.
Cracks wider than
0.1 in. (2.54 mm) Time Limited
are treated as
holes.
Cracks 0.01 in.
(0.254 mm) deep or
less are treated the
same as scratches.
Translating Sleeve Allowable Damage Limits

Table 101 (Sheet 1)
V2500 54-30-00 Page 106

Aug 1/09
Crack Cont’d For metals, stop
drill both ends of Unlimited use Airplane
the cracks per SRM of terminated “A” check
54-02-00, Stop Drill crack between
Cracks. any two fasteners
in a joint of ten
Apply the applicable or more
sealing tape to fasteners.
protect the crack
damage area from Time limited
moisture. Replace
the tape if it
becomes peeled or
damaged.
Repair at next “C”

check
Delamination TS5 No two within 10.0 3.0 in. (76.2 mm) Airplane
/Disbond TS7 in. (254.00 mm). max. length in “A” check
TS10 any direction.
Maximum of 5
delamination/ For TS7, See
disbonds per barrel Figure 102 where
half. Protect damage damage is
from moisture by allowed.
applying appropriate
sealing tape. For TS10, See
Replace the tape if Figure 103 where
it becomes peeled or damage is
damaged. allowed.
Repair all damage at Time limited.

next “C” check.

Table 101 (Sheet 2)
V2500 54-30-00 Page 107

Aug 1/09
Gouge/ TS5 No two within 10.0 in. 0.01 in. Airplane
Scratch TS6 (254.0 mm). (0.254 mm) max. “A” check
TS7 depth, 10.0 in.
TS9 Maximum of 10.0 gouges (254.0 mm) max.
TS10 and 10.0 scratches per length, 0.1 in.
barrel half. (2.54 mm) max.
width.
Apply the applicable
sealing tape to the For TS7, See
damage area to protect Figure 4 where
it from moisture. damage is
Replace the tape if it allowed.
becomes peeled or
damaged. For TS10, See
Figure 103
Scratched deeper than where damage is
25% of material allowed.
thickness are treated
as cracks. Unlimited use.

Table 101 (Sheet 3)
V2500 54-30-00 Page 108

Aug 1/09
Hole/Dent TS5 No two within 10.0 in. For TS7, 1.0 Airplane
TS7 (254.0 mm). Max. of 5 in. diameter “A” check
TS10 holes per barrel half. hole max. See
Cracks wider than 0.10 Figure 4 where
in. (2.54 mm) are to damage is
be treated as holes. allowed.
Apply the applicable For TS5 and

sealing tape to field area of
protect the damage TS10, 3.0 in.
area from moisture. (76.2 mm)
Replace the tape if it diameter hole
becomes peeled or max.
damaged.
For field area
Repair at next “C” of TS10, See
check Figure 103
where damage is
allowed.
Time limited

Table 101 (Sheet 4)
V2500 54-30-00 Page 109

Aug 1/09
Nick TS5 Max. of 14 nicks per 0.01 in. Airplane
TS6 square foot (92903 (0.254 mm) max. “A” check
TS7 square mm) of panel/ depth.
TS9 stiffener. Apply the
TS10 applicable sealing 0.10 in.
tape to the damage (2.54 mm) max.
area to protect it width or length.
from moisture.
Replace the tape if For TS7, See
it becomes peeled or Figure 4 where
damaged. damage is
allowed.
For TS10, See

Figure 103 where
damage is
allowed.
Unlimited use.

Table 101 (Sheet 5)
V2500 54-30-00 Page 110

Aug 1/09
TS7 Inner Barrel - Composite Outer Skin

Figure 102
V2500 54-30-00 Page 111

Aug 1/09
TS10 Pressure Shelf - Composite Outer Skin

Figure 103
V2500 54-30-00 Page 112

Aug 1/09
(2) Allowable Damage - (Configuration 2) (See Table 102)
The allowable damage zones for the Thrust Reverser

Translating Sleeve composite structures are:
TS1 - Area 5.0 in. (127 mm) or less from the upper or lower
sliders on the Outer Barrel and Fairing, Pressure Shelf and
Inner Barrel.
TS2 - Area 1.0 in. (25.4 mm) or less from the Pressure Shelf
fore and aft edges.
TS3 - 3.0 in. (76.2 mm) from forward and aft edges of the
Translating Sleeve (Land Areas - Skin only).
TS4 - Inner Barrel aluminum perforated inner skin surface

of the aluminum honeycomb sandwich.
TS5 - Solid laminate composite outer skin of the Outer

Barrel and Fairing.
TS6 - Composite skin and aluminum core frames of the Outer

Barrel.
TS7 - Inner Barrel aluminum outer skin surface of the

aluminum honeycomb sandwich.
TS8 - Areas 2.0 in. (50.08 mm) or less from the Translating
Sleeve Inner and Outer Barrel joint.
TS9 - Areas 2.0 in. (50.08 mm) or less from the fitting
that attaches the actuator to the Translating Sleeve.
TS10 - Full depth composite skin/aluminum honeycomb

sandwich Pressure Shelf.
NOTE: See Figures 104,105, 106, 107, 108 and 109 for limitations where
damage is not allowed.
V2500 54-30-00 Page 113

Aug 1/09
Abrasion All For composites, Finishes only Operator
zones damage option-
allowed to surface Unlimited use prevent
resin only growth
No fiber damage
Apply applicable
sealing tape to
protect damage area
from moisture.
Replace the tape if
it becomes peeled or
damaged.
Crack TS5 No cracks within 0.25 in. (6.35 mm) Airplane
TS6 10.0 in. (254.0 mm) max. length in any “A” check
TS7 of any other crack direction allowed.
TS10 damage.
For TS7, See
Maximum of 5 cracks Figure 106 where
per barrel half damage is allowed.
Maximum wider than For TS10, See

0.1 in. (2.54 mm) Figure 108 where
deep or less are damage is allowed.
treated the same as
scratches Time limited

V2500 54-30-00 Page 114

Aug 1/09
Crack Cont’d For metals, stop Unlimited use of Airplane
drill both ends of terminated crack “A” check
the cracks per SRM between any two
54-02-00, Stop Drill fasteners in a
Cracks. joint of ten or
more fasteners.
For composites, apply
the applicable Time limited
sealing tape to
protect the crack
damage area from
moisture. Replace the
tape if it becomes
peeled or damaged.
Repair at “C” check.

Delamination TS4 No delamination/ For TS4, TS5, Airplane
/Disbond TS5 disbond within 10.0 TS7 and field “A” check
TS7 in. (254. mm) of any areas of TS10,
TS10 other damage. 3.0 in. (76.2
mm) max length
Maximum of 5 in any
delaminations/ direction.
disbonds per barrel
half. For TS4 and TS7,
see Figure 104
Repair damage that where damage is
has exceeded max. allowed
size.

V2500 54-30-00 Page 115

Aug 1/09
Delamination Protect damage from For field area of
/Disbond moisture by TS10, See
Cont’d applying Figure 108 where
appropriate sealing damage is
tape. Replace the allowed.
tape if it becomes
peeled or damaged.
Repair all damage at Time limited.

next “C” check.

V2500 54-30-00 Page 116

Aug 1/09
Gouge/ TS4 No gouge/scratch 0.01 in. (0.254 Airplane
Scratch TS5 within 10 in. (254.0 mm) max. depth, “A” check
TS6 mm) of any other 10.0 in (254.0
TS7 damage. mm) max. length,
TS9 0.1 in. (2.54 mm)
TS10 Maximum of 10 gouges max width.
and 10 scratches per
barrel half. For metallic
components 0.005
For composites, apply in. (0.127 mm)
the applicable deep or less in
sealing tape to the skins 0.020 in.
damage area to or 0.025 in.
protect it from (0.51 mm) or
moisture. replace the 0.025 in. (0.635
tape if it becomes mm) thick.
peeled or damaged. For skins thicker
than 0.025 in.
Scratches deeper than (0.635 mm) 0.010
25% of the material in. (0.254 mm)
thickness are treated deep or less
as cracks.
For TS4, See
Figure 105 where
damage is
allowed.
For TS7 and TS9,

See Figure 107
where damage is
allowed.

V2500 54-30-00 Page 117

Aug 1/09
Gouge/ For TS10, see
Scratch Figure 108 where
Cont’d damage is
allowed.
Unlimited use.
Hole/Dent TS4 No hole/dent within For TS4, TS5, TS7

TS5 10.0 in. (254.0 mm) and field areas
TS7 of any other damages. of TS10, 3.0 in.
TS10 Max. of 5 holes per (76.2 mm)
barrel half. Cracks diameter hole/
wider than 0.10 in. dent max.
(2.54 mm) are to be
treated as holes. For TS4 and TS7,
see Figure 104
Apply the applicable where damage is
sealing tape to allowed.
protect the damage
area from moisture. For TS10, see
replace the tape if Figure 108 where
it becomes peeled or damage is
damaged. allowed.
Repair at next “C” Time limited

check.

V2500 54-30-00 Page 118

Aug 1/09
Gouge/ TS4 No gouge/scratch 0.01 in. (0.254 mm) Airplane
Scratch TS5 within 10.0 in. max. depth, 10.0 in “A” check
TS6 (254.0 mm) of any (254.0 mm) max.
TS7 other damage. length, 0.1 in.
TS9 (2.54 mm) max
TS10 Maximum of 10 gouges width.
and 10 scratches per
barrel half. For metallic com-
ponents 0.005 in.
For composites, apply (0.127 mm) deep or
the applicable less in skins 0.020
sealing tape to the in. or 0.025 in.
damage area to (0.51 mm) or 0.025
protect it from in. (0.635 mm)
moisture. replace the thick.
tape if it becomes For skins thicker
peeled or damaged. than 0.025 in.
(0.635 mm) 0.010
Scratches deeper than in. (0.254 mm) deep
25% of the material or less
thickness are treated
as cracks. For TS4, see Figure
105 where damage is
allowed.
For TS7 and TS9,

see Figure 107
where damage is
allowed.

V2500 54-30-00 Page 119

Aug 1/09
Gouge/ For TS10, See
Scratch Figure 108 where
Cont’d damage is
allowed.
Unlimited use.
Hole/Dent TS4 No hole/dent within For TS4, TS5, Airplane
TS5 10.0 in. (254.0 mm) TS7 and field “A” check
TS7 of any other areas of TS10
TS10 damages. Max. of 5 3.0 in.(76.2 mm)
holes per barrel diameter hole/
half. Cracks wider dent max.
than 0.10 in. (2.54
mm) are to be
treated as holes.
For TS4 and TS7,
Apply the applicable See Figure 104
sealing tape to where damage is
protect the damage allowed.
area from moisture.
Replace the tape if
it becomes peeled or
damaged. For TS10, See
Figure 108 where
Repair at next “C” damage is
check. allowed.
Time limited.

V2500 54-30-00 Page 120

Aug 1/09
Nick TS4 Maximum of 14 nicks 0.01. (0.254 mm) Airplane
TS5 per square foot max. depth “A” check
TS6 (92903 mm²) of
TS7 panel/stiffener. For 0.10 in.
TS9 composites, apply (2.54 mm)
TS10 the applicable maximum width or
sealing tape to the length.
damage area to
protect it from For metallic
moisture. Replace components 0.005
the tape if it in. (0.127 mm)
becomes peeled or deep or less in
damaged. skins 0.020 in.
(0.51 mm) or
0.025 in.
(0.635 mm)
thick.
For skins
thicker than
0.025 in.
(0.635 mm) 0.010
in. (0.254 mm)
deep or less.
For TS4, See

Figure 105 where
damage is
allowed.

V2500 54-30-00 Page 121

Aug 1/09
Nick For TS7 and TS9,
Cont’d See Figure 107
where damage is
allowed.
For TS10, See

Figure 108 where
damage is
allowed.
Unlimited use.

V2500 54-30-00 Page 122

Aug 1/09
Inner Barrel - Inner Skin (TS4) and Outer Skin TS7

Damage Due to Dents, Delaminations and Holes
Figure 104
V2500 54-30-00 Page 123

Aug 1/09
Inner Barrel - Inner Skin (TS4)

Damage Due to Gouges, Nicks and Scratches
Figure 105
V2500 54-30-00 Page 124

Aug 1/09
Inner Barrel - Outer Skin (TS7)

Damage Due to Cracks Only
Figure 106
V2500 54-30-00 Page 125

Aug 1/09
Inner Barrel - Outer Skin (TS7 and TS9)

Damage Due to Gouges, Nicks and Scratches
Figure 107
V2500 54-30-00 Page 126

Aug 1/09
Pressure Shelf - Inner and Outer Skins (TS10)

Figure 108
V2500 54-30-00 Page 127

Aug 1/09
C. Thrust reverser fixed Structure - Allowable Damage (See Table

103)
The allowable damage zones for the Thrust Reverser fixed

structure are:
FS1 - Outer Skin, Aluminum perforated face sheet
FS2 - Inner Skin, Aluminum face sheet
FS3 - Outer and Inner Skin, Lower Bifurcation, Aluminum

face sheet
FS4 - Outer and Inner Skin, Upper Bifurcation, Aluminum

face sheet.
FS5 - 2.00 in. (50.8 mm) maximum from the upper and lower
bifurcation corner radii.
2.0 in. (50.8 mm) maximum from splices, or end

closures.
7.0 in (177.8 mm) maximum from “V” blade forward edge.
FS6 - if applicable, woven wire mesh (covers FS1)
CAUTION: NO DAMAGED ALLOWED IN ZONE FS5 (NO ALLOWABLE LIMITS)
NOTE: Make sure the fire shield is not damaged and replaced
after repair or inspection is performed on the hot side
of the fixed structure.
V2500 54-30-00 Page 128

Aug 1/09
Thrust Reverser Fixed Structure Zones

Figure 109
V2500 54-30-00 Page 129

Aug 1/09
Disbond FS1 Separated from other 3.0 in. (76 mm) Inspect
FS2 disbonds by a fully maximum every 600
FS3 bonded panel 4 times diameter. Flight
FS4 the diameter of the Hours, 750
disbond. No other Flight
damage on the Cycles or
opposite face sheet 100 days
opposed or Time limited
overlapped. Maximum 2
disbonds per 1.0ft²
(0.09 m²) of panel.
Minimum of 1.5 in.
(38.1 mm) from edges,
splices, joints and
fittings. Refer below
for restrictions on
allowable damage
areas.
Repair before next

6000 Flight Hours,
4500 Flight Cycles or
20 months, whichever
occurs first.
Thrust Reverser Fixed Structure Allowable Damage Limits

V2500 54-30-00 Page 130

Aug 1/09
Disbond Restrictions on Allowable Damage Areas
Cont’d -No Damaged Allowed
FS1 No disbond within 3.0 in. (76 mm) from

the forward edge and within 4.0 in
(101.6 mm) from bottom edge.
No disbond in the area between 12.7 in.
(322.6 mm) and 22.5 in. (571.5 mm)
measured from the forward edge.
No disbond within an area 16.5 in.
(419.1 mm) measured from the aft edge
by 24.0 in (609.6 mm) from the top
edge.
FS2 No disbond within 3.0 in. (76 mm) from

the forward edge.
No disbond in the area between 12.7 in.
(322.6 mm) and 22.4 in. (586.96 mm)
measured from the forward edge.
no disbond within 16.5 in (418 mm)
measured from the aft edge.
FS4 No disbond within a 2 in. (50.8 mm)

distance around the pre cooler duct
opening. No disbond within an area of 4
in. (101.6 mm) measured down from the
top edge by 42 in. (1067 mm) measured
from the aft edge. No disbond within
15.5 in. (394 mm) measured from the aft
edge.

V2500 54-30-00 Page 131

Aug 1/09
Dent FS1 No Face sheet 2 in. (50.8 mm) Inspect
FS3 thinning. maximum diameter. every 600
FS2 Core crush Flight
FS4 acceptable. 0.20 in. (5.08 mm) Hours, 750
No two within 3.0 in. max depth. Flight
(76.2 mm). Cycles or
Min. 1.5 in. (38.1 0.25 in. (6.35 mm) 100 days
mm) from edges, minimum radius.
splices, joints, and
fittings. Dent diameter to
dent depth ratio <
10
Unlimited Use
Gouge FS1 Surface damage of 1.5 in. (38.1 mm) Inspect
FS2 face sheet only. max. length every 600
FS3 No core crushed. Flight
FS4 No two gouges within 0.01 in. Hours, 750
3.0 in. (76 mm). (0.254 mm) max. Flight
Minimum distance of depth Cycles or
1.5 in. (38.1 mm) 100 days
from edges, splices, 0.1 in. (2.54 mm)
joints and fittings. max. width.
No sharp edges
allowed. Unlimited use

V2500 54-30-00 Page 132

Aug 1/09
Nick FS1 No two within 2.0 in. 0.5 in. Inspect
FS2 (50.8 mm). Min. 1.5 (12.7 mm) max. every 600
FS3 in. (38.1 mm) from length Flight
FS4 edges, splices, Hours, 750
joints and fittings. 0.01 in. Flight
No sharp edges (0.254 mm) max. Cycles or
allowed. depth 100 days
0.1 in.
(2.54 mm) max.
width.
Unlimited use
Rip/Tear FS6 No disbond of wire Inspect
Woven mesh from the 100% max. depth every 600
wire perforated face Flight
Mesh sheet. 0.25 in. Hours, 750
No two within 3.0 in. (6.35 mm) max. Flight
(76 mm). length. Cycles or
Minimum distance of 100 days
1.5 in. (38.1 mm)
from edges, splices, Unlimited use
joints and fittings.

V2500 54-30-00 Page 133

Aug 1/09
Scratch FS1 No two within 3.0 in. 1.5 in.(38.1 mm) Inspect
FS2 (76 mm). Min 1.5 in. max. length every 600
FS3 (38.1 mm) from edges, Flight
FS4 splices, joints and 0.01 in.(0.254 mm) Hours, 750
fittings. maximum depth Flight
If damage exceeds Cycles or
basic material 0.05 in. (1.27 mm) 100 days
thickness, consider max. width.
the damage as a
crack. Unlimited use
No sharp edges
allowed.
FS6 No disbond from the 1.5 in. (38.1 mm) Inspect
perforated face max. length every 600
sheet. Flight
0.005 in. Hours, 750
(0.127 mm) Flight
maximum depth. Cycles or
100 days
0.05 in. (1.27 mm)
maximum width.
Unlimited use

V2500 54-30-00 Page 134

Aug 1/09
Crack FS3 No two within 10.0 in. 1.0 in. Inspect
FS4 (254.0 mm). Stop drill (25.4 mm) every 600
crack (refer to maximum length. Flight
section Hours, 750
54-02-00). Apply speed Time limited. Flight
tape over damage area. Cycles or
Refer below for 100 days
restrictions on
allowable damage
areas.
Repair before 600

Flight Hours, 750
Flight Cycles or 100
days whichever occurs
first.
Restrictions on Allowable Damage Areas
- No Damage Allowed
FS3 No cracks within 7.7 in. (196 mm) by

3.0 in. (76 mm) measured down from the
top edge and 26.5 in. (673 mm) away
from forward edge.
No cracks within an area of 10 in. (254
mm) measured from the aft edge by 3.0
in. (76 mm) measured down from the top
edge. No cracks within 9.0 in. (229 mm)
away from aft edge.
FS4 No cracks within 3.5 in. (88.9 mm) from

forward edge of pre-cooler duct open-
ing.
No cracks within 2.0 in. (50.8 mm) on
top, aft and bottom edges of
pre-cooler duct opening.
No cracks within 24 in. (610 mm) from
aft edge.

V2500 54-30-00 Page 135

Aug 1/09
Partial FS1 No two within 10.0 in. 3.0 in. Inspect
Penetration/ FS2 (254.0 mm). No other (25.4 mm) max. every 600
Hole FS3 damage on opposite diameter Flight
FS4 skin surface within Hours, 750
10.0 in. (254 mm) Time limited Flight
No sharp edges Cycles or
allowed. 100 days
Apply speed tape over
damage area.
Refer below for
additional
requirements.
Repair before next

6000 flight hours,
4500 flight cycle or
20 months whichever
occurs.
Additional Requirements
FS2 Requires sealed patch repair prior to

engine operation. Refer to section
54-30-00.
Perform permanent repair at first
opportunity. Refer to SRM 54-30-00.
Full FS1 No full penetration None Inspect
Penetration/ FS2 holes allowed. every 600
Hole FS3 Flight
FS4 Hours, 750
Flight
Cycles or
100 days

V2500 54-30-00 Page 136

Aug 1/09
D. Thrust Reverser Structure - Allowable Damage (see Table 104)
(1) Composite Panel - Blank Cascade

(P/N: 745-0109; see Figure 110)
BC1 - Graphite Skin, Inner Panel Edges
2.0 in. (50.8 mm) or less from panel edges
BC2 - Graphite Skin, Inner
Field of panel, more than 2.0 in. (50.8 mm) from

panel edges
BC3 - Graphite Skin, Outer Panel Edges
BC4 - Graphite Skin, Outer
Field of panel, more than 2.0 in. (50.8 mm) from

panel edges
BC5 - Panel Sides (Sealant)
V2500 54-30-00 Page 137

Aug 1/09
Composite Panel - Blank Cascades Damage Zones

Figure 110
V2500 54-30-00 Page 138

Aug 1/09
Delamination/ BC1 No None.
Disbond BC2 delaminations or
BC3 disbonds allowed.
BC4
BC5
Dent BC1 No dents None.
BC3 allowed.
BC5
BC2 Maximum 3 dents 0.4 in 20 Months,

BC4 per panel surface. (10,2 mm) max 6000 Flight
Dents must be diameter. Hours or
separated from other 4500 Flight
damage by 10.0 in 0.04 in cycles,
(254 mm). No (1,0 mm) max whichever
delaminations or depth. occurs
disbonds allowed. first.
Thrust Reverser Structure - Allowable Damage Limits

V2500 54-30-00 Page 139

Aug 1/09
Nick/Gouge BC1 No None.
BC3 nicks/gouges
allowed.
BC5 No Unlimited
nicks/gouges use.
allowed.
Clean area with
CoMat 01-438. Fill
damage with CoMat
08-149, (Epocast
1617 A/B). Cure at
125°F (51.7°C) for 5
hours.
BC2 Maximum 3 gouges per 0.4 in. 20 Months,

BC4 panel surface. Nicks (10,2 mm) 6000 Flight
and Gouges must be max diameter. Hours or
separated from other 4500 Flight
damage by 0.04 in. cycles,
10.0 in. (254 mm). (1,0 mm) max whichever
No delaminations or depth. occurs
disbonds allowed. first.
Unlimited
use.

V2500 54-30-00 Page 140

Aug 1/09
Scratch BC2 No delamination 0.005 in. 20 Months,
BC4 from face sheet. (0.127) max 6000 Flight
depth Hours or
4500 Flight
0.4 in.(10,2 mm) cycles,
max length. whichever
occurs
Unlimited use. first.
Unlimited use.
BC5 No Scratches
allowed. Clean area
with CoMat 01-438.
Fill damage with
CoMat 08-149,
(Epocast 1617 A/B)
Cure at 125°F
(51.7°C) for 5
hours.
Crack BC1 No cracks allowed. None.
BC2
BC3
BC4
BC5
Partial BC1 No penetration None.
Penetration/ BC2 allowed.
Hole BC3
BC4
BC5
Full BC1 No penetration None.
Hole BC3
BC4

V2500 54-30-00 Page 141

Aug 1/09
E. Crossover Beam- Allowable Damage (See Table 105)
(1) Crossover Beam, Forward

(P/N: 740-0445-509; see Figure 110)
Zone 1 - Horizontal Cross-section of Beam
Zone 2 – Vertical Cross-section of Beam
Zone 3 – Bearing Housing, Beam Fitting Ends
Zone 4 – Guide Pins or Tang
V2500 54-30-00 Page 142

Aug 1/09
Crossover Beam, Forward

V2500 54-30-00 Page 143

Aug 1/09
Crossover Beam, Forward

V2500 54-30-00 Page 144

Aug 1/09
DAMAGE ZONE REQUIREMENTS ALLOWABLE INSPECTION

LIMITS INTERVALS
Cracks Zone 1 No cracks allowed.
Zone 2
Zone 3
Gouges, Zone 1 Repair damage per SPPM 0.025 in.
Scratches, Zone 2 Subtask 0.63 mm) max.
Nicks and 70-35-03-350-001. depth, 0.040
Abrasions. Blend damaged surface in. (1.0 mm)
to 10:1 ratio. max. length.
Apply Alodine and
Primer per SPPM Task
70-38-02-300-503.
Zone 3 Repair damage per SPPM 0.02 in.
Subtask (0.5 mm) max
70-35-03-350-001. depth, 0.25
Blend damaged surface in. (6.3 mm)
to 10:1 ratio. max. length.
Apply Alodine and
70-38-02-300-503.
Cracks Zone 4 Remove the damaged Cracks are Remove and
Tang to within 0.020 in contained in replace
(0,508 mm) of the Tangs only and Crossover
Crossover Fitting do not Beam no
cross-section surface encroach on to later than
per SPPM Subtask beam cross- next
70-35-03-350-001. section. scheduled
Perform Crack test per engine
SPPM change.
70-23-02-230-501 after
repair. Apply Alodine
and Primer per SPPM
Task 70-38-02-300-503.
Crossover Beam, Forward - Allowable Damage Limits
V2500 54-30-00 Page 145

Aug 1/09

LIMITS INTERVALS
Broken or Zone 4 Blend the broken Tang Damage is Remove and

Missing per SPPM Subtask contained in replace
Material 70-35-03-350-001. Tangs only and Crossover
Perform Crack test do not Beam no
per SPPM 70-23-02- encroach on to later than
230-501 after repair. the beam next
cross-section. scheduled
Apply Alodine and engine
Primer per SPPM change.
Subtask
70-38-02-300-503.
CAUTION: DO NOT BLEND INTO THE CROSSOVER BEAM
CROSS-SECTION. IF ANY CONTACT IS MADE IN
THE CROSS-SECTION AREA, THE CROSSOVER
BEAM MUST BE REPLACED.

V2500 54-30-00 Page 146

Aug 1/09

LIMITS INTERVALS
Gouges, Zone 4 Remove damage per 0.020 in.

Scratches, SPPM Subtask (0.508 mm)
Nicks and 70-35-03-350-001, maximum deep
Abrasions. achieve 10:1 blend before and
ratio. Remove after repair
material not to and damages
exceed 10 percent of are contained
parent material. in Tangs only
Maintain 0.25 in. and do not
(6,35 mm) corner encroach on to
radius. Maintain beam cross-
surface finish of 125 section.
RMS. If removed
material exceeds 10
percent of parent
material, remove Tang
to within 0.020 in
(0,508 mm) of the
Crossover Fitting
cross-section surface
per SPPM Subtask
70-35-03-350-001.
Perform Crack test
per SPPM 70-23-02-
230-501 after repair.
Apply Alodine and
70-38-02-300-503.
CAUTION: DO NOT BLEND INTO THE CROSSOVER BEAM
CROSS-SECTION. IF ANY CONTACT IS MADE IN
THE CROSS-SECTION AREA, THE CROSSOVER
BEAM MUST BE REPLACED.

V2500 54-30-00 Page 147

Aug 1/09
F. Thrust Reverser Structure - Allowable Damage (See Table

106)
(1) Composite Panel - Blank Cascade

(P/N: 745-0109; see Figure 110)
BC1 - Graphite Skin, Inner Panel Edges
BC2 - Graphite Skin, Inner
Field of panel, more than 2.0 in. (50.8 mm) from panel
edges
BC3 - Graphite Skin, Outer Panel Edges
BC4 - Graphite Skin, Outer
Field of panel, more than 2.0 in.in. (50.8 mm) from panel
edges
BC5 - Panel Sides (Sealant)
V2500 54-30-00 Page 148

Aug 1/09
Composite Panel – Blank Cascades Damage Zones

Figure 112
V2500 54-30-00 Page 149

Aug 1/09

LIMITS INTERVALS
Delamination/ BC1 No delaminations or None.

Disbond BC2 disbonds allowed.
BC3
BC4
BC5
Dent BC1 No dents allowed. None.

BC3
BC5
BC2 Maximum 3 dents per 0.4 in. (10,2 mm) 20 Months,

BC4 panel surface. max. diameter. 6000
Dents must be Flight
separated from other 0.04 in. (1,0 mm) Hours or
damage by 10.0 in. max. depth. 4500
(254 mm). No Flight
delaminations or Cycles,
disbonds allowed. whichever
occur
first.

V2500 54-30-00 Page 150

Aug 1/09

LIMITS INTERVALS
Nick/Gouge BC1 No nicks/gouges None. 20 Months,

BC3 allowed. 6000
Flight
Hours or
4500
Flight
BC5 No nicks/ gouges Unlimited use. Cycles,
allowed. Clean area whichever
with CoMat 01-438. occur
Fill damage with first.
CoMat 08-149,
(Epocast 1617 A/B).
Cure at 125°F
(51.7°C) for 5
hours.
0.4 in. (10,2

BC2 Maximum 3 gouges per mm) max
BC4 panel surface. length.
Nicks and Gouges
must be separated 0.014 in.
from other damage by (0,356 mm) max
10.0 in. (254 mm). depth.
No delaminations or
disbonds allowed. Unlimited use.

V2500 54-30-00 Page 151

Aug 1/09

LIMITS INTERVALS
Scratch BC2 No delamination from 0.005 in. (0,127) 20 Months,
BC4 face sheet. max depth. 6000 Flight
Hours or
0.4 in. (10,2 mm) 4500 Flight
max length. Cycles,
whichever
Unlimited use. occur
first.
Unlimited use.
BC5 No scratches
allowed. Clean area
with CoMat 01-438.
Fill damage with
CoMat 08-149,
(Epocast 1617 A/B).
Cure at 125°F
(51.7°C) for 5
hours.
Crack BC1 No cracks allowed. None.
BC2
BC3
BC4
BC5
Partial BC1 No penetration None.
Hole BC3
BC4
BC5
Full BC1 No penetration None.
Hole BC3
BC4
V2500 54-30-00 Page 152

Aug 1/09
G. Thrust Reverser Structure - Allowable Damage
(1) Translating Sleeve - Outer Barrel

(P/N 745-0025; See Figure 113)
(a) The entire row of rivets on the edge (circumferential)

of the Forward Split Line of the Translating Sleeve.
(b) The last nine (9) rivets at the outer panel skin
bottom edge (longitudinal), forward of the Forward
Split Line of the Translating sleeve.
(c) Acceptable Damage Limits:

It is acceptable to fly for two (2) flight cycles with
one (1) missing or loose rivet provided the adjacent
rivets are intact after the first flight cycle.
(d) Allowable Damage Mitigation:

Inspect the rivets adjacent to the missing or loose
rivet after the first flight.
(e) Repair Procedures:

Repair in accordance with the repair procedure found
in 54-30-00, REPAIR No. 048, Translating Sleeve
Missing Rivet and/or loose Rivet.
V2500 54-30-00 Page 153

Aug 1/09
Translating Sleeve
Figure 113
V2500 54-30-00 Page 154

Aug 1/09
GENERAL REPAIR
1. General
given

DISCARD CHEMICALS.


adhesive mixture.

Page 201
Feb 1/09

store in cool place until used.
NOTE: The useful life of a one-pound (453.59 gram)

mixture is approximately seven hours. Heat
accelerates both the adhesive mixture gel time and
cure time.
B. EA956 Adhesive

DISCARD CHEMICALS.

adhesive mixture.

NOTE: The useful life on a one-pound (453.59 gram)

mixture is approximately 30 minutes. Heat
cure time.

Page 202
Feb 1/09
C. EA934NA Adhesive

DISCARD CHEMICALS.

metal spatula and mix by hand to avoid heat sire in
adhesive mixture.


mixture is approximately 40 minutes at 77ºF
(25ºC). Heat accelerates both the adhesive mixture
gel time and cure time.
D. EA9390 Resin
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND

OBEY ALL SAFETY INSTRUCTIONS FOR THE CHEMICALS.
THESE INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET
(MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY
DISCARD CHEMICALS.

Page 203
Feb 1/09

adhesive mixture.

NOTE: The useful life of a 8.82 ounce (250 gram) mixture

is approximately 120 minutes. Heat accelerates
both the resin mixture gel time and cure time.
A. The thrust reverser is made of carbon/epoxy bonded structure.

This type of material is repaired with “wet-layup hot-bonded”
procedures. In these procedures, carbon fabric is soaked with
epoxy and put on the damaged area. Repair equipment (parting
film, bleeder and breather cloth, heat blanket, silicone rubber
sheet, and vacuum bag) are installed over the carbon fabric.
The repair is cured at high temperatures for a specified time,
after which the repair equipment is removed. The repair may
then be smoothed as necessary for an aerodynamic finish.
B. The number of carbon fabric repair plies used is equal to the

number of damaged plies. See the Structural Identification
section to find the number of plies in the damaged area. You
cannot examine the damaged skin to count the plies. Cured
carbon plies are very difficult to separate at ply interfaces.
C. A single ply of fiberglass is used on top of repairs exposed to

the free airstream. This is to permit the repair to be made
smooth for an aerodynamic finish.
D. Both the original skin and the repair material must be clean
and dry before the repair can be started. Water on the surface
or in the materials will make the repair weak. All water must be
removed before the repair can be done. Use heat lamps at 230ºF-
250ºF for one hour.

Page 204
Feb 1/09
4. Bonded Acoustic Panel Structure
Acoustic panels make up the air-wetted surfaces of the C-ducts. These

are the outer surface of the inner barrel and the inner surface of
the translating sleeve. Their main purpose is to reduce the noise
that comes from the fan exhaust. The panels are also the main load-
bearing structure for the thrust reverser.
The panels are made up of a bonded assembly of solid outer skins

(back sheet), perforated inner skins (face sheet), and aluminum core.
Woven wire cloth is bonded to the perforated inner skin of the panel.
it contributes to the noise reduction ability of the panel.

Page 205
Feb 1/09

P.O. Box 312
Catalyst L3 2850 Willow Pass Rd.
P.O. Box 312
Base Part A
Catalyst L3
Polyvinyl
Chloride
Resin System, Epoxy EA9390 Dexter Hysol Aerospace, Inc.
Base Part A
Catalyst Part B
Ketone

Table 201

Page 206
Feb 1/09
THRUST REVERSER - LIST OF APPROVED REPAIRS

Limits before you do repairs to acoustic areas of the Thrust
Reverser.
001 FIXED DUCT HEATSHIELD REPAIR

(VRS2005) (REF 78-32-49 LEFT C-DUCT)
(VRS2006) (REF 78-32-79 RIGHT C-DUCT)
002 FIXED DUCT ACOUSTIC PANEL PARTIAL PENETRATION REPAIR
003 FIXED DUCT ACOUSTIC PANEL FULL PENETRATION REPAIR
004 FIXED DUCT WOVEN WIRE SCRATCH, RIP OR TEAR REPAIR
005 FIXED DUCT ACOUSTIC PANEL BOND SEPARATION REPAIR
(VRS2013) DELETED-REFER TO V2500-NAC-78-0231 FOR DISPOSITION
(VRS2014)
006 FIXED DUCT ACOUSTIC PANEL PERFORATED SKIN CRACK REPAIR
007 FIXED DUCT ACOUSTIC PANEL OUTER PERFORATED SKIN SMALL
(VRS2017) HOLE REPAIR
(REF 78-32-79 RIGHT C-DUCT)
008 TRANSLATING SLEEVE OUTER BARREL LAMINATED SKIN FULL
(VRS2019) PENETRATION REPAIR
(VRS2020) (REF 78-32-46 LEFT TRANSLATING SLEEVE)
(REF 78-32-76 RIGHT TRANSLATING SLEEVE)

Page 201
Feb 1/09

009 FIXED DUCT ACOUSTIC PANEL SOLID SKIN CRACK REPAIR
010 FIXED DUCT ACOUSTIC PANEL PARTIAL PENETRATION THROUGH
THE SOLID INNER SKIN REPAIR
011 FIXED DUCT ALUMINUM SKIN/HONEYCOMB BOND SEPARATION
(VRS2025) REPAIR -
(VRS2026) DELETED-REFER TO V2500-NAC-78-0231 FOR DISPOSITION
012 SOLID INNER SKIN SMALL HOLE REPAIR – NOT FULLY THROUGH
(VRS2027) PANEL LEFT OR RIGHT FIXED DUCT ACOUSTIC PANEL
013 TRANSLATING SLEEVE OUTER BARREL FULL PENETRATION HOLE
(VRS2029) REPAIR
014 TRANSLATING SLEEVE OUTER BARREL PARTIAL PENETRATION
(VRS2031) REPAIR
015 TRANSLATING SLEEVE LAMINATED OUTER SKIN REPAIR
(VRS2034) (REF 78-32-76 RIGHT TRANSLATING SLEEVE)
016 TRANSLATING SLEEVE OUTER BARREL FORWARD/AFT EDGE
(VRS2035) REPAIR
017 OUTER BARREL COMPOSITE SKIN DELAMINATION REPAIR LEFT
(VRS2037) OR RIGHT TRANSLATING SLEEVE

Page 202
Feb 1/09

018 TRANSLATING SLEEVE ACOUSTIC PANEL FULL PENETRATION
(VRS2039) HOLE REPAIR-DELETED
(VRS2040)
019 TRANSLATING SLEEVE ACOUSTIC PANEL PARTIAL PENETRATION
(VRS2041) HOLE REPAIR-DELETED
(VRS2042)
020 TRANSLATING SLEEVE ACOUSTIC PANEL PERFORATED INNER
(VRS2043) SKIN SMALL HOLE REPAIR
021 TRANSLATING SLEEVE ACOUSTIC PANEL BOND SEPARATION
(VRS2045) REPAIR
022 TRANSLATING SLEEVE WOVEN WIRE SCRATCH, RIP OR TEAR
(VRS2047) REPAIR
023 TRANSLATING SLEEVE EXTERNAL PAINT REPLACEMENT
024 UPPER HOIST POINT NUTPLATE REPLACEMENT REPAIR LEFT OR
(VRS2065) RIGHT THRUST REVERSER
025 THRUST REVERSER HINGE ACCESS PANEL NUTPLATE
(VRS2075) REPLACEMENT
026 AFT LATCH FASTENER REPLACEMENT REPAIR LEFT OR RIGHT
(VRS2266) TRANSLATING SLEEVE

Page 203
Feb 1/09

027 CASCADE ASSEMBLY – SURFACE DAMAGE BLEND REPAIR
(VRS2251) (REF 78-32-19)
028 CASCADE CRACKED BLADE REMOVAL REPAIR
(VRS2253) (REF 78-32-19)
029 WOVEN WIRE REPLACEMENT DYNAROHRTM L/H AND R/H
(VRS2262) FIXED DUCT ASSEMBLIES
030 EDGE EROSION REPAIR
(VRS2082) LEADING EDGE OF COMPOSITE PARTS
REFER TO SRM 54-02-00 REPAIR NO. 001
031 EDGE SEALANT REPLACEMENT REPAIR FOR THE 7th AND 10th
(VRS2083) STAGE BLEED VALVE CUTOUTS/RIGHT FIXED DUCT ACOUSTIC
PANEL
032 TORQUE RING INNER FAIRING PATCH REPAIR AND FORWARD
(VRS2362) FRAME REPAIR
(VRS2363)
033 TORQUE RING FORWARD FRAME AND INNER FAIRING
(VRS2179) REPLACEMENT REPAIR
(VRS2180)
034 TORQUE RING INNER FAIRING AND FWD FRAME SEGMENT REPAIR
(VRS2181)
(VRS2182)
035 C-DUCT HEAT SHIELD WELD PATCH REPAIR
(VRS2003)
(VRS2004)
036 FULL PENETRATION DAMAGE REPAIR OF COMPOSITE CONE AND
(VRS2176) OUTER FAIRING C-DUCT FIXED STRUCTURE- LEFT AND RIGHT
TORQUE RING ASSEMBLIES
037 DELETED
(VRS2094)

Page 204
Feb 1/09

037 DOUBLER REPAIR AROUND RH C-DUCT 7th AND 10th STAGE
(VRS2338) BLEED VALVES
038 C-DUCT, PAN-DOWN ENGINE BUMPER REPAIR
(VRS2365)
039 COMPOSITE CONE AND COMPOSITE OUTER FAIRING PARTIAL
(VRS2175) PENETRATION REPAIR C-DUCT FIXED STRUCTURE - LEFT AND
RIGHT TORQUE RING ASSEMBLIES (REPAIR WITH M20 PRE-
IMPREGNATED FABRIC)
040 BLEED PORT CLOSURE INSTALLATION UPPER 7TH STAGE BLEED
(VRS2368) VALVE
041 LEFT C-DUCT – FIXED STRUCTURE – REPLACE THE LOWER
(VRS2195) TRACK NUTPLATE WITH BLIND NUT ASSEMBLY
(VRS2196)
042 C-DUCT FIXED STRUCTURE – REPLACE THE PIVOT FITTING
(VRS2052)
(VRS2057)
043 TRANSLATING SLEEVE BLISTER FAIRING CRACK REPAIR
(VRS2323)
044 THRUST REVERSER, C-DUCT, PRE-COLLER DUCT LEADING EDGE
(VRS2324) EROSION REPAIR
045 C-DUCT TORQUE RING, METALLIC TWO-PIECE INNER FAIRING

(VRS2329) REPAIR
046 TRANSLATING SLEEVE (CONFIGURATION 2), OUTER SKIN, AFT
(VRS2341) SECTION METALLIC PATCH REPAIR
047 TRANSLATING SLEEVE LOWER AREA BOTTOM EDGE – NEAR
(VRS2327) DOUBLE LATCH HEAT DAMAGE WET LAYUP REPAIR
048 THRUST REVERSER, TRANSLATING SLEEVE MISSING AND/OR

(VRS2332) LOOSE RIVETS REPAIR
049 THRUST REVERSER, C-DUCT, PRE-COOLER DUCT LEADING EDGE

(VRS2331) WET LAY-UP REPAIR

Page 205
Feb 1/09

050 COMPOSITE BLANK CASCADE FULL PENETRATION REPAIR
(VRS2334)
051 THRUST REVERSER, C-DUCT, TORQUE RING TIE-IN BRACKET
(VRS2328) CRACK REPAIR
052 COMPOSITE BLANK CASCADE PARTIAL PENETRATION REPAIR

(VRS2335)
053 TRANSLATING SLEEVE, FORWARD EDGE EROSION REPAIR
(VRS2343)
(VRS2344)

Page 206
Feb 1/09
REPAIR 001
FIXED DUCT HEATSHIELD REPAIR
(VRS2005/2006)
1. General
A. This repair may be used to repair a hole greater than 0.50-in.

(12.7 mm) in diameter in the heatshield of either the left or
the right fixed duct. It may also be used to repair a tear or a
crack in the heatshield greater than 0.5. in. in length.
VRS2005
VRS2006
A. Standard Equipment.
Drills and drilling equipment

Rivet tools
Hand punch

Index).

CoMat 02-091 Wiping cloth
CoMat 08-030 90-006 Sealant.
CoMat 08-032 DC1200 Primer
CoMat 12-028 Thermal insulation material
CoMat 12-029 Foil (pattern)
CoMat 12-030 Foil (plain)
V2500 54-30-00 REPAIR 001

Page 201
Feb 1/09
C. Repair Parts
PART NO. PART IDENT QTY

NAS1738C4-1 Blind Rivet A/R
AN960C5 Washer A/R
PART IDENT MATERIAL

Heatshield Skin Rigidized CRES Foil, 0.003 in. thick
Fiber Filter Thermal Insulation Material
4. Prepare the Damage Surface of the Repair
A. Cut away any torn heatshield skin pieces with metal cutters.
B. Remove any unwanted material and broken pieces from the

insulation material.
C. Do a check for lost or contaminated fiber fill insulation

material.
5. Prepare the Patch (Reference Figure 201 and 202)
A. Find the size of the repair area. Mark around the damage and add
0.5 in. (12.7 mm) on all sides.
B. Cut out the foil (CoMat 12-029) patch to the marked size.
CAUTION: YOU MUST PUNCH A VENT HOLE IN THE PATCH ONLY IF THE PATCH
IS TO COVER AN AREA WHERE A VENT HOLE ALREADY EXIST. THERE
MUST BE A HOLE FOR EVERY 4 FT² (0.3716 M²) OF HEATSHIELD
SURFACE OR ONE VENT HOLE IN EACH CLOSED SEGMENT. VENT
SHIELDS MUST BE INSTALLED OVER THE VENT HOLES.
C. Make a vent hole though the patch with a 0.25 in. (6.35 mm)
diameter hand punch if the patch is to cover a vent hole.
V2500 54-30-00 REPAIR 001

Page 202
Feb 1/09
6. Make and Install the Vent Shield (Ref Fig. 202)
NOTE: A vent shield is necessary if a vent hole has been

punched through the patch. if there is no vent hole. go
to paragraph 7.
A. Make the vent shield from foil CoMat 12-030 1 in. X 2 in. (25.4
mm X 50.8 mm).
B. Clean the surface around the vent hole on the repair patch and
the faying surface of the vent shield. Use methylethylketone
(CoMat 01-076) and wiping cloth
(CoMat 02-091). Wipe the surface dry before the solvent
evaporates.
NOTE: Use lint free gloves (CoMat 02-097) when you touch the
parts.
C. Drill or punch the rivet holes in the vent shield to make 0.128
in (3.25 mm) diameter holes.
D. Drill the rivet holes through the repair patch.
(1) Use the s a template and put the corner of the shield over
the vent hole.
(2) Point the open side of the vent shield down towards the
lower edge of the heatshield.
(3) Drill 0.143 to 0.146 in. (3.63 to 3.70 mm) diameter holes
through the patch.
(4) Install the rivets and the washers.
V2500 54-30-00 REPAIR 001

Page 203
Feb 1/09
7. Prepare the Patch (Ref Fig 201)
NOTE: The steps which follow apply to a repair which does not cover
a vent hole.
A. Drill or punch the rivet holes n the vent shield to make 0.128
in. (3.25 mm) diameter holes.
B. Drill the rivet through the heatshield.
(1) Use the pre-drill patch as a template and put the center
of the patch over the damage hole.
(2) Drill 0.143 in. to 0.146 in. (3.63 to 3.70 mm) diameter
holes through the heatshield skin. Do not damage the
insulation material under the heatshield skin.
(3) Remove the patch.
8. Install the Patch
A. Clean the faying surfaces around the patch and the repair area
of heatshield. Use methylethylketone (CoMat 01-076) and a
wiping cloth (CoMat 02-091). Wipe the surface dry before the
solvent evaporates.
NOTE: Use lint free gloves (CoMat 02-097) when you touch the
parts.
B. Replace the insulation material (CoMat 12-028) as necessary.

Use clean duckbill pliers. If the insulation material is to be
replaced, cut it to size with scissors.
V2500 54-30-00 REPAIR 001

Page 204
Feb 1/09
C. Apply primer (CoMat 08-032) to the faying surfaces of the patch

and the heatshield. Let the primer dry at 72° F
(22° C).
D. Mix the 90-006 sealant (CoMat 08-030) according to the

E. Apply the sealant to the faying surface of the patch and the
heatshield.
F. Align the rivet holes of the patch and the heatshield and
install the rivet and the washers with the 90-006 sealant
(CoMat 08-030). Make sure that the upper edge of the patch and
the riveted edges of the vent shield (if used) are sealed.
G. Remove unwanted sealant from the repair area with wiping cloth
(CoMat 02-091) before the sealant cures.
H. Let the sealant cure for two hours at 72° F (22° C) before it is
moves. The sealant will cure fully in 24 hours.
V2500 54-30-00 REPAIR 001

Page 205
Feb 1/09
9. Make an Inspection of the Patch
A. Make visual inspection that the upper edges of the rivet patch
are sealed. Do a check for loose rivets and for rough surface.
V2500 54-30-00 REPAIR 001

Page 206
Feb 1/09
EDGE OF DAMAGE
EDGE OF PATCH
PATCH TO CONFORM
APPROX. 0.50 in.(12,7 mm) TO REPAIR AREA
ALL AROUND
CLEAN AREA
ALL AROUND
1.00 in.
(2,54 mm)
PREPARATION PATCH
STRAIGHTEN OR
REMOVE TORN FOIL
0.146 in.(3,70 mm)
DRILL DIA. HOLE
0.143 in.(3,63 mm)
WET INSTALL RIVET (30-800) PATCH

AND WASHER (30-802)(Near side)
FAYING
SURFACE SEAL HEAT SHIELD
0.25 in.(6,3 mm) INSULATION

(Typical)
1.50 in.(38,1 mm)
SPACING
(Typical)
1.00 in.
(25.4 mm)
SPACING
(Typical)
0.25 in.(6,3 mm)
PATCH INSTALLATION (Typical)
13585A
Heatshield Rivet Patch

Figure 201
V2500 54-30-00 REPAIR 001

Page 207
Feb 1/09
0.146 in. (3,70 mm)

DRILL 0.143 in. (3,63 mm) DIA. HOLES (5 places)
INSTALL RIVET AND WASHER
(Near side)
FOLD BACK (Open edge)
DOWN REPAIR PATCH

1.00 in.
0.12 in. (3,0 mm) (25,4 mm)
0.25 in. (6,3 mm)

DIAMETER
VENT HOLE
IN PATCH
0.25 in.
(6,3 mm)
(Typical)
VENT SHIELD
2.00 in.
FAYING SURFACE (50,8 mm)
SEAL (3 sides only)
0.25 in. (6,3 mm)

(Typical)
Note: Open side of vent shield must point down.
13586A
Heatshield Rivet Patch and Vent Shield

Figure 202
V2500 54-30-00 REPAIR 001

Page 208
Feb 1/09
REPAIR 002
PERFORATED SKIN PARTIAL PENETRATION REPAIR
LEFT OR RIGHT FIXED DUCT ACOUSTIC PANEL
(VRS2007/2008)
1. General
A. This repair procedure is used to repair partial penetration

hole damage through the perforated skin side of the left or
right fixed duct acoustic panel. For holes that fully penetrate
the panel, refer to REPAIR 003.
B. This type of damage is repaired by removal of the damaged area

and the installation of a repair plug with doubler. Refer to
the SRM 54-01-00 for the Maximum Acoustical Area Loss Limits.
C. This repair is applicable to the damage in the areas given in

Figure 201. If the damage is not in these areas, you must refer
to the manufacturer for repair instructions.
(1) There must be a minimum distance of 7.0 in. (177,8 mm)

from the inner ring V-blade forward edge to the edge of
the damage.

from the blocker door hinge fittings and the bumper
fittings (found on the backside of the acoustic panel and
the corner radii of the bifurcation) to the edge of the
damage.
(3) There must be a minimum distance of 2.0 in. (50,8 mm) from
the edge closures and splices to the edge of the damage.
(4) The hole area can be up to 144 square inches. (929 square
cm).
the edge of the damage to the junction of the barrel and
the bifurcation.
V2500 54-30-00 REPAIR 002

Page 201
Feb 1/09
(6) This repair is applicable in areas of the outer

(perforated) skin or inner (solid) skin that are 0.025 or
0.045 in. (0,635 mm or 1,14 mm) thick. And the core
material must me made from CoMat 02-324.
D. A ** following a repair referenced in this procedure indicates

that the repair is not yet published in the current revision of
the manual. Contact Goodrich for additional information
concerning FAA approved repair data.
Overhaul Processes and Consumable Index. PCI.

Standard Practices and Processes Index, SPPM.
Structural Repair Manual, SRM.
3. Equipment and Materials
Cutters and cutting tools

Drills and drilling equipment
Explosion proof heat lamp
Heat blanket
Heat gun
Riveting tools
Routers and routing tools
Sheet metal forming tools
Standard shop tools

consumable Index)
CoMat 01-438 Solvent, Turco 6646

CoMat 01-457 Solvent MIBK, alternative for CoMat 01-438
CoMat 02-322 Aluminum sheet, 2024-T3 0.025 in. (0,635 mm)
CoMat 02-324 AL5052 core 4.1 PFC
V2500 54-30-00 REPAIR 002

Page 202
Feb 1/09

CoMat 08-085 Film adhesive, EA9689
CoMat 08-104 Adhesive, EA9394
C. Special Tools - none
D. Expendable Parts - none
PART IDENT MATERIAL

Acoustic Panel Woven wire
Serial Number 1-5000 Perforated aluminum skin
Aluminum honeycomb core
Solid aluminum skin
Acoustic Panel Perforated aluminum skin
Serial Number Aluminum honeycomb core
5001 and on Solid aluminum skin
F. Repair Parts
PART IDENT MATERIAL QTY

CR3523P-4 Rivet A/R
CR3223-4 (Alternate) A/R
CR3553P-4 Oversize Rivet A/R
CR3253-4 (Alternate Oversize) A/R
V2500 54-30-00 REPAIR 002

Page 203
Feb 1/09
4. Prepare the Damaged Area for Repair (See Figure 202)
CAUTION: MAKE SURE YOU REMOVE ALL LOOSE WOVEN WIRE. THE STAINLESS
WOVEN WIRE HAS A STRONG ELECTROLYTIC REACTION WHEN IT IS
IN CONTACT WITH ALUMINUM ALLOYS. THIS CAUSES CORROSION TO
OCCUR.
A. Clean the surface with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub surface dry before solvent
evaporates.
B. Make a mark of the damaged area to be cut out. Use

CoMat 06-131 marking pen. The cutout must have the smallest
repair shape that will remove all of the damage. The cutout can
be circular or rectangular.
C. Make a border 1.5 in. (38,1 mm) more than the cutout all around
on the perforated side of the panel. Use the
CoMat 02-161 Teflon tape. (For SN 1-5001 this also shows the
area of woven wire to be cut and removed from the repair area.)
V2500 54-30-00 REPAIR 002

Page 204
Feb 1/09
5. Remove the Damaged Skin and Core

PPE IS NECESSARY.
CLEANED OR PREPARED SURFACE. THIS PREVENTS CONTAMINATION.
A. SN 1-5000 only (SN 5001 and on go to step 5B): Cut the woven
wire as marked. Use a sharp knife. Do not cut into the
perforated skin. Remove the cut woven wire from the repair
area. Remove the burrs.
B. Rub the surfaces lightly with CoMat 05-020 abrasive paper. Make
the surface rough in the area that was marked in step 4.C. Do
not cause damage to the perforated skin.
C. Cut and remove the damaged skin and core from the area marked.
Use a drive motor and routing tools. Remove the core. Remove
adhesive glossy finish and remaining core residue by lightly
hand sanding adhesive surface on solid skin. It is acceptable
for core imprint to remain. Take extra care not to sand through
adhesive. Use the CoMat 05-020 and CoMat 05-081 abrasive
papers. Do not cut into the solid skin.
NOTE: If the cutout is rectangular, use a minimum radius of 0.50 in.

(12,7 mm) at the corners.
V2500 54-30-00 REPAIR 002

Page 205
Feb 1/09
D. Remove the sharp edges. Use the CoMat 05-020 and 05-081
abrasive papers.
E. Clean the repair area with a CoMat 02-099 lint free cloth made
evaporates.
6. Remove Moisture from the Repair Area
NOTE: Do the following procedure if there are indications of

moisture or other contamination in the repair area.
A. Refer to SRM 54-02-00, REPAIR 002 (VRS2371), for moisture

removal in the repair.
7. Make the Repair Parts (See Figure 202)
V2500 54-30-00 REPAIR 002

Page 206
Feb 1/09

PPE IS NECESSARY.
A. Make the core plug from CoMat 02-324 core material. Make sure
the replacement core has the same shape, size, density, and
ribbon direction as the core that you removed. Remove the
burrs.
B. Put the core plug inside the cutout. Cut the edges as
necessary. The space between the plug and the core must not be
more than 0.05 in. (1,3 mm) all around. Make sure that the skin
and the plug are the same height and contour.
C. Make a repair doubler from CoMat 02-322 or CoMat 02-323

aluminum sheet. Make the repair doubler the same thickness as
the damaged skin. Make the doubler 1.25 in. (31,75 mm) larger
than the cutout all around. Make sure the contour of the
doubler agrees with the contour of the acoustic panel. Chamfer
the edges. Remove the burrs.
NOTE: Make the doubler from 0.045 in. (1,14 mm) material if
you will install it above the 74° splice line. Make the
doubler from 0.025 in (0,635 mm) material if you will
install it below the 74° splice line. If the cutout is
rectangular, use a minimum radius of 0.50 in. (12,7 mm)
at all corners of the repair doubler.
8. Install and Cure the Repair Core Plug
A. Install and cure the repair core plug per SRM 54-02-00, REPAIR
009 (VRS2372), using Method 4.
9. Prepare the Surface of the Doubler and Repair Area
A. Prepare the mating surfaces of the repair doubler and the

repair surface per SRM 54-02-00, REPAIR 003 (VRS2369).
V2500 54-30-00 REPAIR 002

Page 207
Feb 1/09
10. Apply the Primer to the Doubler and Repair Area
CLEANED CORE AND DOUBLER. THIS HELPS PREVENT
CONTAMINATION.
A. Clean the doubler and the repair area. Use a CoMat 02-099 lint
free cloth made moist with CoMat 01-438 solvent. Rub surface
dry before solvent evaporates.
B. Force air dry for 30 minutes at 190° to 210°F (88° to 99°C).
C. Apply adhesive primer to all edges of the core plug, the inner
surface of the solid skin, and all surfaces of the repair
doubler. Refer to SRM 54-02-00, General REPAIR 006 (VRS2374).
11. Install the Repair Parts (See figure 202)
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH FILM
ADHESIVES AND THE CLEANED REPAIR PARTS. THIS HELPS PREVENT
CONTAMINATION.
A. If necessary, clean the doubler and the repair area. Use a dry
CoMat 02-099 lint free cloth. Rub the surface lightly to clean.
V2500 54-30-00 REPAIR 002

Page 208
Feb 1/09
B. Remove the protective lining from one side of the

CoMat 08-085 film adhesive. Apply the film adhesive to the
mating surface of the doubler.
C. Remove the remaining protective lining from the film adhesive

on the doubler.
D. Put the doubler into position.
12. Vacuum Bag and Cure the Repair
A. Prepare a vacuum bag for the repair doubler per SRM 54-02-00,
REPAIR 004 (VRS2370).
NOTE: If fittings or other hard points are near the repair

area, the temperature will not be constant. If
necessary, use more heat blankets to make the heat
supply constant over the repair area.
B. Cure the repair area. Use heat blankets or other explosion

proof equipment and heat the repair area at a rate of 1 to 6°F
(1 to 4°C) to bring all thermocouples within the cure
temperatures range specified below.

TEMPERATURE.
V2500 54-30-00 REPAIR 002

Page 209
Feb 1/09
C. Upon the coldest thermocouple reaching the 350°F (177°C) ±10°F

(±5°C) cure temperature range, begin a 60-minute soak.
Continuously monitor and record all thermocouples to make sure
the cure temperature range is maintained during the soak
period.
D. After the soak at the required temperature is complete, cool to

150°F (65°C) at a rate not to exceed 5°F (3°C) per minute. Upon
reaching 150°F (65°C) the equipment may be removed.
E. Disconnect the heat blankets and the vacuum source. Remove the
bagging materials and thermocouples.
F. Inspect the repair to make sure the doubler has not moved out of
position. If doubler has moved, remove doubler and repeat the
above steps for installation.
13. Install the Fasteners (See Figure 202)

PPE IS NECESSARY.
A. Drill two rows of rivet holes through the doubler and

perforated skin. Do not drill through to the opposite skin.
V2500 54-30-00 REPAIR 002

Page 210
Feb 1/09
NOTE: The rivet hole diameter is 0.129 to 0.132 in. (3,28 to 3,35
mm). The typical edge distance is 0.32 in. (8,1 mm). The
typical center-to-center distance and row spacing between the
holes is 0.50 in. (12,7 mm). Remove the burrs.

SAFELY USE, KEEP, AND DISCARD CHEMICALS. GET
B. Remove the drilling particles. Use a CoMat 02-099 lint free

cloth made moist with CoMat 01-438 solvent. Rub surface dry
before solvent evaporates.
C. Wet install the rivets with CoMat 08-104 adhesive. See Figure
202 for rivet callout and approximate location.
14. Apply Protective Treatments and Primer to the Repair Area
CLEANED CORE AND DOUBLER. THIS HELPS TO PREVENT
CONTAMINATION.
A. Clean the repair area. Use a CoMat 02-099 lint free cloth made
evaporates.
V2500 54-30-00 REPAIR 002

Page 211
Feb 1/09
B. The external surface of the repair area must be water break

free. A surface is water break free if a thin unbroken film of
water can stay on the surface for at least 30 seconds. If the
water breaks free from the surface, repeat the sanding and
cleaning procedures until a thin, unbroken film of water can
remain on the surface for at least 30 seconds.
C. Apply the chromate conversion coating solution, refer to

SRM 54-02-00, General Repair.
D. Apply surface protective primer to the repaired surfaces, refer

to SRM 54-02-00, General Repair.
15. Stabilize the Woven Wire (See Figure 202
evaporates.
B. SN 1-5000 only (SN 5001 and on go to 15. C). Make a border

around the cut edge of the woven wire. Use the CoMat 02-161
Teflon tape. Apply the tape on the woven wire, 0.3 in. (8 mm)
from the cut edge of the woven wire.
V2500 54-30-00 REPAIR 002

Page 212
Feb 1/09
C. Use the manufacturer’s instructions to mix the CoMat 08-104

adhesive.
D. Apply a thin layer of the adhesive mixture to the area between

the Teflon tape and the edge of the doubler.
(SN 1-5000 only: Add more adhesive to fully cover the cut edges
of the woven wire.)
E. Cure the adhesive for one hour at 180° to 200°F (82° to 93°C).
Use an explosion proof heat lamp.
16. Make the Repair Surface Smooth

PPE IS NECESSARY.
A. Remove the sharp edges. Make the surface in the repair area
smooth with the adjacent surface. Use the Comat 05-020 and 05-
081 abrasive papers.
V2500 54-30-00 REPAIR 002

Page 213
Feb 1/09
B. Clean the surface with a CoMat 02-099 lint free cloth made
evaporates.
17. Examine the repair
A. Visually examine the repair area and do a tap test of the

repaired surface per SRM 54-01-00 to check for disbonds. No
disbonds are allowed. Make sure that the procedures in this
repair are done. If necessary, do the applicable steps again.
18. Identify the repair
A. Write VRS2007 on the left panel or VRS2008 on the right panel

adjacent to the assembly number. Use a CoMat 06-131 marking pen
of a color that contrasts.
V2500 54-30-00 REPAIR 002

Page 214
Feb 1/09
Partial Penetration Repair Perforated Skin Side

Fixed Duct Acoustic Panel
V2500 54-30-00 REPAIR 002

Page 215
Feb 1/09

V2500 54-30-00 REPAIR 002

Page 216
Feb 1/09

V2500 54-30-00 REPAIR 002

Page 217
Feb 1/09

Figure 202
V2500 54-30-00 REPAIR 002

Page 218
Feb 1/09
REPAIR 003
FULL PENETRATION REPAIR
LEFT AND RIGHT FIXED DUCT ACOUSTIC PANEL
(VRS2009/2010)
1. General
A. This repair procedure is used to repair full penetration hole

damage through the left or right fixed duct acoustic panel. For
holes that partially penetrate the panel, see REPAIR 002.
B. This type of damage is repaired by removal of the damaged area

and the installation of a repair plug with doublers. Refer to
SRM 54-01-00 for the Maximum Acoustical Area Loss Limits.
C. This repair is applicable to damage in the areas given in

Figure 201. If the damage is not in these areas, you must refer

from the inner ring V-blade forward edge to the edge of
the damage.

from the blocker door hinge fittings and the bumper
fittings (found on the back side of the acoustical panel
and the corner radii of the bifurcation) to the edge of
the damage.
the edge closures and splices to the edge of the damage.
(4) The hole area can be up to 144 square inches (929 square
cm).
the edge of the damage to the junction of the barrel and
the bifurcation.
V2500 54-30-00 REPAIR 003

Page 201
Feb 1/09
(6) This repair is applicable in areas of the outer

(perforated) skin or inner (solid) skin that are 0.025 or
0.040 in. (0,632 or 1,14 mm) thick and the core material
must be made from CoMat 02-324.
D. A ** following a repair reference in this procedure indicates

Overhaul Processes and Consumable Index

Standard Practices and Processes Index, PCI
Structural Repair Manual, SRM
A. Standard Tools

Drills and drilling tools
Explosive proof heat lamp
Heat blankets
Riveting tools
Routers and router tools
Standard shop tools

Consumable Index)

CoMat 02-324 AL5052 core 4.1 PFC honeycomb core
V2500 54-30-00 REPAIR 003

Page 202
Feb 1/09

CoMat 08-085 Film adhesive EA9689
PART IDENT MATERIAL

Solid aluminum skin
F. Repair parts

CR3523P-4 Rivet A/R
CR3223-4 Rivet, (Alternate) A/R
CR3553P-4 Oversize Rivet A/R
CR3253-4 Oversize A/R
4. Prepare The Damage Area For Repair
V2500 54-30-00 REPAIR 003

Page 203
Feb 1/09
CAUTION: MAKE SURE YOU REMOVE ALL LOOSE WOVEN WIRE. THE STAINLESS
WOVEN WIRE HAS A STRONG ELECTROLYTIC REACTION WHEN IT IS
IN CONTACT WITH ALUMINUM ALLOYS. THIS CAUSES CORROSION
SOURCES.
A. Clean the surfaces with CoMat 02-099 lint free cloth made moist
with CoMat 01-438 solvent. Rub surface dry before solvent
evaporates.
B. Make a mark of the damage area to be cut out. Use CoMat 06-131
marking pen. The cutout must go through the two sides of the
panel. It must have the smallest regular shape that will remove
the damage completely from the panel. The cutout can be
circular or rectangular.
C. Make a border 1.5 in. (38,1 mm) more than the cutout all around
on the perforated side of the panel. Use CoMat 02-161 Teflon
tape. (For SN 1-5000, this side also shows the area of woven
wire to be cut and removed from the repair area.)
5. Remove The Damaged Skin And Core

PPE IS NECESSARY.
CONTAMINATION.
V2500 54-30-00 REPAIR 003

Page 204
Feb 1/09
A. SN 1-5000 only (SN 5001 and on, go to step 5B): Cut the woven
wire as marked. Use a sharp knife. Do not cut into the
B. Rub the surface lightly with CoMat 05-020 abrasive paper. Make
the surface rough in the area that was marked in step 4.C. Do
not cause damage to the perforated skin.
C. Cut and remove the damaged skins and core from the cutout area
as marked. Use a drive motor and routing tools. Remove the
burrs.
NOTE: If the cutout is rectangular, use a minimum radius of 0.50

in. (12,7 mm) at the corners.
D. Remove the sharp edges. Use CoMat 05-020 and 05-081 abrasive
paper.
E. Clean the repair area with CoMat 02-099 lint free cloth made
evaporates.
6. Remove Moisture From The Repair Area

A. Refer to SRM 54-02-00, REPAIR 002 (VRS2371) for moisture

removal in the repair.
V2500 54-30-00 REPAIR 003

Page 205
Feb 1/09
7. Make The Repair Parts (See Figure 202)

PPE IS NECESSARY.
A. Make the repair doublers from CoMat 02-322 or 02-323 aluminum

alloy sheet. Make the repair doublers the same thickness as the
skin removed. Make the doublers 1.25 in (31,7 mm) larger than
the cutout all around. Make sure the contour of the doubler
agrees with the contour of the acoustic panel. Chamfer edges.
Remove burrs.
NOTE: Make the doubler from 0.045 in (1,14 mm) material if you
will install it above the 74° splice line. Make the doubler
from 0.025 in. (0,635 mm) material if you will install it
below the 74° splice line.
NOTE: If the cutout is rectangular, use a minimum radius of 0.50

(12,7 mm) at all corners of the repair doubler.
B. Make the core plug from the applicable thickness core material.
Use CoMat 02-324 core material. The core plug must have the
same ribbon direction, size, shape and density as the core you
removed. Remove the burrs.
8. Install And Cure The Repair Core Plug
009 (VRS2372) using Method 4.
V2500 54-30-00 REPAIR 003

Page 206
Feb 1/09
9. Prepare The Surfaces Of The Repair Area And Doublers
A. Prepare the mating surfaces of the repair doublers and the

repair surfaces per SRM 54-02-00, REPAIR 003 (VRS2369).
10. Apply The Primer To The Doublers And Repair Area
CONTAMINATION.
A. Clean the doublers and the repair area. Use CoMat 02-099 lint
free cloth made moist with CoMat 01-438 solvent. Rub surface
dry before solvent evaporates.
C. Apply adhesive primer to all edges of the core plug and the
inner surface of the repair doublers. Refer to SRM 54-02-00,
V2500 54-30-00 REPAIR 003

Page 207
Feb 1/09
11. Install The Repair Parts (See Figure 202)
CONTAMINATION.
A. If necessary, clean the doublers and the repair area. Use CoMat
02-099 lint free cloth made moist with CoMat 01-438 solvent.
Rub the surface dry before the solvent evaporates.

mating surface of the doublers.

on the doublers.
D. Put the doublers into position on both sides of the repair

(perforated skin and solid skin sides).
12. Vacuum Bag And Cure The Repair Doublers
A. Prepare a vacuum bag for both repair doublers per

SRM 54-02-00, REPAIR 004 (VRS2370).

area, the temperature will not be the same over the
repair area. If necessary, use more heat blankets to
adjust the temperature of the repair area.
B. Cure the repair area using heat blankets or other explosive

proof equipment as follows. Heat the repair area at a rate of 1°
to 6°F (1° to 4°C) per minute to bring all thermocouples within
the cure temperature range specified below.
V2500 54-30-00 REPAIR 003

Page 208
Feb 1/09

TEMPERATURE.
C. Upon the coldest thermocouple reaching the 350°F (177°C) ± 10°F

(± 5°C) cure temperature range, begin a 60 minute soak.
the cure temperature range is maintained during soak period.
D. After the soak at the required temperature is complete, cool to

150°F (65°C) at a rate not to exceed 5°F (3°C) per minute. Upon
reaching 150°F (65°), the equipment may be removed.
E. Disconnect the heat blankets and the pressure source. Remove

the bagging materials and thermocouples.
F. Inspect repair to make sure the doublers have not moved out of
position. If the doublers have moved, remove doublers and
repeat the above steps for reinstallation.
13. Install The Fasteners (See Figure 202)
A. Drill two rows of rivet holes through each doubler and the
adjacent skin. Do not drill through the opposite skin.
The rivet hole diameter is 0.129 to 0.132 in. (3,28 to 3,35 mm).
The typical edge distance is 0.32 in. (8,1 mm). The typical
center-to-center distance and row spacing between the holes is
0.50 in. (12,7 mm). Remove burrs.
NOTE: See Figure 202 for rivet callout and approximate location.
V2500 54-30-00 REPAIR 003

Page 209
Feb 1/09
B. Remove the drilling particles. Use a CoMat 02-099 lint free

cloth made moist with CoMat 01-438 solvent. Rub the surface dry
before the solvent evaporates.
C. Wet install the rivets with CoMat 08-104 adhesive.
14. Apply Protective Treatments And Primer To The Repair Area
CONTAMINATION.
V2500 54-30-00 REPAIR 003

Page 210
Feb 1/09
moist with CoMat 01-438 solvent. Rub the surface dry before the
solvent evaporates.
B. The external surface of the repair area must be water break

free. A surface is water break free if a thin unbroken film of
water can stay on the surface for at least 30 seconds. If the
water breaks free from the surface, repeat the sanding and
cleaning procedures until a thin, unbroken film of water can
remain on the surface for at least 30 seconds.
C. Apply the chromate conversion coating solution per

D. Apply surface protective primer to the repaired surfaces per

15. Stabilize The Woven Wire (See Figure 202)
CONTAMINATION.
A. Clean the repair area on the perforated skin side. Use a CoMat
Rub surface dry before solvent evaporates.
B. SN 1-5000 only (SN 5001 and on go to step 15 C): Make a border

around the cut edge of the woven wire. Use CoMat 02-161 teflon
tape. Apply the tape on the woven wire, 0.30 in. (8 mm) from the
cut edge of the woven wire all around.
V2500 54-30-00 REPAIR 003

Page 211
Feb 1/09
C. User manufacturer’s instructions to mix the CoMat 08-104

adhesive.
D. Apply a thin layer of the adhesive mixture to the area between

the teflon tape and the edge of the doubler. (SN 1-5000 only:
Add more adhesive to fully cover the edges of the woven wire.)
E. Cure the adhesive for one hour at 180° to 200°F (82° to 93°C).
Use an explosive proof heat lamp.
16. Make The Repair Surfaces Smooth

PPE IS NECESSARY.
A. Remove sharp edges. Make the surface in the repair area smooth
with the adjacent surfaces. Use CoMat 05-020 and
05-081 abrasive papers.
V2500 54-30-00 REPAIR 003

Page 212
Feb 1/09
B. Clean the surface with CoMat 02-099 lint free cloth made moist
evaporates.
17. Examine The Repair
A. Visually examine the repair area and do a tap test to check for
disbonds. No disbonds are allowed. Make sure that the
18. Identify The Repair
A. Write VRS2009 on the left panel, or VRS2010 on the right panel

adjacent to the assembly number. Use CoMat 06-131 marking pen
V2500 54-30-00 REPAIR 003

Page 213
Feb 1/09
Full Penetration Repair

V2500 54-30-00 REPAIR 003

Page 214
Feb 1/09

V2500 54-30-00 REPAIR 003

Page 215
Feb 1/09

V2500 54-30-00 REPAIR 003

Page 216
Feb 1/09

Figure 202
V2500 54-30-00 REPAIR 003

Page 217
Feb 1/09
V2500 54-30-00 REPAIR 003

Page 218
Feb 1/09
REPAIR 004
FIXED DUCT WOVEN WIRE SCRATCH, RIP, OR TEAR REPAIR
(VRS2011/2012)
1. General
A. This repair procedure is used to repair scratch, rip, or tear

damage to the woven wire of the left or right fixed duct
acoustic panel.
B. This type of damage is repaired by removal of the loose woven

wire and the application of adhesive to the cut edges. Refer to
the SRM 54-01-00 for the maximum acoustical area loss limits.
C. This repair is applicable to damage that is up to 4.0 in. (102

mm) long. Damage more than the limits in section
54-01-00 can be repaired by the use of the woven wire
replacement repair.
VRS2011
VRS2012
A. Standard tools
Plastic spatula
Knife

Consumables Index)
CoMat 01-076 Methylethylketone; Alternative for CoMat 01-438

CoMat 08-021 Adhesive; Alternative for CoMat 08-078
V2500 54-30-00 REPAIR 004

Page 201
Feb 1/09
CoMat 08-078 Adhesive
Part Ident Material

Perforated aluminium skin
Aluminium honeycomb core
Solid aluminium back skin

PPE IS NECESSARY.
CAUTION: 1. MAKE SURE THAT ALL LOOSE WOVEN WIRE IS CUT AWAY. THE
STAINLESS WOVEN WIRE HAS A STRONG ELECTROLYTIC REACTION
WHEN IT IS IN CONTACT WITH ALUMINUM ALLOYS. THIS CAUSES
GALVANIC REACTION TO OCCUR.
2. WHEN YOU CUT THE WOVEN WIRE, OR REMOVE SHARP EDGES, DO

NOT CUT INTO THE PERFORATED SKIN.
V2500 54-30-00 REPAIR 004

Page 202
Feb 1/09
moist with CoMat 01-438 solvent. Rub the surface clean before
the solvent becomes dry.
B. Apply CoMat 02-160 teflon tape around the damage area. Add 0.4
in. (10 mm) around all sides of the damage. This makes an area
that is 0.8 in. (20,3 mm) wide.
C. Cut away all loose woven wire from the repair area. Use a sharp
knife. Do not cut into the perforated skin.
D. Smooth any defects on the perforated skin in the damaged area.

Use the CoMat 05-020 and 05-081 abrasive papers.
5. Stabilize the Woven Wire, (See Figure 201)

PPE IS NECESSARY.
CONTAMINATION.
A. Clean the repair area with a CoMat 02-099 lint free cloth made
solvent becomes dry.
B. Use the manufacturer’s instructions to mix the CoMat 08-078

adhesive.
V2500 54-30-00 REPAIR 004

Page 203
Feb 1/09
C. Apply a thin layer of the adhesive mixture to the area between

the pieces of teflon tape. Add more adhesive, if necessary, to
completely cover the cut edges of the wire.
D. Cure the adhesive for one hour at 180ºF to 200ºF (82ºC to 93ºC).
6. Smooth the Repair Area

PPE IS NECESSARY.
A. Remove the pieces of teflon tape from the repair area.
B. Remove the sharp edges from the stabilized area. Use the CoMat
05-020 and 05-081 abrasive papers.
C. Clean the repair area with a Comat 02-099 lint free cloth made

V2500 54-30-00 REPAIR 004

Page 204
Feb 1/09
TEAR
RIP
ACOUSTIC PANEL
CORE
TEFLON TAPE
SMOOTH DAMAGE
SCRATCH
PERFORATED SKIN
BACK SKIN
APPLY ADHESIVE
SMOOTH REPAIR TO ADJACENT SKIN
13591
Woven Wire Scratch, Rip, or Tear Repair

Fixed Duct Assembly
Figure 201
V2500 54-30-00 REPAIR 004

Page 205
Feb 1/09
V2500 54-30-00 REPAIR 004

Page 206
Feb 1/09
REPAIR 005 (VRS2013/VRS2014)

FIXED DUCT ACOUSTIC PANEL BOND SEPARATION REPAIR
DELETED AUG 1/07 BY SRM REVALIDATION
THIS SRM REPAIR HAS BEEN CANCELLED AND SHOULD NO LONGER BE APPLIED.
IF PREVIOUSLY ACCOMPLISHED, REFER TO V2500-NAC-78-0231 FOR DISPOSITION.
V2500 54-30-00 REPAIR 005

Page 201
Feb 1/09
V2500 54-30-00 REPAIR 005

Page 202
Feb 1/09
REPAIR 006
PERFORATED SKIN CRACK REPAIR
(VRS2015/2016)
1. General
A. This repair may be used to repair a crack to the perforated skin

of the left or the right fixed duct acoustic panel.
B. This type of damage is repaired by the installation of a repair

doubler. Refer to the SRM 54-01-00 for the Maximum Acoustical
Area Loss Limits.
C. This repair is applicable to damage in the areas given in

Figure 201. If the damage is not in these areas, refer to the
manufacturer for repair instructions.
D. Crack must be less than 6 in (152,4 mm) long.
E. There must be a minimum distance of four times the crack length

between two adjacent cracks. There cannot be more than five
repaired cracks in each acoustic panel.
F. The perforated skin must not be disbonded from the core in the
area around the crack. If there is a disbond, refer to REPAIR
002.
G. A ** following a repair Referenced in this procedure indicates

The repair Scheme Number for this procedure is VRS2015/VRS2016

Overhaul Processes and Consumable Index, PCI Standard Practices and
Processes Index, SPPM Structural Repair Manual, SRM.
V2500 54-30-00 REPAIR 006

Page 201
Feb 1/09
A. Standard tools.

Heat gun
Riveting tools

Index)

CoMat 02-322 Aluminum Sheet 2024-T3, 0.025 in.(0,635 mm)
CoMat 02-323 Aluminum Sheet 2024-T3, 0.045 in. (1,14 mm)
CoMat 06-131 marking pen
D. Expandable Parts - None
PART IDENT MATERIAL

Solid aluminum skin
V2500 54-30-00 REPAIR 006

Page 202
Feb 1/09
F. Repair parts

CR3523P4 Rivet A/R
CR3223-4 Rivet, (Alternate) A/R
CR3553P4 Rivet, (Oversize) A/R
CR3253-4 Rivet, (Alternate Oversize) A/R
4. Prepare the Damaged Area For Repair

PPE IS NECESSARY.
CAUTION: 1. MAKE SURE THAT ALL LOOSE WOVEN WIRE IS CUT AWAY.
STAINLESS WOVEN WIRE HAS A STRONG ELECTROLYTIC REACTION
WHEN IT IS IN CONTAT WITH ALUMINUM ALLOYS. THIS CAUSES
GALVANIC REACATION TO OCCUR.
2. WHEN YOU CUT THE WOVEN WIRE, OR REMOVE SHARP EDGES, DO

NOT CUT INTO THE PERFORATED SKIN.
A. Clean the surface with CoMat 02-099 lint free cloth made moist
with CoMat 01-438 solvent. Rub the surface dry before the
solvent dries.
V2500 54-30-00 REPAIR 006

Page 203
Feb 1/09
B. Find the ends of the crack. Do a visual inspection of the

perforated skin using a 10x magnification lens. Refer to the
SPPM for instructions. Make a mark to show the two crack ends.
Use CoMat 06-131 marking pen.
NOTE: 1. Do not dye penetrant inspect the perforated skin.
2. Cut the woven wire (SN 1 thru 5000 only) around the
crack as necessary to do the inspection. Use a sharp
knife. Do not cut into the perforated skin. Remove
the cut woven wire from the crack area. Remove the
burrs.
C. Drill 0.19 in. (4,8 mm) diameter holes at the two ends of the
crack. Remove the burrs.
D. Use a router along the length of the crack to a maximum width of

0.010 in. (2,54 mm) to remove the crack. Do not cause damage to
the underling structure when you route the crack. Remove the
burrs.
E. Make a mark to show the damage area to be covered by the repair

doubler. Use CoMat 06-131 marking pen. The doubler must be
large enough to accept two rows of rivets beyond the edge of
damage all around.
NOTE: 1. The doubler can be circular or rectangular. If the

doubler is rectangular, use a minimum radius of 0.50
2. Before you cut the woven wire, record and keep the
dimensions for the doubler to be used later.
F. Serial Numbers 1 thru 5000 only (SN 5001 and on go to step 4.

I.): Make a mark on the woven wire 0.2 in. (5 mm) more than the
doubler all around. Use CoMat 06-131 marking pen. The woven
wire must be cut along this line and removed from the repair
area.
G. Cut the woven wire as marked. Use a sharp cutting tool. Do not
cut into the perforated skin. Remove the cut woven wire from
the repair area. Remove the burrs.
V2500 54-30-00 REPAIR 006

Page 204
Feb 1/09
H. Lightly mark the surface rough in the area where the woven wire
was removed. Use CoMat 05-020 abrasive paper. Do not cause
damage to the perforated skin.
I. Clean the area with CoMat 02-099 lint free cloth made moist
solvent dries.
5. Make a Repair Doubler (See Figure 202)
A. Make a repair doubler from CoMat 02-323 or CoMat 02-322

aluminum sheet. Use the dimensions recorded in Step 4.E. Use
the same thickness as the damaged perforated skin. Make the
doubler to align with the contour of the acoustic panel. The
final part must align with the contour with light finger
pressure. Chamfer the edges of the doubler. Remove the burrs.
6. Prepare the Surface Area Of The Doubler And Perforated Skin
A. Prepare the mating surfaces for the repair doubler per

SRM 54-02-00, REPAIR 003 (VRS2369).
7. Apply the Primer

PPE IS NECESSARY.
DOUBLER. THIS PREVENTS CONTAMINATION.
V2500 54-30-00 REPAIR 006

Page 205
Feb 1/09
A. Clean the doubler and repair area. Use CoMat 02-099 lint free
cloth made moist with CoMat 01-438 solvent. Rub the surface dry
C. Apply adhesive primer to all bare edges of the perforated skin

and all surfaces of the repair doubler. Refer to
SRM 54-02-00, REPAIR 006 (VRS2374).
D. Cure the adhesive for one hour at 180° to 200°F (82° to 93°C)
with an explosion proof heat lamp.
8. Install the Repair Doubler

PPE IS NECESSARY.
CONTAMINATION.
A. Put CoMat 02-161 Teflon tape around the outer area of the woven
wire 0.2 in. (5 mm) more than the woven wire cutout.

adhesive.
V2500 54-30-00 REPAIR 006

Page 206
Feb 1/09
C. Apply a thin layer of the adhesive mixture to the mating

surfaces of the doubler and the perforated skin. Put the repair
doubler into position.
D. Serial Number 1 thru 5000 (SN 5001 and on go to step 8.E.): Make
sure the woven wire is stable. Apply a thin layer of the
adhesive mixture to the area between the CoMat 02-161 Teflon
tape and the doubler. Add more adhesive to completely cover the
cut edges of the wire.
E. Serial Number 5001 and on: Apply a thin layer of the adhesive
mixture to the area between the CoMat 02-161 Teflon tape and
the doubler.
F. Remove the CoMat 02-161 Teflon tape from the edges of the
adhesive mixture. Remove any unwanted adhesive with CoMat 02-
099 lint free cloth.
G. Cure the adhesive for one hour at 180° to 200°F (82° to 93°C).
Use an explosive proof lamp.
A. Drill two rows of rivets holes through the doubler and the
perforated skin. Do not drill through the opposite skin.
The rivet hole diameter is 0.129 to 0.132 in. (3,28 to 3,35 mm).
center-to-center distance and row spacing between holes is 0.50
in. (12,7 mm). Remove the burrs.
B. Remove the drilling particles. Use CoMat 02-099 lint free cloth
made moist with CoMat 01-438 solvent. Rub the surface dry
C. Wet install the rivets with CoMat 08-104 adhesive. See Figure
202 for the rivet call out and approximate location.
V2500 54-30-00 REPAIR 006

Page 207
Feb 1/09
A. Visually examine and do a tap test of the repair area to check

for disbonds. Make sure that the procedures in this repair are
done. If necessary, do the applicable steps again.
11. Protect and Clean the Repair

PPE IS NECESSARY.
A. Protect any bare metal surfaces in the repair area per

SRM 54-02-00 Par. 1.
solvent dries.
A. Write VRS2015 on the left panel, or VRS2016 on the right panel

V2500 54-30-00 REPAIR 006

Page 208
Feb 1/09
Perforated Skin Crack Repair

V2500 54-30-00 REPAIR 006

Page 209
Feb 1/09

V2500 54-30-00 REPAIR 006

Page 210
Feb 1/09

V2500 54-30-00 REPAIR 006

Page 211
Feb 1/09

Figure 202
V2500 54-30-00 REPAIR 006

Page 212
Feb 1/09
REPAIR 007
FIXED DUCT ACOUSTIC PANEL
OUTER PERFORATED SKIN SMALL HOLE REPAIR
(VRS2017/VRS2018)
1. General
A. This repair can be used to repair a hole in one of the two left
or right fixed duct acoustic panel outer skin field area up to
1.00 in. (25,4 mm) in diameter. Refer to REPAIR 002 to repair
the holes that penetrate one side of the panel and are larger
than 1.00 in. (25,4 mm). Refer to REPAIR 003 to repair the holes
that fully penetrate the panel.
B. This type of damage is repaired by the removal of material

around the damaged area. Potting compound is then used to fill
the cavity.
C. This repair causes blockage to the perforated skin in the

acoustically treated areas. For the applicable allowable
limits, refer to SRM 54-01-00, Acoustic Treatment Blockage Area
Limits.
D. Damage must be in field areas only.

from all pandowns, fittings, ducts and ports to the edge
of the damage.

from the edge of the damage to the junction of the
barrel and the bifurcation.
(3) There must be a minimum distance of 4x Diameter from the

edge of one damage to the edge of another damage.
Overhaul Processes and Consumable Index, PCI

Standard Practices and Processes Index, SPPM
V2500 54-30-00 REPAIR 007

Page 201
Feb 1/09
A. Standard equipments

Drill and drilling tools
Hole saw
B. Consumable materials (Ref. Overhaul Processes and

Consumables Index).

CoMat 05-020 Waterproof silicon carbide abrasive paper.
Grit size 320
CoMat 05-081 Waterproof silicon carbide abrasive paper.
Grit size 150
CoMat 08-078 EA9321 Adhesive
CoMat 08-104 EA9394 Epoxy Paste Adhesive
C. Special tools - None
D. Expendable parts - None
PART IDENT MATERIAL

Solid aluminum skin
V2500 54-30-00 REPAIR 007

Page 202
Feb 1/09
AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,

NECESSARY.
moist with CoMat 01-438 solvent. Wipe the surface dry.
B. Use a CoMat 06-131 marking pen to mark the repair area to the
smallest diameter that makes sure that all of the damage is
removed.
V2500 54-30-00 REPAIR 007

Page 203
Feb 1/09

NECESSARY.
A. For SN 1-5000 only (For SN 5001 and on, go to step 5B): Cut the
woven wire as marked. Use a sharp knife. Do not cut into the
B. Cut and remove the damaged perforated skin and core to the
smallest diameter and depth possible to remove damage. Use a
drill or hole saw. Remove the burrs.
C. Remove the sharp edges. Use the CoMat 05-020 and 05-081
abrasive papers.
D. Clean the repair area with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Clean the surface before the
solvent dries.
6. Smooth the Repair Surface
NOTE: Do this procedure if there are indications of

If not, continue to Step 7.A.
A. Refer to SRM 54-02-00 REPAIR 002 (VRS2371) for moisture removal

in the repair area.
A. Refer to SRM 54-02-00 REPAIR 009 (VRS2372) for Honeycomb Core

Repair Procedure.
B. After the repair procedure is complete, remove the release film

V2500 54-30-00 REPAIR 007

Page 204
Feb 1/09
8. If Woven Wire is on the Panel, Seal the Edges of the Woven Wire
A. Apply a 0.005 to 0.010 in. (0,127 to 0,254 mm) layer of

CoMat 08-078 adhesive or CoMat 08-104 adhesive as an
alternative to the repaired surface. Overlap the adhesive on
the woven wire by 0.25 in.(6,35 mm).
9. Make the Repaired Surface Smooth

NECESSARY.
A. Make the surfaces in the repair area smooth with the adjacent
surfaces. Use the CoMat 05-020 and 05-081 abrasive papers.
solvent dries.
A. Visually examine the repaired area. Make sure the repair is

even with the adjacent skin surface.
V2500 54-30-00 REPAIR 007

Page 205
Feb 1/09
A. Write VRS2017 or VRS2018 adjacent to the repair on the panel

edge. Use CoMat 06-131 marking pen.
V2500 54-30-00 REPAIR 007

Page 206
Feb 1/09
Small Hole Repair

Fixed Duct Acoustic Panel Outer Perforated Skin
Figure 201
V2500 54-30-00 REPAIR 007

Page 207
Feb 1/09
V2500 54-30-00 REPAIR 007

Page 208
Feb 1/09
REPAIR 008
TRANSLATING SLEEVE OUTER BARREL LAMINATED SKIN
FULL PENETRATION HOLE REPAIR
(VRS2019/2020)
1. General
This repair may be used to repair a hole in either the left or right
translating sleeve outer barrel which completely penetrates the
composite skin where there is no honeycomb core material.
A. Repair and Damage limits> See Figure 201, View C-C & D-D.
(1) This repair is only applicable those areas of the

composite skin where honeycomb core is not present.
(2) This repair is not applicable to section “B” of the

composite skin between the fwd edge of the panel and the
Forward Frame.
(3) For repair of damage to the fwd and aft edge of the left
or right translating sleeve see chapter 54-30-00, REPAIR
016.
(4) Maximum acceptable length and width of repair cutout in

the composite skin after damage is removed is: L1=L4=4.0
in. (101,6 mm). Damage shape and size shall be small
enough to fit within the area to be cut out.
(5) Minimum distance between separate repairs cutouts after

damage is trimmed out is: D1=11.0 in. (279,4 mm).
(6) Maximum acceptable number of repairs performed on the

translating sleeve outer panel per this procedure is eight
(8).
(7) Minimum acceptable distance from edge of Access Door

cutout to edge of the repair cutout for damage is: X3=8.0
in. (203,2 mm).
(8) Minimum distance from the edge of the holes to the edge of
the repair cutout is: X3=8.0 in. (203,2 mm).
V2500 54-30-00 REPAIR 008

Page 201
Feb 1/09
(9) Minimum distance between edge of honeycomb core and edge

of repair cutout in composite skin is: X1=1.25 in. in.
(31,7 mm).
(10) Minimum distance between Frame Attachments and edge of

repair cutout in composite skin is: X4=2.0 in. (50,8 mm).
(11) Minimum distance from edge of repair cutout to edge of the

outer panel is: X5=8.0 in. (203,2 mm).
B. This repair is performed from the outside in those areas of the

translating sleeve where there is no access to the inboard
surface except through the hole.
C. This type of damage may be repaired by the removal of the

damaged fibers and the application of fabric plies and resin.
VRS2019
VRS2020

Heat lamp (explosion proof)
Heat blanket
Thermocouple
Vacuum connector
Vacuum pump

Index)

CoMat 02-091 Wiping Cloth
CoMat 02-161 Teflon Tape 2.00-in. (50.8 mm)
V2500 54-30-00 REPAIR 008

Page 202
Feb 1/09
CoMat 02-164 Microballoons - Phenolic, 5 mil

CoMat 02-165 Graphite Fabric (AH370-5H)
CoMat 02-167 181-Fiberglass Fabric
CoMat 02-168 Non-porous Parting film
CoMat 02-169 Porous Parting film
CoMat 02-170 Silicone Rubber Sheet
CoMat 08-050 EA9390 Resin
CoMat 12-024 Tacky Tape
C. Repair Parts - None
PART IDENT MATERIAL

Composite Outer Carbon Fabric
Barrel
4. Prepare the Damaged Panel for Repair (See Figure 201 & 202)
A. Clean the surface with Methylethylketone (CoMat 01-076) and a

Wiping Cloth (CoMat 02-091). Wipe the surface dry.
B. Mark the repair area to the smallest diameter that makes sure
that all of the damage is removed. Make sure the shape of the
cutout will allow a backup plate to be inserted through the
hole and provide 1 1.0 in. (25,4 mm) overlap on the inboard
surface.
V2500 54-30-00 REPAIR 008

Page 203
Feb 1/09

PPE IS NECESSARY.
C. Cut out the damaged skin and use a minimum radius of 0.50-in.
(12.7 mm) at all corners. Chamfer the edges of the outer
surface of the skin panel to 45 degrees and remove all loose
particles.
D. Mask around the repair area with 2.00-in. wide Teflon Tape
(CoMat 02-161). Add 5.00-in. (127,0 mm) to the repair area all
around the hole to give an overlap area.
CAUTION: DO NOT TAPER OR BREAK THE CARBON FIBERS OF THE TOP SURFACE
OF THE OUTER SKIN PLY.
E. Lightly roughen the repair area with Waterproof Abrasive Paper

(CoMat 05-022 and 05-081) to remove all of the surface finish
and to lightly roughen the outer surface of the skin.
F. Lightly roughen the inner surface of the skin 1.00-in. (25.4

mm) all around the cutout. This must be done by working through
the cutout from the outside.
G. Clean the surface with Methylethylketone (CoMat 01-076) and a

H. Let the repair area dry for one hour at 230°F-250°F (110°C-
121°C) with an explosion proof heat lamp.
V2500 54-30-00 REPAIR 008

Page 204
Feb 1/09
5. Prepare the Fiberglass Fabric Backup Plate (See Figure 202 and 203)
A. Find the size and shape of the backup plate. The plate must pass
through the cutout and overlap the cutout by 1.00-in. (25.4 mm)
all around when it is installed.
B. Cut three pieces of 181-Fiberglass Fabric (CoMat 02-167) 1.50-

in. (38.1 mm) larger all around than the cutout.
(1) Cut ply no. 1 with the warp at 0 degrees.
(2) Cut ply No. 2 with the warp at 90 degrees.
(3) Cut ply no. 3 with the warp at 0 degrees.
C. Mix the EA9390 resin (CoMat 08-050) according to the

D. Prepare the backup plate plies to match the faying surfaces

(curved or flat).
(1) Put the first fiberglass ply on a sheet of Non-porous

Parting Film (CoMat 02-168).
(2) Apply the EA9390 resin (CoMat 08-050) to the ply and cove
the ply with another sheet of the Non-porous Parting Film
(CoMat 02-168).
(3) Use a roller to force the EA9390 resin (CoMat 08-050) into
the ply thoroughly.
(4) Remove the top sheet of Non-porous Parting Film (CoMat 02-
168) from the first ply.
V2500 54-30-00 REPAIR 008

Page 205
Feb 1/09
(5) Do steps (1), (2), and (3) for the second ply.
(6) Remove the bottom sheet of Non-porous Parting Film (CoMat

02-168) from the second ply and put the ply over the
center of the first ply. Make sure that the warp of the
second ply is 90° to the warp of the first ply.
(7) Smooth out any wrinkles and remove the top sheet of Non-
porous Parting Film (CoMat 02-168).
(8) Do steps (1) through (7) again for the third ply.
(9) Trim the ply stack to the correct size and shape.
6. Make a Vacuum Bag (See Figure 204)
A. Put a minimum of four thermocouples around the perimeter of the

backup plate. Do not put thermocouples on the backup plate.
B. Cover the backup plate with a sheet of Porous Parting Film

(CoMat 02-169) which is 3.00-in. (76.2 mm) larger all around
than the backup plate.
C. Put three plies of 181-Fiberglass Fabric (CoMat 02-167) over

the Porous Parting Film (CoMat 02-169) to serve as bleeder
cloth.
D. Put a sheet of Non-porous Parting Film (CoMat 02-168) over the

bleeder cloth.
E. Put a sheet of Silicone Rubber Sheet (CoMat 02-170) over the

Non-porous Parting Film (CoMat 02-168).
F. Cover the Silicone Rubber Sheet (CoMat 02-170) with the heat
blanket and two plies of 181-Fiberglass Fabric (CoMat 02-167)
to serve as a breather cloth.
G. Cover the repair area with the Nylon Bagging Film (CoMat 02-
163) that is a minimum of 2.00-in. (5038 mm) larger all around.
Put the vacuum connector under the vacuum bag and seal the
edges with the Tacky Tape (CoMat 12-024).
H. Attach the vacuum pump hose to the vacuum connector and connect
the heat blanket to an electrical source.
V2500 54-30-00 REPAIR 008

Page 206
Feb 1/09
7. Cure the Backup Plate (See Figure 203)
A. Cure the backup plate at 190F°-210°F (88°C-99°C) for 220

minutes while you keep a steady vacuum pressure of 20 inches of
mercury inside the vacuum bag.
B. After the EA9390 resin (CoMat 08-050) has cured, remove the
layup materials from the backup plate.
C. Trim the backup plate to make a 1.00-in. (25.4mm) overlap all

around the cutout.
8. Install the Backup Plate (See Figure 202)
WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPESPPM)

INJURED IF YOU DO NOT USE PPE. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON WHICH PPE IS NECESSARY.
A. Drill 0.070-in. (1.9mm) holes through the backup plate near the
centerline. Drill the holes as sets spaced 0.38-in. (9.5 mm)
apart.
B. Put a loop of Lockwire (CoMat 02-156) through each set of holes

in the plate. Twist the ends loosely together.

manufacturer’s instructions. Add 5 percent by wight of
Microballoons (CoMat 02-164) and mix thoroughly to a paste
thickness.
V2500 54-30-00 REPAIR 008

Page 207
Feb 1/09
D. Apply the resin mix to an area 1.00-in. (25.4 mm) wide all
around the inner faying surface of the skin through the cutout
and to the faying surface of the backup plate.
E. Put the backup plate through the cutout and put it against the
inner skin surface.
F. Put a rod over the cutout and twist the Lockwire (CoMat 02-156)
ends around it to firmly hold the backup plate to the inner skin
surface.
NOTE: Do not twist the Lockwire (CoMat 02-156) ends too tightly
or you may warp the backup plate.
G. Apply the resin to the Lockwire (CoMat 02-156) holes.
H. Cure the EA9390 resin (CoMat 08-050) at 190F°-210°F (88°C-99°C)

for 220 minutes with an explosion proof heat lamp.
I. After the EA9390 resin (CoMat 08-050) is cured, remove the heat
lamp and the support rod. Cut the Lockwire (CoMat 02-156) even
with the surface of the backup plate.
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS..
J. Clean the surface with Methylethylketone (CoMat 01-076) and a

V2500 54-30-00 REPAIR 008

Page 208
Feb 1/09
9. Install the Skin Filler (See Figure 202)

A. Cut four (4) Graphite Fabric (CoMat 02-165) filler plies to the
shape of the cutout. Make enough plies to give the same
thickness as the adjacent skin. Cut the plies so that their
warps are at 0°/+45°/-45°/0° to each other. Repeat warp
sequence if addtional filler plies are required..
NOTE: Cut the plies 0.50-in. (12.7 mm) larger all around so
that they do not get frayed. Trim them to the correct
size after they are impregnated with resin.
B. Mix the EA9390 resin (CoMat 08-050) according to the

C. Prepare the cutout filler.
(1) Put the first 181-Fiberglass Fabric (CoMat 02-167) ply on

a sheet of Non-porous Parting Film (CoMat 02-168).
(2) Apply the EA9390 resin (CoMat 08-050) to the ply and cover
the ply with another sheet of the Non-porous Parting Film
(CoMat 02-168).
(3) Use a roller to force the EA9390 resin (CoMat 08-050) into
the ply thoroughly.
V2500 54-30-00 REPAIR 008

Page 209
Feb 1/09
(4) Remove the top sheet of Non-porous Parting Film (CoMat 02-
168) from the first ply.
(5) Do steps (1), (2) and (3) for the second ply.
(6) Remove the bottom sheet of Non-porous Parting Film (CoMat

02-168) from the second ply and put the ply over the
center of the first ply. Make sure that the warp of the
second ply is 90 degrees to the warp of the first ply.
(7) Smooth out any wrinkles and remove the top sheet of Non-
porous Parting Film (CoMat 02-168).
(8) Do steps (1) through (7) again for any additional plies.
D. Trim the ply stack to the size and shape of the cutout.
E. Apply the EA9390 resin (CoMat 08-050) to the faying surfaces of

the backup plate and the original inner skin.
F. Remove the bottom sheet of Non-porous Parting Film (CoMat 02-

168) from the ply stack and put the stack into the repair
cutout. Press the ply stack into position with the roller.
G. Remove the top sheet of Non-porous Parting Film (CoMat 02-168).
10. Install the Outer Skin Repair Patch (See Figure 204)
A. Cut four (4) pieces of Graphite Fabric (CoMat 02-165) larger

all around than the cutout.
(1) Cut ply no. 1 with the warp at 0 degrees. Cut the ply
1.00-in. (25.4 mm) larger all around than the cutout. Trim
the corners 45 degrees by 1.00-in. (25.4 mm).
(2) Cut ply no. 2 with the warp at +45 degrees. Cut the ply
0.75-in. (19.1 mm) larger all around than the first ply.
Trim the corners 45 degrees by 1.00-in. (25.4 mm).
(3) Cut ply no. 3 with the warp at -45 degrees. Cut the ply
0.75-in. (19.1 mm) larger all around than the first ply.
Trim the corners 45 degrees by 1.00-in. (25.4 mm).
V2500 54-30-00 REPAIR 008

Page 210
Feb 1/09
(4) Cut ply no. 4 with the warp at 0 degrees. Cut the ply
1.00-in. (25.4 mm) larger all around than the cutout. Trim
the corners 45 degrees by 1.00-in. (25.4 mm).
B. Cut a 181-Fiberglass Fabric (CoMat 02-167) sanding ply large

enough to cover all of the repair plies and to extend 0.75-in.
(19.1 mm) past the top repair ply all around to the 2.00-in.
wide Teflon Tape (CoMat 02-161) mask area. Trim the corners 45
degrees by 1.00-in. (25.4 mm).

D. Put the first carbon ply on a sheet of Non-porous Parting Film

(CoMat 02-168) and apply the EA9390 resin (CoMat 08-050) to the
ply. Cover the ply with another sheet of the Non-porous Parting
Film (CoMat 02-168).
E. Use a roller to force the EA9390 resin (CoMat 08-050) into the
ply thoroughly.
F. Remove the bottom sheet of Non-porous Parting Film (CoMat 02-

168) from the first ply and put the ply over the center of the
outer skin filler of the repair.
G. Smooth out any wrinkles and remove the top sheet of Non-porous
Parting Film (CoMat 02-168).
H. Do steps 10.D through 10.G again for each successive Graphite

Fabric (CoMat 02-165) plies and the 181-Fiberglass Fabric
(CoMat 02-167) sanding ply.
NOTE: Make sure that the warp of each ply is installed

properly (Ref Step 10.A).
V2500 54-30-00 REPAIR 008

Page 211
Feb 1/09
11. Make a Vacuum Bag (See Figure 203)

fiberglass sanding ply. Do not put thermocouples on the
B. Cover the repair plies with a sheet of Porous Parting Film

(CoMat 02-169) which is 3.00-in. (76.2 mm) larger all around
than the repair.
C. Put for plies of 181-Fiberglass Fabric (CoMat 02-167) over the

Porous Parting Film (CoMat 02-169) to serve as a bleeder cloth.
D. Put a sheet of Non-porous Parting Film (CoMat 02-168) over the

bleeder cloth.
E. Put a sheet of Silicone Rubber Sheet (CoMat 02-170) over the

Non-porous Parting Film (CoMat 02-168).
F. Cover the Silicone Rubber Sheet (CoMat 02-170) with the heat
blanket and two plies of 181-Fiberglass Fabric (CoMat 02-167)
to serve as a breather cloth.
G. Cover the repair area with the Nylon Bagging Film (CoMat 02-
163) that is a minimum of 2.00-in. (50.8 mm) larger all around.
Put the vacuum connector under this vacuum bag and seal the
edges with the Tacky Tape (CoMat 12-024).
H. Attach the vacuum pump hose to the vacuum connector and connect
I. Cure the repair at 190F°-210°F (88°C-99°C) for 220 minutes

while you keep a steady vacuum pressure of 20 inches of mercury
inside the vacuum bag.
J. After the EA9390 resin (CoMat 08-050) has cured, remove the
layup materials from the repair.
K. Remove the 2.00-in. wide Teflon Tape (CoMat 02-161).
V2500 54-30-00 REPAIR 008

Page 212
Feb 1/09
12. Finish the Outer Skin Repair Surface

A. Smooth the outer surface of the repair all around to a feather

edge and to a smooth contour suitable to paint. Use the
Waterproof Abrasive Paper (CoMat 05-022 and 05-081).
B. Clean the surface with Methylethylketone (CoMat 01-076) and a

C. Apply a primer and a top coat to the repair area in accordance

with standard painting procedures (See Repair No. 023).
A. Visually examine and do a tap test of the repair area to make

sure the repair integrity and to make sure that the procedures
in the repair have been done. If necessary, do the applicable
steps again.
V2500 54-30-00 REPAIR 008

Page 213
Feb 1/09
Full Penetration Hole Through the Forward Frame Left or Right

Translating Sleeve Outer Barrel
V2500 54-30-00 REPAIR 008

Page 214
Feb 1/09

V2500 54-30-00 REPAIR 008

Page 215
Feb 1/09

V2500 54-30-00 REPAIR 008

Page 216
Feb 1/09
o
45
0.75 in.(19,0 mm) (Typical)
REPAIR PLY
NO.1 1.0 in. (25 mm) 0.50 in.
(12,7 mm)
REPAIR PLY RADIUS
NO.2
13911
A A
CUTOUT
REPAIR PLY
NO.3
REPAIR PLY
NO.4 1.0 in.
(25 mm)
(Typical)
SANDING PLY
REPAIR PLY NO.3 REPAIR PLY NO.4

REPAIR PLY NO.2
SANDING PLY
REPAIR PLY NO.1
TEFLON TAPE TEFLON TAPE
FILLER PLIES
o SKIN PANEL
BACKUP PLATE 45 CUTOUT
SECTION A-A 13911A
Laminated Skin Repair Layup

Fig 201
V2500 54-30-00 REPAIR 008

Page 217
Feb 1/09
CUTOUT
BACKUP PLATE
ROD
A A
13912
LOCKWIRE HOLES,
PLATE 4 HOLES, LOCATED
INSERTION NEAR THE CENTERLINE
POSITION OF THE BACK-UP
PLATE AS SHOWN
LOCKWIRE NOT SHOWN

SKIN PANEL
SKIN PANEL
LOCKWIRE
ROD
45°
1.0 in. (25 mm)

(TYPICAL)
BACKUP PLATE SECTION A - A
13912A
Backup Plate Installation

Fig 202
V2500 54-30-00 REPAIR 008

Page 218
Feb 1/09
VACUUM BAG FIBERGLASS FABRIC BREATHER PLIES (2)
SILICONE RUBBER SHEET

REPAIR PLIES (4)
NONPOROUS PARTING FILM
FIBERGLASS SANDING PLY
BLEEDER CLOTH PLIES
HEAT BLANKET
POROUS PARTING FILM
VACUUM HOSE
13913 TEFLON TAPE
TEFLON TAPE
SEALANT
CUTOUT
o
45 BACKUP PLATE
PANEL SKIN
THERMOCOUPLE
13913B
Vacuum Bag Assembly

Fig 203
V2500 54-30-00 REPAIR 008

Page 219
Feb 1/09
V2500 54-30-00 REPAIR 008

Page 220
Feb 1/09
REPAIR 009
FIXED DUCT ACOUSTIC PANEL SOLID SKIN CRACK REPAIR
(VRS2021/2022)
1. General
A. This repair procedure is used to repair cracks to the solid

skin of the left hand or the right hand fixed duct acoustic
panel.
B. This type of damage is repaired by the installation of a repair

doubler.
C. This repair is applicable to damage in the areas shown in

manufacturer for repair instructions.
D. Crack must be less than 6.0 in. (152,4 mm) long.
E. There must be a minimum distance of four times the crack length

between two adjacent cracks.
F. The solid skin must not be disbonded from the core in the area
around the crack. If there is a disbond, refer to REPAIR 010.
2. Reference information
The Repair Scheme Number for this procedure is VRS2021/VRS2022


Heat lamp (Explosion proof)
Heat gun
Riveting tools
Sheet Metal formaing tools
V2500 54-30-00 REPAIR 009

Page 201
Feb 1/09

Consumable Index)

CoMat 01-457 Solvent MIBK, alternate for CoMat 01-438
CoMat 02-360 Aluminum Sheet 2024-T3, 0.045 or 0.050 in.
(1,14 or 1,27 mm)
CoMat 07-028 Chromate Conversion (Alodine 1200)
CoMat 07-106 Chromate Conversion
(Substitute to CoMat 07-028)
CoMat 07-115 I Primer Class M
PART IDENT MATERIAL

Acoustic Panel Serial Woven wire
Number 1-5000 Perforated aluminium skin
Solid aluminium skin
Acoustic Panel Serial Perforated aluminium skin
Number 5001 and on Aluminium honeycomb core
Solid aluminium skin
V2500 54-30-00 REPAIR 009

Page 202
Feb 1/09
F. Repair Parts
CR3523P4 Rivet A/R

CR3223-4 Rivet, Alternative A/R
CR3553P4 Rivet, Oversize A/R
CR3253-4 Rivet, Alternative Oversize A/R

NECESSARY.
solvent dries.
B. Find the ends of the crack. Do a visual inspection of the skin

using a 10x magnification lens. Refer to the SPPM for
instructions. Make a mark to show the two crack ends. Use CoMat
06-131 marking pen.
C. Drill 0.19 in. (4,83 mm) diameter holes at the two ends of the
crack. Remove the burrs.
V2500 54-30-00 REPAIR 009

Page 203
Feb 1/09
D. Visual inspect the stop drills using a 10X magnifying glass.

Make sure that crack does not re-appear on the other side. Do
again stop drill as required.
E. Use a router along the length of the crack to a maximum width of

0.250 in. (6,35 mm) to remove the crack. Do not cause
damage to the underlying structure when you route the crack.
Remove the burrs.
F. Make a mark to show the damaged area covered by the repair

doubler. Use CoMat 06-131 marking pen. The repair doubler must
be large enough to accept two rows of rivets more than the edge
of damaged area.
NOTE: 1. The doubler can be circular or rectangular. If the

doubler is rectangular, use a minimum radius of 0.50
2. Before you cut the woven wire, record and keep the
dimensions for the doubler to be used later.
G. Apply CoMat 02-161 Teflon tape around repair area

approximately 0.50 in. (12,7 mm) from bond faying surface. Mask
other areas that can contaminate by this procedure.
H. Clean the area with CoMat 02-099 lint free cloth made moist
solvent dries.
V2500 54-30-00 REPAIR 009

Page 204
Feb 1/09
5. Make a Repair Doubler (See Figure 202)

NECESSARY.
A. Make a repair doubler from CoMat 02-360 aluminum sheet

0.045 or 0.050 in. (1,14 or 1,27 mm). Use the dimensions
recorded in step 4.F. Make the doubler to align with the
contour of the acoustic panel. The doubler must conform to
contour with light finger pressure. Chamfer the edges of the
doubler. Remove the burrs.
B. Put the repair doubler above the damaged area. Refer to figure
202 for overlap.
C. Drill two rows of rivet holes through the repair doubler and
the solid skin assembly. Do not drill through the opposite
skin.
D. The rivet hole diameter is 0.129 to 0.132 in. (3,28 to 3,35 mm).
center-to-center distance and row distance between the holes is
0.50 in. (12,7 mm). Remove the burrs.
E. Remove the drilling particles from the repair doubler and skin
assembly. Use a CoMat 02-099 lint free cloth made moist with
CoMat 01-438 solvent. Clean the surfaces before solvent dries.
6. Prepare the Surface Area of the Doubler and Solid Skin
A. Apply thin layer of CoMat 07-028 Chromate Conversion coating to

bare surfaces of all made repair parts. CoMat 07-106 is
permitted alternative to CoMat 07-028.
7. Apply the Adhesive Primer
A. Apply one layer of CoMat 07-115 I Primer Class M to the entire

surfaces of all fabricated repair parts.
V2500 54-30-00 REPAIR 009

Page 205
Feb 1/09
8. Install the Repair Doubler (Ref. Figure 202)

NECESSARY.
CONTAMINATION.
A. Use the manufacturer’s instructions to mix the CoMat 08-104

adhesive.
B. Apply a thin layer of the adhesive mixture to the bonding

surface of the solid skin. Fill the slot performed to remove
the crack. Apply the adhesive at least 0.25 in. (6,35 mm)
larger than the repair doubler.
C. Apply a thin layer of the adhesive mixture to the bonding

surface of the repair doubler. Put the repair doubler into
position. Use temporary fasteners at some fastener location to
prevent movement during installation of fasteners.
D. Wet install the rivets with CoMat 08-104 adhesive. The

installation of all permanent fasteners must be done during the
pot life of the adhesive. Refer to Figure 202.
E. Remove the excess of adhesive from repair doubler periphery.
V2500 54-30-00 REPAIR 009

Page 206
Feb 1/09
9. Cure the Repair (See Figure 202)
A. Cure adhesive for 1 hour at 180o to 200oF (82o to 93oC). Use

explosion proof heating device. If necessary, add more
pressure during curing use dead weight or equivalent.
A. Visually examine and do a tap test of the repair area to check

for disbonds. Make sure that the procedures in this repair are
done. If necessary, do the applicable steps again.

NECESSARY.
A. Sand edges of repair doubler lightly use 180 grit or better

aluminum oxide paper. Remove the dust by wiping with
CoMat 02-099 lint free cloth.
B. Protect bare metal surfaces in the repair area per

SRM 54-02-00 Par. 1.
C. Clean the surface with a CoMat 02-099 lint free cloth made
solvent dries.
V2500 54-30-00 REPAIR 009

Page 207
Feb 1/09
A. Write VRS2021 on the left hand panel, or VRS2022 on the right

hand panel adjacent to the assembly number. Use a CoMat 06-131
marking pen of a color that contrasts.
V2500 54-30-00 REPAIR 009

Page 208
Feb 1/09
Solid Skin Crack Repair

V2500 54-30-00 REPAIR 009

Page 209
Feb 1/09

V2500 54-30-00 REPAIR 009

Page 210
Feb 1/09

V2500 54-30-00 REPAIR 009

Page 211
Feb 1/09

Figure 202
V2500 54-30-00 REPAIR 009

Page 212
Feb 1/09
REPAIR 010
FIXED DUCT ACOUSTIC PANEL PARTIAL PENETRATION
THROUGH THE SOLID INNER SKIN REPAIR
(VRS2023/VRS2024)
1. General
A. This repair procedure is used to repair partial penetration

damage through the solid skin side of the left hand or right
hand fixed duct acoustic panel. For holes that fully
penetrate the panel, refer to REPAIR 003.
B. This repair is applicable to damage in the areas shown in

manufacturer for repair instructions. (If an autoclave repair
is necessary, contact the manufacturer for
instructions and increased repair limits.).
C. This type of damage can be repaired by removal of the damaged

area and the installation of a repair plug with doubler. This
repair is not applicable to the bifurcation panels.
D. The total damage area for the left or right panel is a

maximum of 144 in². (929 cm²)
E. There must be a minimum distance of 2.0 in. (50,8 mm) from the
edge of the damage to the junction of the barrel and the
bifurcation. There must be a minimum distance of four times the
diameter of the damage between the edges of two adjacent damage
areas

V2500 54-30-00 REPAIR 010

Page 201
Feb 1/09

Heat blankets
Heat gun
Plastic spatula
Riveting tools
Standard shop tools

Consumables Index).

CoMat 02-324 AL5052 core 4.1 PFC
CoMat 08-085 Bonding film adhesive EA9689, supported
V2500 54-30-00 REPAIR 010

Page 202
Feb 1/09
PART IDENT MATERIAL

Solid alumunum skin
Serial Number Aluminium honeycomb core
F. Repair Parts
Part No. Part Ident QTY
CR3523P4 Rivet A/R

CR3223-4 Rivet, Alternative A/R
CR3553P4 Rivet, Oversize A/R
CR3253-4 Rivet, Alternative Oversize A/R
4. Prepare the Damaged Area For Repair, (See Figure 202)

NECESSARY.
V2500 54-30-00 REPAIR 010

Page 203
Feb 1/09
CONTAMINATION.
moist with CoMat 01-438 solvent. Rub the surface clean and dry
B. Make a mark of the damaged area. Use CoMat 06-131 marking pen.
The cutout must have the smallest regular shape that removes
all of the damage. The cutout can be circular or rectangular.
C. Make a border 1.5 in. (38,1 mm) more than around the cutout. Use
the CoMat 02-161 Teflon tape.
D. Cut and remove the damaged skin and core from the area marked.
Use a drive motor and routing tools. Remove the core. Remove
adhesive glossy finish and remaining core residue by lightly
hand sanding adhesive surface on solid skin. It is acceptable
for core imprint to remain. Take extra care not to sand through
adhesive. Use the CoMat 05-020 and CoMat 05-081 abrasive
papers. Do not cut into the perforated skin.
NOTE: If the cutout is rectangular, use a minimum radius of

0.50 in. (12,7 mm) at the corners.
E. Remove the sharp edges. Use the CoMat 05-020 and CoMat 05-081
abrasive papers.
F. Clean the repair area with a CoMat 02-099 lint free cloth made
solvent dries
5. Remove the Moisture From the Repair Area
NOTE: Do this procedure if there are indications of moisture in

the repair area.
A. Refer to SRM 54-02-00, REPAIR 002 (VRS2371) for moisture

removal in the repair area.
V2500 54-30-00 REPAIR 010

Page 204
Feb 1/09
6. Make the Repair Parts (See Figure 203)

NECESSARY.
A. Make the core plug from CoMat 02-324 core material. Make sure
the replacement core has the same shape, size, density, and
ribbon direction as the core that you removed. Remove the
burrs.
B. Put the core plug into the cutout. Trim the edges as
necessary. The space between the plug and the existing core
must not be more than 0.05 in. (1,27 mm) around. Make the core
plug the same height and contour with the solid skin of the
acoustic panel.
C. Make a repair doubler from CoMat 02-322 aluminum sheet. Make

the doubler from material that is the same thickness as the
damaged skin. Make the doubler 1.25 in. (31,75 mm) larger than
the cutout all around. Make sure the contour of the
doubler agrees with the contour of the acoustic panel.
Chamfer the edges. Remove the burrs.
NOTE: If the cutout is rectangular, use a minimum radius of

0.50 in. (12,7 mm) at all corners of the repair
doubler.
7. Install and Cure the Repair Core Plug
009 (VRS2372) using Method 4.
8. Prepare the Surfaces of the Doubler and Repair Area
A. Prepare the mating surfaces of the repair doubler and the

repair surface per SRM 54-02-00, REPAIR 003 (VRS2369).
V2500 54-30-00 REPAIR 010

Page 205
Feb 1/09
9. Apply the Primer to the Doubler, Core, and Repair Area

NECESSARY.
CONTAMINATION.
A. Clean the doubler and the repair area. Use a CoMat 02-099 lint
free cloth made moist with CoMat 01-438 solvent. Clean the
surfaces before solvent dries.
B. Force air dry for 30 minutes at 190o to 210oF (88o to 99o C).
C. Apply adhesive primer to all exposed edges of the core plug,

the solid skin and all surfaces of the repair doubler. Refer to
SRM 54-02-00, REPAIR 006 (VRS2374).
V2500 54-30-00 REPAIR 010

Page 206
Feb 1/09
10. Install the Repair Parts, (See Figure 203)

NECESSARY.
CONTAMINATION.
A. If necessary, clean the doubler and the repair area. Use a

CoMat 02-099 lint free cloth made moist with CoMat 01-438
solvent. Rub the surfaces clean and dry before the solvent
dries.

mating surface of the doubler.

on the doubler.
D. Put the doubler into position.
V2500 54-30-00 REPAIR 010

Page 207
Feb 1/09
11. Vacuum Bag and Cure the Repair
A. Prepare a vacuum bag for the repair area use SRM 54-02-00,
REPAIR 006 (VRS2370) as guide.

area, the temperature will not be constant. If
necessary, use more heat blankets to make the heat
supply constant above the repair area
B. Cure the repair area using heat blankets or other explosion

proof equipment as follows. Heat the repair area at a rate of 1
to 6°F (1 to 4°C) per minute to put all thermocouples in the
cure temperature range specified below.

TEMPERATURE.
C. When the coldest thermocouple have the 350°F (177°C)± 10°F (±

5°C) cure temperature range, start a 60-minute soak.
the cure temperature range is kept during soak period.
D. After the soak at the necessary temperature is complete, cool

to 150°F (65°C) at a rate not to exceed 5°F (3°C) per minute.
When the temperature read 150°F (65°C), the equipment can be
removed.
E. Disconnect the heat blankets and the vacuum source. Remove the
bagging materials and thermocouples.
F. Examine the repair to make sure doubler has not moved out of
position. If doubler has moved, remove doubler and do again the
above steps for installation.
A. Drill two rows of rivet holes through the doubler and the solid
skin. Do not drill through to the opposite skin.
V2500 54-30-00 REPAIR 010

Page 208
Feb 1/09
B. The rivet hole diameter is 0.129 to 0.132 in. (3,28 to 3,35 mm).
The typical edge distance is 0.32 in. (8,1 mm). The
typical center-to-center distance and row spacing between the
holes is 0.50 in. (12,7 mm). Remove the burrs.
C. Remove the drilling particles. Use a CoMat 02-099 lint free

cloth made moist with CoMat 01-438 solvent. Clean the
surfaces before solvent dries.
D. Wet install the rivets with CoMat 08-104 adhesive. See Figure
203 for rivet call out and approximate location.
13. Apply Protective Treatments and Primer to the Repair Area

NECESSARY.
CONTAMINATION.
moist with CoMat 01-438 solvent. Clean the surface before
solvent dries.
B. The external surface of the doubler must be a water break free

surface. Perform a water break free test of this surface.
V2500 54-30-00 REPAIR 010

Page 209
Feb 1/09
C. Perform protective treatment of repair materials per

SRM 54-02-00, General Repair, Paragraph 1.A.(1) and Paragraph
1.A.(2).

NECESSARY.
A. Remove the sharp edges. Make the surface in the repair area
smooth with the adjacent surface. Use the CoMat 05-020 and 05-
solvent dries.

A. Write VRS2023 or VRS2024 adjacent to the assembly number. Use a

CoMat 06-131 marking pen of a color that contrasts.
V2500 54-30-00 REPAIR 010

Page 210
Feb 1/09
Partial Penetration Repair, Solid Skin

V2500 54-30-00 REPAIR 010

Page 211
Feb 1/09

V2500 54-30-00 REPAIR 010

Page 212
Feb 1/09
28.0 in.
31.0 in. (711,2 mm)
(787,4 mm)
20.0 in.
(508,0 mm)
7.0 in.
(177,8 mm)
4 in.
(101,6 mm)
SPLIT
4.0 in.
37.0 in. LINE
(101,6 mm)
(939,8 mm)
6.0 in.
(152,4 mm)
3.0 in.
(76,2 mm) 3.0 in.
(76,2 mm)
9.0 in. 4 in.
(228,6 mm) (101,6 mm)
15.0 in. B
(381 mm) 31.0 in. LEFT HAND ASSEMBLY
(787,4 mm) VIEW LOOKING INBOARD
(Typical)
Note: Do not make repairs in these areas:
Inner barrel cutouts
Upper and lower bifurcations

gc00a5s089

V2500 54-30-00 REPAIR 010

Page 213
Feb 1/09

Figure 202
V2500 54-30-00 REPAIR 010

Page 214
Feb 1/09

Figure 203
V2500 54-30-00 REPAIR 010

Page 215
Feb 1/09
V2500 54-30-00 REPAIR 010

Page 216
Feb 1/09
REPAIR 011 (VRS2025/VRS2026)

FIXED DUCT ALUMINUM SKIN/HONEYCOMB BOND SEPARATION REPAIR
DELETED AUG 1/07 BY SRM REVALIDATION
THIS SRM REPAIR HAS BEEN CANCELLED AND SHOULD NO LONGER BE APPLIED.
IF PREVIOUSLY ACCOMPLISHED, REFER TO V2500-NAC-78-0231 FOR DISPOSITION.
V2500 54-30-00 REPAIR 011

Page 201
Feb 1/09
V2500 54-30-00 REPAIR 011

Page 202
Feb 1/09
REPAIR 012
SOLID INNER SKIN SMALL HOLE REPAIR – NOT FULLY THROUGH PANEL
(VRS2027/2028)
1. General
A. This repair procedure can be used to repair small hole damage

up to 1.0 in. (25,4 mm) in diameter to the solid inner skin side
of the left or right fixed duct acoustic panel.
B. This type of damage is repaired by removal of the damaged area.

Adhesive is used to fill the hole. Refer to the
SRM 54-01-00 for the maximum acoustical area loss limits.
C. This repair is applicable to the damage limits given below. If

the damage is more than the limits given below, you must refer
to the manufacturer for repair instructions:
(1) This repair is not applicable in the bifurcation areas and

in the area between the 7th stage bleed port and ACC duct
cutouts on the Right C-duct. (See the notes in Figure 201,
Sheets 1 and 2)
(2) Minimum distance from the edge of this damage to the edge
of other damage is 5.0 in. (127 mm).
VRS2027
VRS2028
A. Standard tools
Heat blanket
Hole saw
Plastic spatula
V2500 54-30-00 REPAIR 012

Page 201
Feb 1/09

Consumable Index)

CoMat 01-457 Solvent, alternate for CoMat 01-438
CoMat 02-168 Non-porous Parting film
CoMat 02-170 Silicone Rubber Sheet
CoMat 08-021 EA934NA Adhesive Alternative for CoMat 08-104
CoMat 08-078 Adhesive Alternative for CoMat 08-104
C. Repair parts - None
PART IDENT MATERIAL

Acoustic Panel Woven wire, Perorated aluminum skin,
Aluminum honeycomb core, Solid
Aluminum inner skin
4. Prepare the Damaged Area For Repair, (See Figure 201, Sheet 3)
V2500 54-30-00 REPAIR 012

Page 202
Feb 1/09

PPE IS NECESSARY.
A. Make a mark of the damage area with the smallest diameter that
removes all the damage. Apply CoMat 02-160 teflon tape around
the marked area.
B. Remove the damaged skin and core from the repair area to the
smallest depth possible. Use a hole saw. Do not cut into the
perforated skin.
C. Remove the sharp edges. Use the CoMat 05-020 and 05-081
waterproof silicon carbide abrasive papers.
the solvent dries.
5. Repair the Damaged Panel, (See Figure 201, Sheet 3)

PPE IS NECESSARY.
CAUTION: PUT ON COMAT 02-097 LINT FREE GLOVES BEFORE YOU TOUCH THE
CONTAMINATION.

adhesive.
V2500 54-30-00 REPAIR 012

Page 203
Feb 1/09
B. When you fill the damage area with the adhesive, make sure that
the adhesive does not flow out of the perforated skin. To stop
the flow of adhesive, put a piece of CoMat 02-168 non-porous
parting film over the perforated skin side of the panel in the
repair area. Use pieces of CoMat 02-160 teflon tape to hold the
non-porous parting film in place. Apply pressure as necessary.
C. Fill the damage area with CoMat 08-104 adhesive. Fill the
damage area until a small quantity of adhesive is higher than
the adjacent surface.
D. Put the CoMat 02-168 non-porous parting film on the repair

area. Hold the film in place with CoMat 02-160 teflon tape.
E. Put a sheet of CoMat 02-170 silicone rubber on the nonporous

parting film.
F. Cure the repair for 60 minutes at 180o to 200oF (82o to 93oC).

Use a heat blanket or an explosion proof heat lamp.
G. Remove the parting film and teflon.
6. Make the Repair Area Smooth

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 012

Page 204
Feb 1/09
A. Use the CoMat 05-020 and 05-081 abrasive papers. Remove the
sharp edges. Make the surface in the repair area smooth with
the adjacent surface.
the solvent dries.

A. Write the repair numbers VRS2027 for the left fixed duct
acoustic panel or VRS2028 for the right fixed duct acoustic
panel adjacent to the assembly number. Use a CoMat 06-131
V2500 54-30-00 REPAIR 012

Page 205
Feb 1/09
28.0 in.
(711,2 mm) 31.0 in.
(787,4 mm)
20.0 in.
(508,0 mm)
7.0 in.
(177,8 mm)
4 in.
(101,6 mm)
SPLIT
3.0 in. LINE 4.0 in. 37.0 in.
(76,2 mm) (101,6 mm) (939,8 mm)
6.0 in.
(152,4 mm)
3.0 in.
4 in. (76,2 mm)
(101,6 mm)
9.0 in.
4 in. (228,6 mm)
(101,6 mm) 15.0 in.
31.0 in. (381 mm)
(787,4 mm)
Inner barrel cutouts

LEFT HAND ASSEMBLY
Upper and lower bifurcations VIEW LOOKING INBOARD
(Typical) VRS2027-1
Bonded panel Assembly - Inner Barrel

Solid Inner Skin Small Hole Partial Penetration Repair
V2500 54-30-00 REPAIR 012

Page 206
Feb 1/09
31.0 in.
28.0 in.
(787,4 mm)
(711,2 mm)
3.0 in.
(76,2 mm) 20.0 in.
(508,0 mm)
7.0 in.
(177,8 mm)
37.0 in. 4.0 in.

(939,8 mm) 4.0 in. (101,6 mm)
(101,6 mm) SPLIT
LINE
4.0 in. 7.0 in

(101,6 mm) (177,8 mm)
6.0 in.
7.0 in. (152,4 mm)
(177,8 mm)
4.0 in.
(101,6 mm)
44.0 in. 3.0 in.

(1117,6 mm) (76,2 mm)
Inner barrel cutouts RIGHT HAND ASSEMBLY

VIEW LOOKING INBOARD
(Typical)
Upper and lower bifurcations
VRS2027-2
Bonded Panel Assembly - Inner Barrel

Solid Inner Skin Small Hole Partial Penetration Repair
V2500 54-30-00 REPAIR 012

Page 207
Feb 1/09
SOLID INNER SKIN

DRILL OUT DAMAGE
CORE
PERFORATED SKIN
AND WOVEN WIRE
SMALL HOLE DAMAGE TEFLON TAPE
TYPICAL DAMAGE
APPLY PRESSURE ADHESIVE TEFLON TAPE

NON-POROUS SOLID SKIN
PARTING FILM
PERFORATED SKIN
AND WOVEN WIRE DRILL TO MINIMUM
NON-POROUS DEPTH AND DIAMETER
PARTING FILM APPLY PRESSURE TO REMOVE DAMAGE
SECTION A-A
VRS2027-3
Bonded Panel Assembly - Inner Barrel

Solid Skin Small Hole partial Penetration Repair
V2500 54-30-00 REPAIR 012

Page 208
Feb 1/09
REPAIR 013
FULL PENETRATION HOLE REPAIR THROUGH THE FORWARD FRAME
LEFT OR RIGHT TRANSLATING SLEEVE OUTER BARREL
(VRS2029/2030)
1. General
A. This repair procedure is used to repair a hole, which fully

penetrates the outer barrel of the left or right translating
sleeve forward frame. See Figure 201 and view D-D and E-E for
repair and damage limits.
B. This type of damage is repaired by the removal of the damaged

skins, replacement of the damaged honeycomb core and the
installation of co-cured graphite and fiberglass patches with
resin. It can be necessary to remove the translating sleeve
before you do this repair.
C. Maximum width (L1) and length (L2) of repair Cutout is:

L1=L2=3.50 in. (88,9 mm).
D. Minimum distance from edge of repair Cutout to the edge of

honeycomb core is: L3=0.25 in. (6,35 mm).
E. Minimum distance between separate Repair Cutouts is: D1=9.0 in.

(228,6 mm).
F. Minimum acceptable distance of repair Cutout from slider

fittings is 8.0 in. (203,2 mm).
G. Maximum number of times this repair can be performed on the

translating sleeve outer barrel panel at the forward frame is
five (5) times.
VRS2029
VRS2030
V2500 54-30-00 REPAIR 013

Page 201
Feb 1/09
A. Standard tools
Heat blanket
Standard shop tools
Thermocouples
Vacuum probe
Vacuum pump

Consumable Index)
CoMat 01-076 Methylethylketone; Alternate for CoMat 01-438

CoMat 02-165 Graphite fabric
CoMat 05-081 Waterproof Silicone carbide abrasive paper
CoMat 08-050 Resin
CoMat 08-131 Resin; alternative for CoMat 08-050
V2500 54-30-00 REPAIR 013

Page 202
Feb 1/09
E. Component material
PART IDENT MATERIAL

Composite outer barrel Graphite fabric;
F. Component materials
PART IDENT MATERIAL

Honeycomb core 5052 Aluminium honeycomb core
(Reference 54-30-00, Structural
Identification, Figure 1)
4. Prepare the Damaged Area For Repair, (See Figure 201 and 202)
CAUTION: WHEN YOU ABRADE THE COMPOSITE SURFACE, DO NOT TAPER OR

BREAK THE GRAPHITE FIBERS.
becomes dry.
B. Make a circular or rectangular mark of the damaged area to be

cut out. Use CoMat 06-131 marking pen. THe area must have the
smallest regular shape that will remove the damage completely.
The stiffener frame construction must remain intact.
C. Cut out the damaged skins and core as marked. Use cutters and
cutting tools. If the cutout is rectangular, use a minimum
radius of 0.50 in. (12,7 mm) at all corners.
V2500 54-30-00 REPAIR 013

Page 203
Feb 1/09
D. Chamfer the edges of the cutout on the outer and inner

surfaces. Remove all loose pieces and fibers. Make the edges
smooth. Use the CoMat 05-020 and 05-081 abrasive papers.
E. Make s border around the cutout on the outer and inner

surfaces. Use CoMat 02-161 Teflon tape. Add 5.0 in. (127,0 mm)
all around the repair area. This provides an overlap area.
F. Remove all of the surfaces finish and lightly make the surfaces
rough in the area between the pieces of Teflon tape. Use CoMat
G. Clean the internal and external surfaces in the repair area

with a CoMat 02-099 lint free cloth made moist with CoMat 01-
438 solvent. Rub the surface dry before the solvent becomes
dry.
H. Let the repair area dry for one hour at 230° to 250°F (110° to
121°C). Use an explosive proof heat lamp.
V2500 54-30-00 REPAIR 013

Page 204
Feb 1/09
5. Install the Honeycomb Core, (See Figures 202 and 203)
A. Make a repair plug from repair core material to fit the size and
length of the removed damage core. Make the repair plug with
the same ribbon direction ad the original core. See
54-30-00 Structural identification to determine the type,
density and thickness of the core material.
NOTE: Visually examine the repair plug to make sure that it

has the correct dimensions and ribbon direction. Make
sure it aligns with the core material acoustic panel.

adhesive. Add 5 percent of CoMat 02-164 microballoons. Mix
thoroughly to a paste thickness.
C. Apply the adhesive mixture to the exposed surfaces of the core

material in the cutout area and repair plug.
D. Put the repair plug into the cutout.
V2500 54-30-00 REPAIR 013

Page 205
Feb 1/09
6. Install the Inner Skin Fillers Plies, (See Figure 202)
A. Find the size and shape of the filler plies. Cut the plies 0.050
in. (12,7 mm) larger than the cutout all around. Cut the filler
plies to the correct size after they are impregnated with
resin.
B. Cut the first filler ply from the CoMat 02-167 fiberglass
fabric. Cut the filler plies from CoMat 02-165 graphite fabric.
Cut the filler plies with alternating warp directions of 0°/
+45°/-45°/0° degrees. Make enough plies to give the same
thickness as the inner skin.
NOTE: Visually examine the filler plies to make sure that they
have the correct warp orientation.

resin.
V2500 54-30-00 REPAIR 013

Page 206
Feb 1/09
D. Prepare the filler plies.
NOTE: Warp direction of filler plies shall be 0°/+45°/-45°/0°

degrees. Make enough plies to give the same thickness as
the inner skin.
(1) Put the first filler ply on a sheet of CoMat 02-168 non-
(2) Apply the resin to the ply on a sheet of parting film

above the filler ply.
(3) Use a roller to force the resin fully into the ply.
(4) Repeat steps (1), (2) and (3) for the other filler plies.
(5) Remove the non-porous parting film from the top of the
first 0° degree filler ply. Remove the non-porous parting
film from the bottom of the second ply.
(6) put the second filler ply (+45° degrees) over the center
of the first filler ply (0° degree) and smooth out all
wrinkles.
(7) Repeat steps (5) and (6) for the remaining graphite filler
plies to make a stack of filler plies.
(8) Cut the edges of the stack of the filler plies to the
correct size of the cutout.
E. Apply the resin to the mating surface of the honeycomb core

inside the cutout and to all applicable edges.
V2500 54-30-00 REPAIR 013

Page 207
Feb 1/09
F. Remove the non-porous parting film from the fiberglass fabric

side of the stack of filler plies. Put the stack into the
cutout. Press the stack into position against the honeycomb
core. Remove the wrinkles, use a roller if necessary.
NOTE: The fiberglass ply must be in contact with the aluminum

core plug when installed. Make sure the fiberglass ply
is on top of the stack.
G. Remove the remaining non-porous parting film from the stack.
7. Install the Inner Skin Repair Plies, (See Figures 202 and 203)
A. Cut the repair plies from the CoMat 02-165 graphite fabric. Cut
the corners of the plies 45 degrees by 1.0 in. (25,4 mm). See
Figure 202.
(1) Cut ply No. 1 with the warp at 0° degree. Cut the ply 1.0
in. (25,4 mm) larger that the cutout all around.
in. (19 mm) larger than the first ply all around.
(3) Cut ply No. 3 with warp at 0° degree. Cut the ply 0.75 in.
(19 mm) larger than the second ply all around.
(19 mm) larger than the third ply all around.
V2500 54-30-00 REPAIR 013

Page 208
Feb 1/09
B. Cut a fiberglass sanding ply from the CoMat 02-167 fiberglass

fabric. Cut the ply 1.0 in. (25,4 mm) larger than the fourth
repair ply all around, or large enough to reach the Teflon
tapes. Trim the corners of the ply 45° degrees by 1.0 in. (25,4
mm).
NOTE: Do not cover the Teflon tape with the fiberglass sanding
ply.

resin.
D. Put the first repair p[ly on a sheet of non-porous parting

film. Apply the resin to the ply.
E. Put another sheet of parting film above the repair ply. Use a
roller to force the resin fully into the ply.
F. Install the first repair ply.
(1) Remove the bottom sheet of nonporous parting film from the
repair ply. Put repair ply above the cutout and filler
plies.
NOTE: Make sure you use the correct warp direction.
(2) Press the ply into position and remove the wrinkles. Use a
roller if necessary.
(3) Remove the top sheet of the non-porous parting film from
the ply.
V2500 54-30-00 REPAIR 013

Page 209
Feb 1/09
G. Do Steps D., E., and F for the remaining repair plies and for
the fiberglass sanding ply.
NOTE: Make sure repair plies are put together with the correct
warp direction. Make sure you remove the non-porous
parting films from the plies.
NOTE: If necessary, it is acceptable for the repair plies to

overlap the fwd and aft edges of the closure plies on the
fwd frame.
8. Install the Outer Skin Filler Plies, (See Figure 202 and 203)
resin.
B. Cut the first filler ply from the CoMat 02-167 Fiberglass
fabric. Cut the remaining filler plies from the CoMat 02-165
Graphite fabric. Cut the filler plies with warp directions of
0°/+45°/-45°/0° degrees to each other. Repeat warp sequence if
additional filler lies are needed. Make enough filler plies to
give the same thickness as the outer skin.
NOTE: Visually examine the repair plies to make sure that they
have the same warp orientation as the original acoustic
panel outer skin.
C. Use the manufacturer’s instructions to mix CoMat 08-050 resin.
V2500 54-30-00 REPAIR 013

Page 210
Feb 1/09
(2) Apply the resin to the ply. Put another sheet of parting
film above the filler ply.
(4) Do steps (1), (2) and (3) for the other filler plies.
first ply. Remove the non-porous parting film from the
bottom of the second ply.
(6) Put the second ply over the center of the first ply and
smooth out all wrinkles. Warp direction of the warp
sequence for additional filler plies.
(8) Cut the edges of the crack of the filler plies to the
E. Apply resin to the applicable edges.
F. Remove the non-porous parting film from the fiberglass side of

the stack of filler plies. Put the stack into the cutout. Press
the stack into position against the core plug. Remove the
wrinkles. Use the roller if necessary.
V2500 54-30-00 REPAIR 013

Page 211
Feb 1/09
NOTE: The fiberglass ply must be in contact with the aluminum

core plug when installed. Make sure the fiberglass ply
in on the bottom of the stack.
9. Prepare Vacuum Bags For the Repair on the Two Sides, (See Figure 203)
A. Prepare a vacuum bag for the outer surface side of the repair.
(1) Put a minimum of four thermocouples around the perimeter

of the repair area.
(2) Put a sheet of CoMat 02-169 porous parting film above the
repair area. The sheet must be 3.0 in. (76,2 mm) larger
than the repair area all around.
(3) Put four plies of CoMat 02-167 fiberglass fabric above the
porous parting film. This will serve as the bleeder cloth.
(4) Put a sheet of CoMat 02-168 non-porous parting film above

the bleeder cloth.
(5) Put an aluminum caul plate above the non-porous parting

film. The caul plate must have the same contour as the
outer skin in the damage area.
(6) Put a heat blanket above the caul plate.
(7) Put two plies of CoMat 02-166 breather cloth above the
heat blanket.
(8) Put a sheet of CoMat 02-163 nylon bagging film above the
repair area. THe sheet must be 2.0 in. (50,8 mm) larger
than the repair pieces all around.
(9) Put a vacuum probe under the nylon bagging film. Seal the
thermocouples and vacuum probe. Use CoMat 12-024 sealant.
Seal the edges of the nylon bagging film to the skin. Use
CoMat 12-024 sealant.
V2500 54-30-00 REPAIR 013

Page 212
Feb 1/09
B. Prepare a vacuum bag for the inner surface side of the repair.
Repeat the above steps for the inner surface, but do not use a
caul plate. When you do step (5), put a sheet of CoMat 02-170
silicone rubber above the non-porous parting film.
C. Connect the two vacuum hoses to a single vacuum source. Connect

10. Cure the Repair
A. Cure the repair for 220 minutes at 190° to 210°F (88° to 99°C).
Keep a steady vacuum pressure on 22 inches of mercury during
the cure.
B. Disconnect the heat blanket and the pressure source. Remove the
bagging materials.
11. Make the Repair Area On the Outer Surface Smooth
A. Remove sharp edges in the repair area on the outer surface. Use
the CoMat 05-020 and 05-081 abrasive papers.
B. Clean the surface with a CoMat 01-438 solvent. Rub surface dry
before the solvent becomes dry.
12. Install the Outer Skin Repair Plies, (See Figure 202)
the corners of plies 45° degrees by 1.0 in. (25,4 mm). See
Figure 202.
(25,4 mm) larger than the cutout all around.
V2500 54-30-00 REPAIR 013

Page 213
Feb 1/09
(2) Cut ply No. 2 with warp at +45° degrees. Cut the ply 0.75
(3) Cut ply No. 3 with the warp at -45° degrees. Cut the ply
0.75 in. (19 mm) larger than the second ply all around.

fabric. Cut the ply 0.75 in. (19 mm) larger than the fourth
tapes. Trim the corners of the ply 45 degrees by 1.0 in. (25,4
mm).
NOTE: Do Not cover the Teflon tape with the fiberglass sanding
ply.
C. Use the manufacturer’s instruction to mix the CoMat 08-050

resin.
D. Put the first repair ply on a sheet of CoMat 02-168 non-porous

parting film. Apply the resin to the ply.
roller to force the resin full into the ply.
(1) Remove the bottom sheet of the non-porous parting film

from the repair ply. Put the repair ply above the cutout
and filler plies.
V2500 54-30-00 REPAIR 013

Page 214
Feb 1/09
the ply.
G. Repeat steps D., E., and F. for the remaining repair plies and
for the fiberglass sanding ply.
NOTE: Make sure the repair plies are put together with the
correct warp direction. Make sure you remove the non-
porous parting film from the plies.
13. Prepare a Vacuum Bag For the Repair Plies On The Outer Surface (See
Figure 204)
(1) Put a minimum of four thermocouples around the perimeter

of the repair area.
(2) Put a sheet of CoMat 02-169 porous parting film above the
repair area. The sheet must be 3.0 in. (76,2 mm) larger
than the repair area all around.
(3) Put four plies of CoMat 02-167 fiberglass fabric above the
(4) Put a sheet of CoMat 02-168 non-porous parting film above

the bleeder cloth.
(5) Put an aluminum caul plate above the non-porous parting

film. The caul plate must have the same contour as the
outer skin in the damage area.
(6) Put a heat blanket above the caul plate.
(7) Put two plies of CoMat 02-166 breather cloth above the
heat blanket.
(8) Put a sheet of CoMat 02-163 nylon bagging film above the
repair area. THe sheet must be 2.0 in. (50,8 mm) larger
than the repair pieces all around.
V2500 54-30-00 REPAIR 013

Page 215
Feb 1/09
(9) Put a vacuum probe under the nylon bagging film. Seal the
thermocouples and vacuum probe. Use CoMat 12-024 sealant.
Seal the edges of the nylon bagging film to the skin. Use
CoMat 12-024 sealant.
B. Connect the vacuum pump hose to a vacuum source. Connect the

heat blanket to an electrical source.
14. Cure the Repair
the cure.
bagging materials.

sure that the procedures in this repair are done. If necessary,
do the applicable steps again.
V2500 54-30-00 REPAIR 013

Page 216
Feb 1/09
17. Do the External Paint Repair
A. Apply the external paint to the repair area. See SRM 54-30-00,
Repair No. 023 (VRS2049/2058).
18. Do the Internal Surface Treatment
A. Apply primer to the repair area of the internal skin.

(Reference SRM 54-02-00 for primer application and warnings.
A. Make a mark VRS2029 or VRS2030 adjacent to the assembly number.

Use CoMat 06-131 marking pen of a color that contrasts.
V2500 54-30-00 REPAIR 013

Page 217
Feb 1/09
Full penetration Hole Repair Through the Forward Frame

Left or Right Translating Sleeve Outer Barrel
V2500 54-30-00 REPAIR 013

Page 218
Feb 1/09

V2500 54-30-00 REPAIR 013

Page 219
Feb 1/09

V2500 54-30-00 REPAIR 013

Page 220
Feb 1/09

Figure 202
V2500 54-30-00 REPAIR 013

Page 221
Feb 1/09

Figure 203
V2500 54-30-00 REPAIR 013

Page 222
Feb 1/09

Figure 204
V2500 54-30-00 REPAIR 013

Page 223
Feb 1/09
V2500 54-30-00 REPAIR 013

Page 224
Feb 1/09
REPAIR 014
OUTER BARREL PARTIAL PENETRATION HOLE REPAIR OUTER STIFFENER FRAMES
LEFT OR RIGHT TRANSLATING SLEEVE OUTERSKIN
(VRS2031/2032)
1. General
A. This repair procedure is used to repair hole damage to the

outer barrel of the left or right translating sleeve over the
frame stiffeners where honeycomb core material is present. See
Figure 201 and views C-C, D-D & E-E. Extent of damage
applicable to this repair is defined as follows:
(1) Outer skin composite plies are punctured.
(2) Honeycomb core material is crushed or damaged.
(3) Closure plies for the frames are not punctured or damaged.

skins, replacement of the damaged honeycomb core and the
installation of a graphite patch with resin.
C. Damage and repair limits for the forward frame (sta 11.9) are
as Follows:
(1) Maximum acceptable width (L1) of the repair cutout is the

full width of the honeycomb core (only) as measured in the
fore-aft direction. Dimension is and length (L2) of repair
Cutout is: L1=4.5 in. (114,3 mm) (approx). Width of cutout
does not extend over closure plies beyond the width of the
honeycomb core.
(2) Minimum acceptable length of repair cutout in the

circumferential direction is: L2=4.5 in. (114,2 mm).
(3) Minimum acceptable distance between separate Repair

Cutouts is: D1=9.0 in. (228,6 mm).
(4) Minimum acceptable distance from the edge of the repair

Cutout to the slider fittings is 8.0 in. (203,2 mm).
(5) Maximum number of times this repair can be performed on

the forward frame is five (5) times.
V2500 54-30-00 REPAIR 014

Page 201
Feb 1/09
VRS2031
VRS2032
A. Standard tools
Heat blanket
Standard shop tools
Thermocouples
Vacuum probe
Vacuum pump

Consumable Index)

CoMat 08-050 Resin
V2500 54-30-00 REPAIR 014

Page 202
Feb 1/09
E. Component materials
PART IDENT MATERIAL

Composite outer barrel Graphite fabric;
F. Repair parts
PART IDENT MATERIAL

Honeycomb core 5052 Aluminium honeycomb core
(Reference 54-30-00 Structural
Identification, Figure 1)
4. Prepare the Damaged Area For Repair, (See Figure 202 and 203)

becomes dry.

cut out. Use CoMat 06-131 marking pen. THe area must have the
The stiffener frame construction must remain intact.
V2500 54-30-00 REPAIR 014

Page 203
Feb 1/09
C. Cut out the damaged skins and core as marked. Use cutters and
cutting tools. If the cutout is rectangular, use a minimum
radius of 0.50 in. (12,7 mm) at all corners.
D. Remove the damage core from the frame up to the inside surface
of the inner skin. DO not remove the adhesive nuggets from the
inner skin surface. Do not damage the skin fibers. Chamfer the
edges. Remove all loose pieces and fibers. Make the edges
smooth. Use CoMat 05-020 and 05-081 abrasive papers.
E. Make a border around the cutout on the outer and inner

surfaces. Use CoMat 02-161 Teflon tape. Add 5.0 in. (127,0 mm)
all around the repair area. This provides an overlap area.
F. Remove all of the surfaces finish and lightly make the surfaces
rough in the area between the pieces of Teflon tape. Use CoMat
G. Clean the internal and external surfaces in the repair area

with a CoMat 02-099 lint free cloth made moist with
CoMat 01-438 solvent. Rub the surface dry before the solvent
becomes dry.
H. Let the repair area dry for one hour at 230° to 250°F (110° to
V2500 54-30-00 REPAIR 014

Page 204
Feb 1/09
5. Install the Honeycomb Core, (See Figures 202 and 203)
A. Make a repair plug from repair core material to fit the size and
length of the removed damage core. Make the repair plug with
the same ribbon direction ad the original core.
See 54-30-00 Structural identification to determine the type,
density and thickness of the core material.
NOTE: Visually examine the repair plug to make sure that it has
the correct dimensions and ribbon direction. Make sure it
aligns with the core material acoustic panel.

adhesive. Add 5 percent of CoMat 02-164 microballoons. Mix
C. Apply the adhesive mixture to the exposed surfaces of the core

material in the cutout area and repair plug.
D. Put the repair plug into the cutout.
V2500 54-30-00 REPAIR 014

Page 205
Feb 1/09
6. Install the Outer Skin Fillers Plies, (See Figure 202 and 203)
resin.
B. Cut the first filler ply from the CoMat 02-167 fiberglass
fabric. Cut the filler plies from CoMat 02-165 graphite fabric.
Cut the filler plies with alternating warp directions of 0°/
+45°/-45°/0° degrees. Repeat sequence if additional filler
plies are needed. Make enough plies to give the same thickness
as the outer skin. See 54-30-00 Structural Identification
Figure 1, Table 1 for correct warp orientation.
NOTE: Visually examine the filler plies to make sure that they
have the correct warp orientation as the original
acoustic panel outer skin.

resin.
NOTE: Warp direction of filler plies shall be 0°/+45°/-45°/0°

degrees. Make enough plies to give the same thickness as
the inner skin.
V2500 54-30-00 REPAIR 014

Page 206
Feb 1/09
(2) Apply the resin to the ply on a sheet of parting film

above the filler ply.
(4) Repeat steps (1), (2) and (3) for the other filler plies.
first 0° degree filler ply. Remove the non-porous parting
film from the bottom of the second ply.
(6) Put the second filler ply (+45° degrees) over the center
of the first filler ply (0° degree) and smooth out all
wrinkles.
(8) Cut the edges of the stack of the filler plies to the
E. Apply the resin to the mating surface of the honeycomb core

inside the cutout and to all applicable edges.
F. Remove the non-porous parting film from the fiberglass fabric

side of the stack of filler plies. Put the stack into the
cutout. Press the stack into position against the honeycomb
core. Remove the wrinkles, use a roller if necessary.
NOTE: Make sure the fiberglass ply is on the bottom of the

stack.
V2500 54-30-00 REPAIR 014

Page 207
Feb 1/09
7. Install the Outer Skin Repair Plies, (See Figures 202 and 203)
the corners of the plies 45º by 1.0 in. (25,4 mm). See Figure
202.

mm).
ply.
V2500 54-30-00 REPAIR 014

Page 208
Feb 1/09

resin.
D. Put the first repair ply on a sheet of non-porous parting film.

Apply the resin to the ply.
plies.
the ply.
NOTE: If necessary, it is acceptable for the repair plies to

overlap the fwd and aft edges of the closure plies on
the fwd frame.
V2500 54-30-00 REPAIR 014

Page 209
Feb 1/09
8. Prepare Vacuum Bags For the Repair On the Two Sides, (See Figure 204)
B. Put a minimum of four thermocouples around the perimeter of the

repair area.
C. Put a sheet of CoMat 02-169 porous parting film above the

repair area. The sheet must be 3.0 in. (76,2 mm) larger than the
repair area all around.
D. Put four plies of CoMat 02-167 fiberglass fabric above the

E. Put a sheet of CoMat 02-168 non-porous parting film above the

bleeder cloth.
F. Put an aluminum caul plate above the non-porous parting film.

The caul plate must have the same contour as the outer skin in
the damage area.
G. Put a heat blanket above the caul plate.
H. Put two plies of CoMat 02-166 breather cloth above the heat
blanket.
I. Put a sheet of CoMat 02-163 nylon bagging film above the repair
area. THe sheet must be 2.0 in. (50,8 mm) larger than the repair
pieces all around.
J. Put a vacuum probe under the nylon bagging film. Seal the
thermocouples and vacuum probe. Use CoMat 12-024 sealant. Seal
the edges of the nylon bagging film to the skin. Use CoMat 12-
024 sealant.
K. Prepare a vacuum bag for the inner surface side of the repair.
Repeat the above steps for the inner surface, but do not use a
caul plate. When you do step (5), put a sheet of CoMat 02-170
silicone rubber above the non-porous parting film.
L. Connect the two vacuum hoses to a single vacuum source. Connect

V2500 54-30-00 REPAIR 014

Page 210
Feb 1/09
9. Cure the Repair
the cure.
bagging materials.

A. Apply the external paint to the repair area.

See SRM 54-30-00, REPAIR 023 (VRS2049/2058).
13. Do the Internal Surface Treatment
A. Apply primer to the repair area of the internal skin.

(Reference SRM 54-02-00 for primer application and warnings.
V2500 54-30-00 REPAIR 014

Page 211
Feb 1/09

V2500 54-30-00 REPAIR 014

Page 212
Feb 1/09

V2500 54-30-00 REPAIR 014

Page 213
Feb 1/09
Full Penetration Hole Repair Through the Forward Frame

V2500 54-30-00 REPAIR 014

Page 214
Feb 1/09

V2500 54-30-00 REPAIR 014

Page 215
Feb 1/09

Figure 202
V2500 54-30-00 REPAIR 014

Page 216
Feb 1/09

Figure 203
V2500 54-30-00 REPAIR 014

Page 217
Feb 1/09

Figure 204
V2500 54-30-00 REPAIR 014

Page 218
Feb 1/09
REPAIR 015
OUTER BARREL LAMINATED SKIN SURFACE DAMAGE REPAIR
LEFT OR RIGHT TRANSLATING SLEEVE OUTER SKIN
(VRS2033/2034)
1. General
A. This repair procedure is used to repair nick, scratch, gouge,

erosion and disbond on the outer skin of the outer barrel of the
left or right translating sleeve. See Figure 201 and view B-B
for ares applicable to this procedure is defined as follows:
(1) Outer skin composite plies that are nicked, scratched.

gouged, eroded and/or disbonded. Inner skin at the same
location is undamaged.
(2) Bottom outer skin composite ply is damaged but not fully
penetrated.
(3) Honeycomb core material is not crushed, punctured or

damaged.
(4) Inner skin closure plies are not damaged.

skin fibers, and the installation of graphite repair plies with
resin.
C. Specific limits applicable to this repair are as follows:
(1) Maximum acceptable length of repair area after damage is

removed is: L1=4.0 in. (101,6 mm).
(2) Maximum acceptable width of repair area after damage is

removed is: L2=4.0 in (101,6 mm).
(3) Minimum acceptable distance between separate or pre-

existing repair ares is: D1=11 in. 279,4 mm).
(4) Minimum acceptable distance between the edge of the repair

area and the slider fittings is: 8.0 in.
(203,2 mm).
V2500 54-30-00 REPAIR 015

Page 201
Feb 1/09

area and the Access Door cutouts is X3=8.0 in. 203,2 mm).
(6) Minimum acceptable distance between the aft, upper and

lower edge of the outer panel is: X5=8.0 in. 203,2 mm).

and the fasteners for the internal Frame (shown in Figure
201) is: X4=2.0 in. (50,8 mm).

area and existing holes as shown in view B-B is: X2=8.0
in. (203,2 mm).
(9) Maximum number of times this repair can be performed on

the outer barrel panel is ten (10) times.
VRS2033
VRS2034
A. Standard tools
Heat blanket
Thermocouples
Vacuum probe
Vacuum pump

Consumable Index)

V2500 54-30-00 REPAIR 015

Page 202
Feb 1/09

CoMat 08-050 Resin
E. Component materials
PART IDENT MATERIAL

Composite Outer Skin Graphite fabric;
Resin

becomes dry.
V2500 54-30-00 REPAIR 015

Page 203
Feb 1/09

sanded. Use CoMat 06-131 marking pen. THe area must have the
C. Make a border around the marked area with CoMat 02-161 Teflon
tape. To make a border, add 4.75 in. (120,6 mm) all around the
repair area for four (4) repair plies and one (1) fiberglass
sanding ply as shown in Figure 202.
D. Remove the damaged skin fibers. Use the CoMat 05-020 and
05-081 abrasive papers. Remove the minimum amount of material
that will remove the damage completely. Remove the surface
finish and lightly make the surface rough in the area between
the pieces of Teflon tape.
E. Clean the repair area with a CoMat 02-099 lint free cloth made
F. Let the repair area dry for one hour at 230° to 250°F (110° to
V2500 54-30-00 REPAIR 015

Page 204
Feb 1/09
5. Fill the Damaged Area, (See Figures 202)

resin. Add 5 percent of CoMat 02-164 microballoons. Mix
B. Apply the resin mixture to fill the damaged area to a level

slightly higher than the adjacent skin.
C. Cure the resin for 220 minutes at 190° to 210°F (88° to 99°C).
Use a heat lamp.
D. Make the resin smooth with the adjacent surface. Use the CoMat
E. Clean the repair area with CoMat 02-099 lint free cloth and
V2500 54-30-00 REPAIR 015

Page 205
Feb 1/09
6. Install the Outer Skin Repair Plies, (See Figure 202)
the corners of the plies 45º by 1.0 in. (25,4 mm). Make one (1)
graphite fabric repair ply for each damaged outer skin ply,
plus one (1) additional fiberglass sanding ply. See Figure 202.
NOTE: The number of graphite fabric repair plies must be

the same as the number of damaged skin plies, plus
one (1) additional fiberglass sanding ply.

mm).
ply.
V2500 54-30-00 REPAIR 015

Page 206
Feb 1/09

resin.
D. Put the first repair ply on a sheet of non-porous parting film.

Apply the resin to the ply.
plies.
the ply.
V2500 54-30-00 REPAIR 015

Page 207
Feb 1/09
7. Prepare Vacuum Bag For the Repair, (See Figure 203)

repair area.
B. Put a sheet of CoMat 02-169 porous parting film above the

repair area. The sheet must be 3.0 in. (76,2 mm) larger than the
repair area all around.
C. Put four plies of CoMat 02-167 fiberglass fabric above the

D. Put a sheet of CoMat 02-168 non-porous parting film above the

bleeder cloth.
E. Put a sheet of CoMat 02-170 silicone rubber above the non-

F. Put a heat blanket above the sheet of silicone rubber
G. Put two plies of CoMat 02-166 breather cloth above the heat
blanket.
H. Put a sheet of CoMat 02-163 nylon bagging film above the repair
area. The sheet must be 2.0 in. (50,8 mm) larger than the repair
pieces all around.
I. Put a vacuum probe under the nylon bagging film. Seal the
024 sealant.
J. Connect the vacuum pump hose to the vacuum source. Connect the
8. Cure the Repair
the cure.
bagging materials.
V2500 54-30-00 REPAIR 015

Page 208
Feb 1/09


See SRM 54-30-00, REPAIR 023, (VRS2049/2058)

V2500 54-30-00 REPAIR 015

Page 209
Feb 1/09
Laminated Outer Skin Repair

Left or Right Translating Sleeve
V2500 54-30-00 REPAIR 015

Page 210
Feb 1/09

V2500 54-30-00 REPAIR 015

Page 211
Feb 1/09

V2500 54-30-00 REPAIR 015

Page 212
Feb 1/09

V2500 54-30-00 REPAIR 015

Page 213
Feb 1/09
VACUUM BAG
FIBERGLASS FABRIC BREATHER PLIES
SILICONE RUBBER SHEET

REPAIR PLIES
NONPOROUS PARTING FILM
FIBERGLASS SANDING PLY
BLEEDER CLOTH PLIES

HEAT BLANKET
POROUS PARTING FILM
VACUUM HOSE
TEFLON TAPE
BAG SEALANT
FILLED DAMAGE AREA

TRANSLATING SLEEVE
OUTER SKIN
THERMOCOUPLE
13907B

Figure 203
V2500 54-30-00 REPAIR 015

Page 214
Feb 1/09
REPAIR 016
FORWARD AND AFT EDGE REPAIR
LEFT OR RIGHT TRANSLATING SLEEVE
(VRS2035/2036)
1. General
A. This repair procedure is used to repair damage to either the

forward or the aft edge of the left or right translating
sleeve. See Figure 201.
B. This type of damage is repaired by removal of the damaged skin

fibers and the installation of a graphite and fiberglass patch
with resin.
C. This repair is not applicable if the damage extends into the

junction of the outer skin and the closure angle on the forward
frame.
D. Repair and damage limits applicable to this repair for the

forward edge are as follows:
(1) For all skin plies missing, the maximum length and width
of damage area is: L1=4.0 in. (101,6 mm) and X1=0.75 in.
(19,05 mm).
(2) First four (4) outer skin plies are nicked, scratched,
gouged or missing. The inner skin closure plies are not
damaged. The maximum length and width of the damage area
is: L1=4.0 in. (101,6 mm) and X2=1.50 in.
(38,1 mm).
(3) Minimum distance between separate damage areas or pre-

existing repairs is: D1=11.0 in. (279,4 mm).
(4) Maximum number of repairs that can be performed on the fwd

edge of the outer panel of the translating sleeve is five
(5).
E. Repair and damage limits applicable to this repair for the aft
edge are as follows:
V2500 54-30-00 REPAIR 016

Page 201
Feb 1/09
(1) For all skin plies missing, the maximum length and width
of damage area is: L2=4.0 in. (101,6 mm) and X3=1.0 in.
(25,4 mm).
(2) First four (4) outer skin plies are nicked, scratched,
gouged or missing. The inner skin closure plies are not
damaged. The maximum length and width of the damage area
is: L2=4.0 in. (101,6 mm) and X4=2.0 in.
(50,8 mm).
(3) Minimum distance between separate damage areas or

pre-existing repairs is: D2=11.0 in. (279,4 mm).
(4) Maximum number of repairs that can be performed on the fwd

edge of the outer panel of the translating sleeve is five
(5).
VRS2035
VRS2036
A. Standard Tools

Heat blankets
Thermocouples
Vacuum probe
Vacuum pump

Consumable Index)

V2500 54-30-00 REPAIR 016

Page 202
Feb 1/09

CoMat 02-172 Aluminum alloy plate
CoMat 08-050 Resin
CoMat 08-131 Resin, alternative for CoMat 08-050
D. Expandable Parts - none
E. Component Materials
PART IDENT MATERIAL

Composite Outer Skin Graphite Fabric; Resin
4. Prepare the Damaged Area For Repair (See Figure 202)
moist with CoMat 01-438 solvent. Rub the surface dry before
solvent evaporates.
V2500 54-30-00 REPAIR 016

Page 203
Feb 1/09

cut out. Use CoMat 06-131 marking pen. The area must have the

PPE IS NECESSARY.
CAUTION: WHEN YOU ABRADE COMPOSITE SURFACE, DO NOT TAPER OR BREAK

THE GRAPHITE FIBERS.
C. Cut out the damaged skin as marked. Remove all loose particles
and bond separations. Use cutters and cutting tools. If the
cutout is rectangular, use a minimum radius of 0.25 in. (6,4
mm) at all corners. Taper the sides of the cutout 45 degrees
towards the out surface of the skin.
D. Make a border around the cutout with CoMat 02-161 teflon tape.
Distance between the edge of the cutout and edge of the teflon
tape shall be as follows:
(1) Forward Edge Repairs: 5.50 in. (139,70 mm)
(2) Aft Edge Repairs: 5.50 in. (139,70 mm).
NOTE: The size of the border can vary depending on the number
of repair plies used. Distance between the edge of the
fiberglass sanding ply and the edge of the Teflon tape
shall be approximately 0.75 in. (19,05 mm).
V2500 54-30-00 REPAIR 016

Page 204
Feb 1/09
E. Remove all of the surface finish and lightly make the outer
surface rough in the area between the pieces of teflon tape.
Use the CoMat 05-020 and 05-081 abrasive paper.
F. Clean the repair area with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub surface dry before the
solvent evaporates.
G. Let the repair area dry for one hour at 230° to 250°F (110° to
5. Install the Aluminum Back-up Plate (See Figure 203)
A. Cut a piece of CoMat 02-172 aluminum plate larger that the

damage cutout. This is used as a back-up plate. Put a sheet of
CoMat 02-161 non-porous parting film over the back-up plate.
B. Attach the back-up plate to the underside of the translating

sleeve land to overlap the repair cutout. Hold the plate in
position with clamps or use CoMat 02-161 Teflon tape.
NOTE: The back-up plate must have the same contour as the
damaged area. The plate must align with the contour of
the land with light finger pressure.
V2500 54-30-00 REPAIR 016

Page 205
Feb 1/09
6. Install the Outer Skin Filler Plies (See Figure 202)

PPE IS NECESSARY.
A. Find the size, shape and number of filler plies needed to make
the filler ply stack the same thickness as the adjacent
surface.
B. Cut the filler plies from CoMat 02-165 graphite fabric. Cut the
plies 0.50 in. (12,7 mm) larger than the cutout all around. Cut
the plies to the correct size after they are impregnated with
resin. See Figure 201.
(1) Cut ply No. 1 with warp at zero degrees.
(2) Cut ply No. 2 with warp at +45 degrees.
(3) Cut ply No. 3 with warp at -45 degrees.
(4) Cut ply No. 4 with warp at zero degrees.
(5) Follow this pattern for any additional plies.
V2500 54-30-00 REPAIR 016

Page 206
Feb 1/09

resin.

DISCARD CHEMICALS.
(2) Apply the resin to the ply. Put another sheet of parting
film above the filler ply.
(6) Put the second ply over the center of the first ply and
smooth out all wrinkles.
V2500 54-30-00 REPAIR 016

Page 207
Feb 1/09
(7) Repeat steps (5) and (6) for the remaining filler plies to
make a stack of the filler plies.
(8) Cut the edges of the sack of filler plies to the correct
size of the cutout.
NOTE: Make sure the repair plies are put together with the
correct warp direction. Make sure you remove the
non-porous parting film from the plies before you
put them together.
E. Install the stack of filler plies.

DISCARD CHEMICALS.
(1) Apply the resin to the edges of the cutout.
(2) Make sure the back-up plate is properly positioned. Use

clamps or teflon tape as necessary to keep the plate in
place.
NOTE: The back-up plate must have the same contour as the
damaged area. The plate must align with the contour
of the land with light finger pressure.
(3) Remove the bottom non-porous parting film from the stack
of filler plies.
(4) Put the stack into the cutout. Press the stack into
position against the back-up plate. Remove the wrinkles.
Use the roller if necessary.
(5) Remove the top non-porous parting film from the stack of
filler plies.
V2500 54-30-00 REPAIR 016

Page 208
Feb 1/09
7. Prepare A Vacuum Bag For the Filler Ply Stack (See Figure 203)
NOTE: You can co-cure the filler ply stack and the repair plies,
if you are sure you can get the correct contour. If filler
and repair plies are to be co-cured proceed to step 10.

filler ply stack. Do not put them on the filler ply stack.
B. Put as sheet of CoMat 02-169 porous parting film above the

filler ply stack. The sheet must be 3.0 in. (76,2 mm) larger
than the filler ply stack all around.
C. Put five plies of CoMat 02-167 fiberglass above the porous

parting film. This will serve as the bleeder cloth.

bleeder cloth.
E. Put a sheet of CoMat 02-170 silicon rubber above the non-porous

parting film.
F. Put a heat blanket above the sheet of silicon rubber.
blanket.
pieces all around.
I. Put the vacuum probe under the nylon bagging film. Seal the
024 sealant.
J. Connect the vacuum pump hose the vacuum source. Connect the
8. Cure the Filler Ply Stack
Keep a steady vacuum pressure of 22 inches of mercury during
the cure.
V2500 54-30-00 REPAIR 016

Page 209
Feb 1/09
bagging materials. Remove the teflon tape.
C. Visually examine and do a tap test of the repair area. If

necessary, do the applicable steps again.
9. Make the Filler Ply Stack Smooth (See Figure 202)

PPE IS NECESSARY.
A. Remove sharp edges. Make the filler ply surface in the repair
area smooth with the adjacent surface. Use CoMat 05-020 and 05-
B. Shape the forward and/or aft edge of the ply stack to a 4:1
ratio taper. Use the CoMat 05-020 and 05-081 abrasive papers.
V2500 54-30-00 REPAIR 016

Page 210
Feb 1/09
C. Clean the surface with CoMat 02-099 lint free cloth made moist
solvent evaporates.
A. For the forward edge repair patch, cut four repair plies from
the CoMat 02-165 graphite fabric. Cut the corners of the plies
45 degrees by 1.0 in. (25,4 mm). See Figure 202.
(1) Cut ply No.1 with the warp at zero degrees. Cut the ply
1.0 in. (25,4 mm) larger than the cutout all around.
(2) Cut ply No. 2 with the warp at +45 degrees. Cut the ply
0.75 in. (19,0 mm) larger than the first ply all around.
(3) Cut ply No. 3 with the warp at -45 degrees. Cut the ply
0.75 in. (19,0 mm) larger than the second ply all around.
(4) Cut ply No. 4 with the warp at zero degrees. Cut the ply
V2500 54-30-00 REPAIR 016

Page 211
Feb 1/09
(6) Cut a fiberglass sanding ply from the CoMat 02-167

fiberglass fabric. Cut the ply 0.75 in. (19,0 mm) larger
than the fourth repair ply all around. Trim the corners of
the ply 45 degrees by 1.0 in. (25,4 mm).
NOTE: Do not cover the Teflon tape with the fiberglass

sanding ply.
B. For the aft edge repair patch, cut five repair plies from the
CoMat 02-165 graphite fabric. Cut the corners of plies at 45
degrees by 1.0 in. (25,4 mm). See Figure 202.
(1) Cut ply No.1 with the warp at zero degrees. Cut the ply
1.0 in. (25,4 mm) larger than the cutout all around.
(2) Cut ply No. 2 with the warp at +45 degrees. Cut the ply
0.75 in. (19,0 mm) larger than the first ply all around.
(3) Cut ply No. 3 with the warp at -45 degrees. Cut the ply
0.75 in. (19,0 mm) larger than the second ply all around.
(6) Cut a fiberglass sanding ply from the CoMat 02-167

fiberglass fabric. Cut the ply 0.75 in. (19,0 mm) larger
than the fourth repair ply all around. Trim the corners of
the ply 45 degrees by 1.0 in. (25,4 mm).
NOTE: Do not cover the Teflon tape with the fiberglass

sanding ply.
V2500 54-30-00 REPAIR 016

Page 212
Feb 1/09

resin.
D. Put the first repair ply on a sheet of CoMat 02-168

non-porous parting film. Apply the resin to the ply.
E. Put another sheet of paring film above the repair ply. Use a

from the repair ply. Put the repair ply above the cutout
and filler plies.
NOTE: Make sure to use the correct warp direction.
the ply.
G. Repeat steps D, E and F for the remaining repair plies and for
NOTE: Make sure the repair plies are put together in the correct
warp direction. Make sure you remove the
non-porous parting film from the plies.
V2500 54-30-00 REPAIR 016

Page 213
Feb 1/09
11. Prepare A Vacuum Bag For the Repair (See Figure 204)

sanding ply. Do not put them on the sanding ply.
B. Put as sheet of CoMat 02-169 porous parting film above the

sanding ply. The sheet must be 3.0 in. (76,2 mm) larger than the
sanding ply all around.
C. Put five plies of CoMat 02-167 fiberglass above the porous

parting film. This will serve as the bleeder cloth.

bleeder cloth.
E. Put a sheet of CoMat 02-170 silicon rubber above the

F. Put a heat blanket above the sheet of silicon rubber.
blanket.
pieces all around.
I. Put the vacuum probe under the nylon bagging film. Seal the
024 sealant.
J. Connect the vacuum pump hose the vacuum source. Connect the
12. Cure the Repair
Keep a steady vacuum pressure of 22 inches of mercury during
the cure.
bagging materials. Remove the teflon tape.
V2500 54-30-00 REPAIR 016

Page 214
Feb 1/09
13. Make the Repair Smooth

PPE IS NECESSARY.
A. Remove sharp edges. Make the filler ply surface in the repair
area smooth with the adjacent surface. Use CoMat 05-020 and 05-
solvent evaporates.
C. If shaping has not yet been performed, do it now. Shape the

forward and/or aft edge of the ply stack to a 4:1 ratio taper.
Use the CoMat 05-020 and 05-081 abrasive papers.
V2500 54-30-00 REPAIR 016

Page 215
Feb 1/09


Refer to 54-30-00, REPAIR 023 (VRS2049/2058).

V2500 54-30-00 REPAIR 016

Page 216
Feb 1/09
Damage location
V2500 54-30-00 REPAIR 016

Page 217
Feb 1/09
Damage Location
V2500 54-30-00 REPAIR 016

Page 218
Feb 1/09
Repair Construction
V2500 54-30-00 REPAIR 016

Page 219
Feb 1/09
Repair Construction
V2500 54-30-00 REPAIR 016

Page 220
Feb 1/09
Filler Ply Stack Layup and Vacuum Bag Installation

Figure 203
V2500 54-30-00 REPAIR 016

Page 221
Feb 1/09
REpair Patch Layup and Vacuum Bag Installation

Figure 204
V2500 54-30-00 REPAIR 016

Page 222
Feb 1/09
REPAIR 017
OUTER BARREL COMPOSITE SKIN DELAMINATION REPAIR
(VRS2037/2038)
1. General
A. This repair procedure is used to repair a delamination between

the plies of the outer barrel composite skin. The repair is
applicable on the composite skin of the left or right
translating sleeve outer barrel.
B. This repair is not applicable to bond separation damage between

the composite skin and the core.
C. This type of damage is repaired by injection of the adhesive

into the area of bond separation between the skin plies.
D. This repair is applicable to the damage that is up to 3.0 in.

(76 mm) in diameter. To repair delamination damage that is
larger, go to REPAIR 014 and repair the damage as a whole. There
must be a distance of at least 10 in. (254 mm) between repairs.
The edge of the damage must be a minimum of 5.0 in. (127 mm)
from the edge of closures.
VRS2037
VRS2038
A. Standard Tools

Standard shop tools
V2500 54-30-00 REPAIR 017

Page 201
Feb 1/09

Consumable Index)
CoMat 01-076 Methylethylketone; Alternative for

CoMat 01-438
CoMat 02-162 Syringe
D. Expandable Parts - none
E. Component Materials
PART IDENT MATERIAL

Outer Barrel Graphite skin;
Aluminium honeycomb core;
Graphite skin
4. Prepare the Damaged Area for Repair, (See Figures 201 and 202)
V2500 54-30-00 REPAIR 017

Page 202
Feb 1/09

PPE IS NECESSARY.
the solvent dries.
B. Find the size of the delamination. Use the tap test method.
Make a border around the damage area. Use CoMat 02-160 teflon
tape.
CAUTION: DRILL THROUGH THE DAMAGED PLIES ONLY. DO NOT DRILL THROUGH
THE SKIN OR THROUGH THE PANEL.
C. Drill 0.125 in. (3,17 mm) diameter holes along one side of the
repair area at 1.00 in. (25,4 mm) intervals. Use drills and
drilling tools. Drill the holes through the damaged plies only.
Do not damage the adjacent structure. Remove the burrs.
NOTE: These holes will be used to receive the injected

adhesive into the damage area.
D. Do the same procedure to drill vent holes along the other side
of the repair area. Remove the burrs.
5. Repair the Delamination (See Figure 201 and 202)
V2500 54-30-00 REPAIR 017

Page 203
Feb 1/09
CONTAMINATION.
moist with CoMat 01-438 solvent. Remove all debris. Rub the
surface clean before the solvent dries.

adhesive.
C. Put the adhesive mixture into a clean CoMat 02-162 syringe.

Inject the adhesive into the bond separation area through the
injection holes until the adhesive comes out of the opposite
vent holes.
D. Remove the unwanted adhesive with a CoMat 02-099 lint free

cloth made moist with CoMat 01-438 solvent. Rub the surface
clean before the solvent dries.
E. Put a piece of CoMat 02-168 non-porous film over the repair

area. Use pieces of CoMat 02-160 teflon tape to hold the film in
place.
F. Apply enough pressure to the repair area for the delaminated

plies to come together. Keep the pressure applied while the
adhesive cures.
G. Cure the adhesive for one hour at 190 to 210ºF (88 to 99ºC). Use
an explosion proof heat lamp, as necessary.
H. Remove the pressure. Remove the non-porous films and the pieces
of teflon tape around the bonded panel.
V2500 54-30-00 REPAIR 017

Page 204
Feb 1/09

PPE IS NECESSARY.
A. Remove the sharp edges from the cured adhesive around the
injection holes. Make the surfaces smooth with the adjacent
surfaces. Use the CoMat 05-020 and CoMat 05-081 abrasive
papers.
B. Clean the repair area with a CoMat 02-099 lint free cloth made
the solvent dries.

procedures in this repair are done. Do a tap test to make sure
there is no additional delamination between the plies. If
A. Make a mark VRS2037 for the outer barrel, left translating

sleeve, or VRS2038 for the outer barrel, right translating
sleeve, adjacent to the assembly number. Use a CoMat 06-131
V2500 54-30-00 REPAIR 017

Page 205
Feb 1/09
A. Apply the external paint to the repair area. (See the

applicable repair in this SRM section.)
V2500 54-30-00 REPAIR 017

Page 206
Feb 1/09
Composite Skin Delamination Repair

Figure 201
V2500 54-30-00 REPAIR 017

Page 207
Feb 1/09
A COMPOSITE SKIN
DELAMINATION
CORE
COMPOSITE
SKIN
ADHESIVE
PARTING FILM APPLY PRESSURE VENT HOLE INJECTION HOLE
SECTION A-A SECTION A-A
13914A
Composite Skin Delamination Repair Translating Sleeve Outer Barrel

Figure 202
V2500 54-30-00 REPAIR 017

Page 208
Feb 1/09
REPAIR 020
TRANSLATING SLEEVE ACOUSTIC PANEL
PERFORATED INNER SKIN SMALL HOLE REPAIR
(VRS2043/VRS2044)
1. General
A. This repair is applicable to Product Improvement

Configuration (Config 2) acoustic metallic panel only.
B. VRS2043 is applicable for the left hand translating sleeve

acoustic panel and VRS2044 is applicable for the right hand
translating sleeve acoustic panel.
C. This repair is for damage that did not penetrate to the

underlying outer skin.
D. This repair may be used to repair a small hole in either the

left or right translating sleeve acoustic panel field area up
to 1.0 in.(25,4 mm) in diameter.
E. This type of damage is repaired by removal of material around

the damaged area. Potting compound is then used to fill the
cavity.
F. This repair causes blockage to the perforated skin in the

Limits.
G. Damage must be located in field areas only. See Figure 201 for
areas where no damage is allowed.
(1) There must be a minimum distance of 4 x Diameter from the

edge of the damage to other adjacent damage.
the edge of the damage to fittings on the panel.
V2500 54-30-00 REPAIR 020

Page 201
Feb 1/09
2. Reference information


Hole Saw

Consumable Index)

PART IDENT MATERIAL

Configuration 2- Aluminum honeycomb core
Product Improvement Aluminum back skin
V2500 54-30-00 REPAIR 020

Page 202
Feb 1/09

PPE IS NECESSARY.
A. Clean the damage area with CoMat 02-099 lint free cloth made
B. Use a CoMat 06-131 marking pen to mark the damage to be repaired

to the smallest diameter possible ensuring that all of the
damage is within the marking. Find the depth of the damage to
the honeycomb core.
C. Mask off 1.5 in. (38,1 mm) around the damage area. Use CoMat 02-
161 Teflon tape.
V2500 54-30-00 REPAIR 020

Page 203
Feb 1/09

PPE IS NECESSARY.
CONTAMINATION.
A. Cut and remove the damaged skins and core to the smallest
diameter and depth possible to remove damage. Use a drill or
hole saw. Remove the burrs.
B. Remove the sharp edges. Use the CoMat 05-020 and 05-081
abrasive papers.
C. Clean the repair area with a CoMat 02-099 lint free cloth made
solvent dries.
V2500 54-30-00 REPAIR 020

Page 204
Feb 1/09
6. Remove Moisture From the Repair Area

Otherwise, proceed to Step 6.A.
A. Refer to SRM 54-02-00 REPAIR 002 (VRS2371) for moisture removal

in the repair area.
A. Refer to SRM 54-02-00 REPAIR 009 (VRS2372) for Honeycomb Core

Repair Process.
B. After the repair process is complete, remove the release film

and the Teflon tape.

PPE IS NECESSARY.
A. Make the surfaces in the repair area smooth with the adjacent
surfaces. Use the CoMat 05-020 and 05-081 abrasive papers.
solvent dries.
V2500 54-30-00 REPAIR 020

Page 205
Feb 1/09
A. Visually examine the repair area. Make sure the repair is even
with the adjacent skin surface.
A. Use CoMat 06-131, Marking Pen to identify the repair.

Adjacent to the repair on the panel edge, mark VRS2043 for left
hand translating sleeve acoustic panel and mark VRS2044 for
right hand translating sleeve acoustic panel.
V2500 54-30-00 REPAIR 020

Page 206
Feb 1/09
Translating Sleeve Acoustic Panel

Perforated Inner Skin Small Hole Repair
Figure 201
V2500 54-30-00 REPAIR 020

Page 207
Feb 1/09
V2500 54-30-00 REPAIR 020

Page 208
Feb 1/09
REPAIR 021
TRANSLATING SLEEVE ACOUSTIC PANEL
BOND SEPARATION REPAIR
(VRS2045/VRS2046)
1. General
A. This repair procedure is used to repair a bond separation

between the perforated skin and the core of the acoustic panel,
inner surface of the left or right Translating Sleeve.
B. This type of damage is repaired by the injection of adhesive

into the damage area.
C. This repair is applicable to damage that is up to 3.0 in.

(76,2 mm) in diameter.
D. This repair is limited to damage location referred as “Repair

Area” in Figure 201, Sheet 2.
E. This repair causes blockage to the perforated skin in the

Limits”.
F. For damage larger than 3.0 in. (76.2 mm) contact Goodrich for
further disposition.
2. Effectivity
This repair is applicable to the components with serial

numbers listed below.
Part No. Serial No.
745-0006 5001 and Subsequent
V2500 54-30-00 REPAIR 021

Page 201
Feb 1/09


Consumable Index)
CoMat 01-076
Methylethylketone; Alternative for CoMat 01-438
CoMat 01-438
Solvent Turco 6646
CoMat 02-097
Lint Free Gloves
CoMat 02-099
Lint Free Cloth
CoMat 02-160
Teflon tape
CoMat 02-162
Syringe
CoMat 02-168
Non-porous parting film
CoMat 05-020
Waterproof silicon carbide abrasive paper
CoMat 05-081
Waterproof silicon carbide abrasive paper
CoMat 06-131
Marking pen
CoMat 08-021
Epoxy Paste Adhesive, EA934NA (Alternate to
CoMat 08-078)
PART IDENT MATERIAL

Acoustic Panel Perforated Aluminum Sheet Skin
Aluminum Honeycomb Core
Aluminum Sheet Back Skin
V2500 54-30-00 REPAIR 021

Page 202
Feb 1/09
4. Prepare the Damaged Area for Repair (See Figure 201,

Sheets 1 and 2)
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS
with CoMat 01-438 solvent. Rub the surface dry before solvent
becomes dry.
B. Find the size of the bond separation. Use the tap test method.
C. Make a border around the damage area. Apply Comat 02-160 teflon
tape around all sides 0.5 in (13 mm) away from the border of the
damaged area.
CAUTION: WHEN YOU CUT THE WOVEN WIRE, OR REMOVE SHARP EDGES DO NOT
CUT INTO THE PERFORATED SKIN.
D. Increase the size of one perforated sheet hole by drilling

0.125 in. (3,17 mm) diameter along the inside edge of the
damage area. This hole is used to inject the adhesive into the
damage area. Drill the hole in the perforated skin only. Do not
cause damage to the underlying structure.
E. Increase the size of one perforated sheet hole 180° opposite

the perforated skin hole increased in size. Drill 0.125 in.
(3,17 mm) diameter along the inside edge of the damaged area.
This hole will serve as the vent hole. Drill the hole in the
perforated skin only. Do not cause damage to the underlying
structure.
V2500 54-30-00 REPAIR 021

Page 203
Feb 1/09
5. Repair the Bond Separation, (See Figure 202)

PPE IS NECESSARY.
CLEANED OR PREPARED SURFACES. THIS PREVENTS CONTAMINATION
A. Clean the damage area with CoMat 02-099 lint free cloth made

adhesive.
C. Cover the perforated sheet holes within the damaged area with
CoMat 02-160 Teflon Tape. Keep the injection and vent holes
open.
D. Apply adhesive. Use a CoMat 02-162 syringe to form a partial

solid fill on the exposed honeycomb core to prevent leakage of
adhesive through the perforated skin on opposite side of panel.
Fill cells to approximately 1/3 to 1/2 depth. Do not fill core
cells completely. See Figure 202 for reference.
NOTE: Every honeycomb cell under the damage are must be filled
with adhesive without any void area.
V2500 54-30-00 REPAIR 021

Page 204
Feb 1/09
E. Remove CoMat 02-160 teflon tape used as perforation cover on

the damaged area.
F. Remove unwanted adhesive until flush with the adjacent area.

Use CoMat 02-099 lint free cloth made moist with CoMat 01-438
solvent. Rub the surface dry before the solvent
dries.
G. Cover the damage area with CoMat 02-168 non-porous parting

film. The CoMat 02-168 non-porous film must be slightly larger
than the damage area.
H. Get a metal plate slightly smaller than the CoMat 02-168

non-porous parting film. To help disperse applied pressure, put
the metal plate on the top of the CoMat 02-168 non-porous
parting film.
I. Apply sufficient pressure to the repair area for the

perforated skin to touch the honeycomb core. Keep the
pressure while the adhesive cures.
J. Cure the adhesive for one hour at 180° to 200°F (82° to 93°C).
K. Remove the pressure. Remove the non-porous film and the pieces
of teflon tape from around the repair area after
curing.
V2500 54-30-00 REPAIR 021

Page 205
Feb 1/09

PPE IS NECESSARY.
A. Remove the sharp edges from the repair area, and make the
surface smooth with the adjacent surface. Use the CoMat
B. Clean the repair area with CoMat 02-099 lint free cloth made

that there is no remaining disbond. If necessary, do again the
applicable steps.
A. Mark the VRS2045/VRS2046 adjacent to the repair on the panel

edge. Use CoMat 06-131, Marking Pen.
V2500 54-30-00 REPAIR 021

Page 206
Feb 1/09

Bond Separation Repair
V2500 54-30-00 REPAIR 021

Page 207
Feb 1/09

V2500 54-30-00 REPAIR 021

Page 208
Feb 1/09

Figure 202
V2500 54-30-00 REPAIR 021

Page 209
Feb 1/09
V2500 54-30-00 REPAIR 021

Page 210
Feb 1/09
REPAIR 022
TRANSLATING SLEEVE WOVEN WIRE SCRATCH, RIP, OR TEAR REPAIR
(VRS2047/VRS2048)
1. General
A. This repair procedure is used to repair scratch, rip, or tear

damage to the woven wire of the left or right translating
sleeve.
B. This type of damage is repaired by removal of the loose woven

wire and the application of adhesive to the cut edges. Refer to
the SRM 54-01-00 for the maximum acoustical area loss limits.

mm) long.
2. Reference Information -
VRS2047
VRS2048
Plastic spatula
Knife

Consumable Index)

V2500 54-30-00 REPAIR 022

Page 201
Feb 1/09
PART IDENT MATERIAL

Perforated composite skin
Aluminum and titanium honeycomb core
Composite back skin

PPE IS NECESSARY.
A. Clean the surface with a CoMat 02-099 lint-free cloth made

solvent becomes gas.
B. Apply CoMat 02-160 teflon tape around the damage area. Add 0.4
in. (10 mm) around all sides of the damage. This makes an area
that is 0.8 in. (20 mm) wide.
C. Cut away all loose woven wire from the repair area. Use a sharp
knife. Do not cut into the perforated skin.
V2500 54-30-00 REPAIR 022

Page 202
Feb 1/09
D. Remove the sharp edges from the cut wire and from the
perforated skin in the damaged area. Use the CoMat 05-020 and
5. Stabilize the Woven Wire, (See Figure 201)

PPE IS NECESSARY.
CONTAMINATION.
moist with coMat 01-438 solvent. Rub the surface dry before

adhesive.
C. Apply a thin layer of the adhesive mixture to the area between

the pieces of teflon tape. Add more adhesive, if necessary, to
completely cover the cut edges of the wire.
D. Cure the adhesive for one hour at 180º to 200ºF (82º to 93ºC).
V2500 54-30-00 REPAIR 022

Page 203
Feb 1/09
6. Smooth the Repair Area

PPE IS NECESSARY.
A. Remove the pieces of teflon tape from the repair area.
B. Remove the sharp edges from the stabilized area. Use the CoMat

V2500 54-30-00 REPAIR 022

Page 204
Feb 1/09
Woven Wire Scratch, Rip, or Tear Repair

Figure 201
V2500 54-30-00 REPAIR 022

Page 205
Feb 1/09
V2500 54-30-00 REPAIR 022

Page 206
Feb 1/09
REPAIR 023
TRANSLATING SLEEVE EXTERNAL PAINT REPLACEMENT REPAIR
(VRS2049/2058)
1. General
A. This repair is used to replace the external paint on the outer

surface of the left or right translating sleeve.
B. Repairs to the external paint are made by the application of a

layer of primer and a layer of external paint.
VRS2049
VRS2058
PCI-V2500-1IA Overhaul Process
Spray tools for paint

Consumable Index)

CoMat 07-126 Water Soluble Primer
NOTE: To identify consumable materials, refer to Overhaul

Processes and Consumables Index, PCI.
V2500 54-30-00 REPAIR 023

Page 201
Feb 1/09
PART IDENT MATERIAL

Bonded Panel Composite skin

PPE IS NECESSARY.
NOTE: More than one layer of primer is frequently required.
A. Clean the surface with a CoMat 02-099 lint-free cloth made

B. Apply CoMat 02-178 masking tape around the damage area. This
prevents unwanted spray damage to adjacent areas.

water-soluble primer with the CoMat 07-127 water-soluble primer
and CoMat 07-128 water-soluble primer. Let the mixture set for
30 minutes before using it.
D. Apply a thin layer of the primer mixture to the repair area. Use
a spray gun or brush.
V2500 54-30-00 REPAIR 023

Page 202
Feb 1/09
E. Cure the primer for one hour at 180º to 200ºF (82º to 93ºC). Use
an explosion-proof heat lamp.
5. Examine the Primer Application
A. Apply a 1.00 inch (25,4 mm) wide strip of CoMat 02-178 masking
tape to the primer surface. Pull the tape from the primer
surface in one sudden movement. If any of the primer is removed
by the tape, reject the primer layer and do Steps 4.A. through
4.E. again.
6. Apply the External Paint

PPE IS NECESSARY.
CAUTION: 1. USE COMAT 02-097 LINT-FREE GLOVES WHEN YOU TOUCH THE
CONTAMINATION.
2. WHEN YOU ABRADE THE SURFACE, DO NOT CUT INTO THE

COMPOSITE SKIN.
A. Lightly abrade the surface in the repair area. Use

CoMat 05-129 aluminum oxide abrasive paper.
B. Clean the surface with a CoMat 02-099 lint-free cloth made

V2500 54-30-00 REPAIR 023

Page 203
Feb 1/09
C. Use the airline specification to select the external paint

color.
D. Use the manufacturer’s instructions to mix the external paint.
E. Use the manufacturer’s instructions to apply the external paint

mixture to the repair area. Use spray equipment.
F. Use the manufacturer’s instructions to cure the external paint.

Use an Explosion-proof heat lamp.
G. Remove the CoMat 02-178 masking tape.
7. Examine the External Paint
A. Apply a 1.00 inch (25,4 mm) wide strip of CoMat 02-178 masking
tape to the external paint surface. Pull the tape from the
surface in one sudden movement. If the tape removes the paint,
reject the external paint and do the applicable steps again.
V2500 54-30-00 REPAIR 023

Page 204
Feb 1/09
REPAIR 024
UPPER HOIST POINT NUTPLATE REPLACEMENT REPAIR
LEFT OR RIGHT THRUST REVERSER
(VRS2065/2085)
1. General
A. This repair procedure is used to replace the upper hoist point

of the left or right thrust reverser.
B. This type of damage can be repaired by the removal of the

section of the fairing that covers the damaged nutplate,
replacement of the damaged nutplate with a new one, and
installation of a doubler on the fairing.
VRS2065
VRS2085
A. Standard tools
Brush
Clamps
Hole finder
Riveting tools
Standard shop tools
Temporary fasteners

Consumable Index)

CoMat 02-171 Aluminum sheet
CoMat 02-178 Masking Tape
CoMat 05-074 Aluminum oxide abrasive paper
V2500 54-30-00 REPAIR 024

Page 201
Feb 1/09

CoMat 07-028 Chromate Conversion Coating; Alternative for CoMat
07-106
CoMat 07-106 Chromate Conversion Coating
PART IDENT MATERIAL

Thrust reverser Aluminum alloy
upper track
F. Repair Parts
PART NO. PART IDENT Qty

CR3212-5-3 Rivet A/R
CR3242-5-3 Rivet, Oversize A/R
63605-048Q Nutplate A/R
MS20427M4C8 Rivet A/R
NOTE: 1. All rivets are commercially available.
2. Use the alternate and oversize rivets only when

necessary.
V2500 54-30-00 REPAIR 024

Page 202
Feb 1/09
4. Remove the Damaged Nutplate, (See Figure 201)

PPE IS NECESSARY.
B. Cut a section of the fairing to gain access to the damaged

nutplate. Cut in a regular shape. Remove the burrs.
C. Remove the primer from the attaching rivets for the damaged
nutplate. Use Comat 05-074 abrasive paper.
D. Remove the nutplates. Use drills and drilling tools. Remove the
burrs.
E. Cure the primer for one hour at 180 to 200ºF (82 to 93ºC). Use
an explosion-proof heat lamp.
V2500 54-30-00 REPAIR 024

Page 203
Feb 1/09
5. Make the Patch and the Doubler, (See Figure 201 and 202)

PPE IS NECESSARY.
A. Make a patch and a doubler from CoMat 02-171 clad aluminum

alloy sheet. The patch must be the same size and shape as the
cutout. The doubler must be a minimum of 1.25 in. (3,8 mm) wide
and have the correct length. Remove the burrs.
B. Make the patch and the doubler to align with the contour of the
fairing in the repair area. The finished parts must align with
the contour with light finger pressure.
C. Make a mark of the holes around the outside edge of the cutout
and inside edge of the patch. Use a CoMat 06-131 marking pen.
D. Drill the pilot holes as marked. Remove the burrs.
V2500 54-30-00 REPAIR 024

Page 204
Feb 1/09
E. Put the doubler into position on the fairing. Use clamps as

necessary to hold it in place. Make sure the doubler is in the
correct position, then use the pilot holes to drill the holes
in the doubler. Use drills and drilling tools. Use temporary
fasteners as necessary, then drill the holes to the final size.
Remove the burrs.
NOTE: If a hole is damaged, enlarge the holes to the oversize

diameter and use an oversize rivet. The oversize hole
diameter is 0.176 to 0.180 in. (4,47 to 4,57 mm). The
oversize countersink diameter is 0.282 to 0.290 in.
(7,16 to 7,37 mm).
F. Put the patch into position on the doubler. Repeat the same
procedure to drill the remaining holes. Remove the burrs.
G. Remove the doubler and the patch. Countersink the rivet holes
on the patch and the fairing as required.
H. Remove the sharp edges. Use CoMat 05-074 abrasive paper.
6. Install the Repair Parts, (See Figures 201 and 202)

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 024

Page 205
Feb 1/09
CAUTION: 1. USE COMAT 02-097 LINT-FREE GLOVES WHEN YOU TOUCH THE
CONTAMINATION.
2. DO NOT SOLVENT CLEAN THE FASTENERS. FASTENERS CAN BE

LUBRICATED; YOU MUST NOT REMOVE THE LUBRICANT.
A. Clean the repair area and the repair parts with a

solvent. Rub the surfaces dry before the solvent becomes dry.
B. Use a nylon brush or CoMat 02-099 lint free cloth to apply CoMat
07-106 conversion coating to the cleaned, bare aluminum
surfaces. Do not let the solution become dry on the surface.
Keep the surfaces wet with the solution for 2 to 5 minutes.
C. Rinse the conversion coated surfaces fully with demineralized

water. Air dry for 30 minutes. The conversion coated surfaces
will be colorless.
NOTE: If you use the CoMat 07-028 alternative conversion

coating, the surfaces will have a golden color.
D. Use the manufacturer’s instructions to mix the CoMat 07-126,

07-127, and 07-128 water soluble primers. Let the mixture
coagulate for 30 minutes.
E. Apply a thin layer of the primer mixture to the mating surfaces

of the nutplates. Put the nutplates in position and wet install
the applicable rivets with the primer mixture.
F. Apply a thin layer of the primer mixture to all repair

surfaces. Put the repair parts in position and wet install the
applicable rivets with the primer mixture.
G. Remove the unwanted primer before it cures. Use a

solvent. Rub the surface dry before solvent becomes dry.
H. Air dry the primer for 30 minutes. Cure the primer for one hour
at 180º to 200ºF (82º to 93ºC). Use an explosion proof heat
lamp.
V2500 54-30-00 REPAIR 024

Page 206
Feb 1/09
7. Apply the Adhesive to the Spaces

PPE IS NECESSARY.
A. Apply pieces of the CoMat 02-178 masking tape to the two sides
of the space between the fairing and the patch all around.

adhesive.
C. Apply the adhesive to fill the space between the pieces of

masking tape.
D. Remove the unwanted adhesive before it cures. Use a

CoMat 02-099 lint free cloth mad moist with CoMat 01-438
solvent. Rub the surface clean before solvent becomes dry.
E. Cure the adhesive for one hour at 190º to 210ºF (88º to 99ºC).
Remove the masking tape before the adhesive cures.

V2500 54-30-00 REPAIR 024

Page 207
Feb 1/09

Use a CoMat 06-131 marking pen of a color that contrasts.
V2500 54-30-00 REPAIR 024

Page 208
Feb 1/09
APPROX.
2.5 in.
(63 mm)
3.5 in.
(88,9 mm)
1.2 in.
(30 mm)
0.5 in. (12,70 mm)

RADIUS (TYPICAL)
3.0 in. (76,2 mm)

REF.
DETAIL AT A
FORWARD
CUTOUT
13918B
Upper Hoist Point Nutplate Replacement Repair

Figure 201
V2500 54-30-00 REPAIR 024

Page 209
Feb 1/09
RIVET 0.31 in.

CR3212-5 (7,87 mm)
(WET INSTALL)
0.31 in.
(7,87 mm)
(TYPICAL)
1.0 in.
(25,4 mm)
(TYPICAL)
0.31 in.
(7,87 mm)
DOUBLER
1.25 in.
(31,75 mm)
PATCH
0.625 in. 0.31 in.

(15,87 mm) (7,87 mm)
(TYPICAL) (TYPICAL)
1.0 in.
(25,4 mm)
(TYPICAL) THIS PAGE INTENTIONALLY LEFT BLANK
FAIRING
0.164 in. (4,17 mm)

0.161 in. (4,09 mm)
DIAMETER RIVET HOLES
RIVET (TYPICAL)
MS20427M4C-8
(WET INSTALL)
NUTPLATE
(4 PLACES)
63605-048Q
(2 PLACES)
RIVET
CR3212-5
(WET INSTALL)
13919C
Upper Hoist Point Nutplate Replacement Repair

Figure 202
V2500 54-30-00 REPAIR 024

Page 210
Feb 1/09
REPAIR 025
THRUST REVERSER HINGE ACCESS PANEL NUTPLATE REPLACEMENT
(VRS2075/2076)
1. General
A. This repair procedure is used to replace the hinge access panel

nutplate of the left or right thrust reverser.
B. This repair is done by removing the damaged nutplate and

installing a new nutplate.
TASK 78-32-49-300-XXX VRS2075 V24500 Engine Manual
TASK 78-32-79-300-XXX VRS2074 V24500 Engine Manual
A. Standard tools
Riveting tools

Consumable Index)

CoMat 07-066 TL52-66 Thinner
CoMat 07-067 X337 Primer converter
CoMat 08-029 463-6-27 Primer base
PART IDENT MATERIAL

Thrust Reverser Aluminum Alloy
Upper Track
V2500 54-30-00 REPAIR 025

Page 201
Feb 1/09
4. Remove the Damaged Nutplate, (See Figure 201)
A. Drill out the rivets and remove the nutplate. Do not make the
rivet holes larger.
5. Install the New Nutplate, (See Figure 201)

NECESSARY.
A. Mix the 463-6-27 base (CoMat 08-029), the X337 converter (CoMat
07-067) and the TL52-66 thinner (CoMat 07-066) in accordance
with the manufacturer’s instruction. Let the mixture stand for
30 minutes before you use it.
B. Put the new MS21062-4 or MS21076-4 nutplate in to position and

wet install the MS20426AD-3-4 rivets with the primer mix.
A. Make sure the rivets are tight.
V2500 54-30-00 REPAIR 025

Page 202
Feb 1/09
HINGE ACCESS PANEL
B
B
B
A A
A
A
A
A
A
A
RIVET
MS20426AD3-5
RIVET
MS20426AD3-4
NUTPLATE
MS21076-4
NUTPLATE
NAS1789C4 LOCATION B
(TYPICAL)
LOCATION A
(TYPICAL)
13926B
Hinge Access Panel Nutplate Replacement

Figure 201
V2500 54-30-00 REPAIR 025

Page 203
Feb 1/09
V2500 54-30-00 REPAIR 025

Page 204
Feb 1/09
REPAIR 026
AFT LATCH FASTENER REPLACEMENT REPAIR
(VRS2266/2267)
1. General
A. This repair procedure is used to repair the aft latch fasteners

of the left or right translating sleeve. This procedure is also
used to repair the damaged adhesive in the aft latch area. The
repair is applicable to the “Early Production Version” and
“Product Improvement Version” translating sleeve assemblies.
B. This type of damage is repaired by removal of the damaged

aerodynamic adhesive filler, replacement of damaged, loose, or
missing rivets, and application of new adhesive.
C. If the damage to the adhesive filler extends beyond the

adhesive filler, and affects the composite skin, you must refer
VRS2267
VRS2266
A. Standard tools
Plastic spatula
Rivet installation tools
Rivet selector gage
Temporary fasteners
Standard shop tools

Consumable Index)

V2500 54-30-00 REPAIR 026

Page 201
Feb 1/09

CoMat 06-131 Marking Pen
PART IDENT MATERIAL

Translating Sleeve Composite skin, Graphite and Fiberglass
Aft Latch Area
F. Repair Parts
ASPFF-DT06-14 Pin A/R
ASPFF-DT06-15NL Pin A/R
ASPFF-DT06-16 Pin A/R
ASPF-S-DT06-NL Sleeve A/R
ASP-LC-2AC-06 Collar A/R

CR3224-5-2 Rivet, Alternative A/R
CR3524-4-2 Rivet, A/R

CR3524P4-2 Rivet, Alternative A/R
V2500 54-30-00 REPAIR 026

Page 202
Feb 1/09





CT420-5-200 Rivet A/R

MS20426AD4 Rivet A/R

MS20426AD5 Rivet A/R
MS20426AD4-6 Rivet A/R

MS20426D4-6 Rivet A/R
MS20427M4-7 Rivet A/R
V2500 54-30-00 REPAIR 026

Page 203
Feb 1/09

MS20427F4-7 Rivet, Alternative A/R


NAS1097AD5-10 Rivet A/R

NAS1097D5-10 Rivet, Alternative A/R
NAS1200M3-5 Rivet A/R

NAS1200-3-5 Rivet, Alternative A/R
NAS9309MP-4-4 Rivet A/R

2. Use the alternate and oversize fasteners only when

necessary.
V2500 54-30-00 REPAIR 026

Page 204
Feb 1/09
4. Prepare the Damaged Area for Repair, (See Figures 201 and 202)

PPE IS NECESSARY.
CAUTION: 1. WHEN YOU REMOVE THE ADHESIVE FILLER, DO NOT SCRATCH OR

BREAK THE FIBERS OF THE COMPOSITE SKIN, OR APPLY FORCE
TO THE SIDE OF THE RIVET HEADS.

LUBRICATED. YOU MUST NOT REMOVE THE LUBRICANT.
B. Make a mark of the damage area to the smallest size that removes
all the damage. Apply Comat 02-160 Teflon tape around the
marked area.
C. Remove all adhesive filler from the area between the pieces of
Teflon tape. Use a plastic spatula and the CoMat 05-020 and 05-
D. Remove the damaged or loose fasteners. Use drills and drilling

tools. Do not damage the holes. Remove the burrs.
NOTE: Install temporary fasteners in the rivet holes as

necessary to keep the holes aligned.
V2500 54-30-00 REPAIR 026

Page 205
Feb 1/09
E. Examine the repair area to make sure all damage has been
removed. Make sure the existing structure is not damaged.
F. Examine the holes to make sure they are not damaged. Remove the
burrs.
5. Install the Rivets, (See Figures 201 and 202)

PPE IS NECESSARY.
CONTAMINATION.
A. Clean the repair area. Use dry air blast or vacuum as necessary
to remove sanding and drilling particles from the repair area.
Clean with CoMat 02-099 lint free cloth made moist with CoMat
01-438 solvent. Wipe the surfaces dry before the solvent
becomes dry.

adhesive. Prepare enough mixture for fastener installation and
for application to the surface in the repair area.
V2500 54-30-00 REPAIR 026

Page 206
Feb 1/09
C. Wet install the replacement fasteners with the CoMat 08-104

adhesive. Use rivet installation tools.
NOTE: Use a rivet selector gage to find the correct rivet

diameter and grip length.
D. Remove the unwanted adhesive from the repair area before it

cures. Use CoMat 02-099 lint free cloth made with
CoMat 01-438 solvent. Do not let the solvent go into the joint.
6. Examine the Area
A. Visually examine the repair are to make sure that the fasteners
are installed correctly. If necessary, do the applicable steps
again.
7. Apply the Adhesive Filler, (See Figures 201 and 202)

PPE IS NECESSARY.
CONTAMINATION.
A. Apply a thin layer of the CoMat 08-104 adhesive to the repair

area. Make the repair area level with the adjacent skin
surface. The adhesive should be approximately 0.005 to 0.010
in. (0,13 to 0,25 mm) thick.
V2500 54-30-00 REPAIR 026

Page 207
Feb 1/09
B. Cure the adhesive for twenty-four hours at room temperature or

for one hour at 180º to 200ºF (82º to 93ºC). Use an explosion
proof heat lamp. Do not touch the repair area until the
adhesive is fully cured.

PPE IS NECESSARY.
A. Make the surface in the repair area smooth with the adjacent
surface. Use the CoMat 05-020 and 05-081 abrasive papers.


Use a CoMat 06-131 marking pen of a color that contrasts.
V2500 54-30-00 REPAIR 026

Page 208
Feb 1/09
A. Apply the external paint to the repair area. Refer to

SRM 54-30-00 REPAIR 023 (VRS2049/2058).
V2500 54-30-00 REPAIR 026

Page 209
Feb 1/09
Translating Sleeve Aft Latch Fastener Repair

(Early Production Version)
Figure 201
V2500 54-30-00 REPAIR 026

Page 210
Feb 1/09

(Early Production Version)
Figure 202
V2500 54-30-00 REPAIR 026

Page 211
Feb 1/09

(Product Improvement Version)
Figure 203
V2500 54-30-00 REPAIR 026

Page 212
Feb 1/09

(Product Improvement Version)
Figure 204
V2500 54-30-00 REPAIR 026

Page 213
Feb 1/09
V2500 54-30-00 REPAIR 026

Page 214
Feb 1/09
REPAIR 027
CASCADE ASSEMBLY - SURFACE DAMAGE BLEND REPAIR
(VRS2251)
1. General
A. You can blend out the damage and apply an adhesive or resin to
the damaged area to repair this type of minor surface damage to
the cascade.
B. This repair is applicable to the damage that is within the

limits given below. If the damage is not within the limits
given below, refer to the manufacturer for repair instructions:
(1) The maximum depth of the blended repair must not be more
than 0.50 in. (12,7 mm).
(2) Do not make repairs within 3.0-in. (76,2 mm) from the
forward and aft edge of the cascade in. Refer to Figure
201.
(3) Do not make repairs within 0.125 in. (3,175 mm) of any
vane/rail joint.
(4) Crack/nick/gouge - Blend out the damage to a ratio of 2 to

1 with a 0.50-in. (12,7 mm) minimum radius. Refer to
Figure 202.
NOTE: If the blend repair goes through the cascade, or

is more than 0.50 in. (12,7 mm) deep, treat the
damage the same as a crack. Refer to Repair 28.
VRS2251
V2500 54-30-00 REPAIR 027

Page 201
Feb 1/09

CoMat 08-050 Resin
PART IDENT MATERIAL

Cascade Composite (graphite/carbon)
4. Blend Out the Damage (Reference Figure 202)

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 027

Page 202
Feb 1/09
A. Use a routing tool or CoMat 05-021 abrasive paper to blend out

the damaged area to a ratio of 2 to 1 with a 0.50 in. (12,7 mm)
minimum radius.
B. Use CoMat 05-020 waterproof silicon carbide abrasive paper to

make the repair area smooth.

PPE IS NECESSARY.
A. Use a CoMat 02-099 lint free cloth made moist with CoMat 01-438
solvent. Rub the surface clean before the solvent dries.
6. Apply the Resin or Adhesive

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 027

Page 203
Feb 1/09
NOTE: You can use CoMat 08-028 adhesive or CoMat 08-050 resin.

resin or the CoMat 08-028 adhesive.
B. Fill the repair area with the resin or adhesive.
C. Use an explosion proof heat lamp. Cure the resin for 220
minutes at 200ºF (93ºC). If you use the adhesive, cure the
repair for 60 minutes at 180ºF (82ºC).
NOTE: Full cure of the CoMat 08-028 adhesive is not

necessary. The uncured adhesives is structurally and
functionally acceptable.
7. Make the Adhesive or Resin Smooth

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 027

Page 204
Feb 1/09
A. Use the CoMat 05-020 waterproof silicon carbide abrasive paper.

Make the adhesive or resin smooth and level with the adjacent
surfaces.
A. Visually examine the completed repair to make sure that all of

the requirements of this repair procedure are done.
A. Use a CoMat 06-131 marking pen of a color that contrasts. Write

VRS2251 adjacent to the assembly number.
V2500 54-30-00 REPAIR 027

Page 205
Feb 1/09
3.0 in.
(76,2 mm)
3.0 in.
(76,2 mm)
3.0 in.
CASCADE (76,2 mm)
740-0105
740-0106
740-0107
740-0235
(Typical)
3.0 in.
(76,2 mm)
CASCADE
740-0184
NOTE: Do not make repairs (Typical)
in these areas
13931A
Cascade Blend Repair Damage Limits

Figure 201
V2500 54-30-00 REPAIR 027

Page 206
Feb 1/09
VANE
RAIL
GOUGE
0.125 in.
(3,175 mm)
MIN.
2xD
MINIMUM
D
2xD
TAPER
CRACK
0.50 in. (12,7 mm)

MINIMUM RADIUS
NOTES: 2xD
TAPER
D = DEPTH OF DAMAGE
REMOVE MATERIAL NOTCH

(NICK)
0.50 in. (12,7 mm)
MINIMUM RADIUS
13932A
Cascade Blend Repair

Figure 202
V2500 54-30-00 REPAIR 027

Page 207
Feb 1/09
V2500 54-30-00 REPAIR 027

Page 208
Feb 1/09
REPAIR 028
CASCADE ASSEMBLY - CRACKED VANE OR RAIL (BLADES) REMOVAL REPAIR
(VRS2253)
1. General
A. To repair this type of damage, you can remove the cracked blade
and seal the edges with resin or adhesive to prevent moisture
penetration into the exposed carbon.
B. This repair is applicable to the damage that is within the

limits given below. If the damage is not within the limits
given below, refer to the manufacturer for repair instructions:
(1) No two adjacent blades can be removed. Refer to Figure

201.
(2) A maximum of 3 blades can be removed in each cascade.
VRS2253
Routing tool

CoMat 08-028 Adhesive, alternative to CoMat 08-050
CoMat 08-050 Resin
V2500 54-30-00 REPAIR 028

Page 201
Feb 1/09
NOTE: To identify the consumable materials, refer to the

Overhaul Processes and Consumables Index, PCI.
PART IDENT MATERIAL

Cascade Composite (graphite/carbon)
4. Remove the Cracked Blade (See Figure 202)

PPE IS NECESSARY.
A. Use a routing tool to remove the cracked blade. Leave a minimum

distance of 0.125 in. (3,175 mm) from the joint where the vane
and rail blades connect.
B. Use the CoMat 05-021 silicone carbide abrasive paper to make

the cut edges smooth.
V2500 54-30-00 REPAIR 028

Page 202
Feb 1/09

PPE IS NECESSARY.
A. Use a CoMat 02-099 lint free cloth made moist with

CoMat 01-438 solvent. Rub the repair area clean before the
solvent dries.
6. Apply the Resin or Adhesive to the Cut Edges

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 028

Page 203
Feb 1/09
NOTE: You can use CoMat 08-050 resin or CoMat 08-028 adhesive.

resin or the CoMat 08-028 adhesive.
B. Apply the resin or adhesive to seal the cut edges.
C. Use an explosion proof heat lamp. Cure the resin for 220
minutes at 200ºF (93ºC). If adhesive is used, cure for 60
minutes at 180º to 200ºF (82º to 93ºC) or at 77ºF (25ºC) for 5
to 7 days.
NOTE: Full cure of the CoMat 08-028 adhesive is not

necessary. The uncured adhesives is structurally and
7. Make the Adhesive or Resin Smooth

PPE IS NECESSARY.
A. Use the CoMat 05-020 waterproof silicon carbide abrasive paper.

Make the adhesive or resin smooth and level.
A. Visually examine the completed repair to make sure that all of

the requirements of this repair procedure are done.
V2500 54-30-00 REPAIR 028

Page 204
Feb 1/09
A. Use a CoMat 06-131 marking pen of a color that contrasts. Write

VRS2253 adjacent to the assembly number.
V2500 54-30-00 REPAIR 028

Page 205
Feb 1/09
Cascade Cracked Vane or Rail Removal Repair

Figure 201
V2500 54-30-00 REPAIR 028

Page 206
Feb 1/09
0.125 in.
(3,175 mm)
MINIMUM
0.125 in.
(3,175 mm)
MINIMUM
TYPICAL CRACKED BLADE REMOVAL
Notes:
1. Do not remove adjacent blades
2. Do not remove more than three
blades in each cascade 13934A
Cascade Cracked Vane or Rail Removal Repair

Figure 202
V2500 54-30-00 REPAIR 028

Page 207
Feb 1/09
V2500 54-30-00 REPAIR 028

Page 208
Feb 1/09
REPAIR 029
WOVEN WIRE REPLACEMENT DYNAPHOR™
R/H AND LH FIXED DUCT ASSEMBLIES
(VRS2262/2263)
1. General
A. This repair removes the damaged/corroded woven wire and replace

it with new woven wire. The repair materials used are
proprietary in nature. Repair parts/materials can be purchased
from Goodrich Corporation, including the test panels.
B. Before you start the repair, find which peel test (Step 27)
will be used. Make sure the test panel configuration and the
subsequent test specimens will agree to the applicable peel
test. All bonding procedures from Step 13 and steps 15 through
26 (i.e. cleaning and priming through the inspection) must be
applied at the same time. The same way applies to both the TP140
test panel and to the repair area. At step 27 the test panel
will be destructively tested to verify the quality of the
repair bond. If the test specimens fail the peel test, do not
repeat the repair, contact a Goodrich Customer Support
Representative for evaluation and disposition.
C. It is recommended that the large repairs be accomplished by

means of an oven. When repairing a fixed duct acoustic panel,
the repair requires that the translating sleeves, cascades, all
actuators, and electrical components be removed per the V2500
engine manual.
D. If the intended repair can be performed using a heat blanket,

remove the translating sleeves in reference to the V2500 engine
manual. Refer to Special Bagging Instructions in the SAE
ARP5143 for repair curing with a heat blanket instead of an
oven. Generally, the use of a heat blanket is limited to a 24 X
24 in. (609,6 X 609,6 mm) area but can be accomplished in
multiple sections to cover larger areas.
E. Most of the adhesives use in this repair have limited shelf

lives. The shelf lives are as follows:
RMS078, RMS042, RMS070 6 Months at 40° F (4.5° C)

RMS058 6 Months at 0° F (-17.8° C)
V2500 54-30-00 REPAIR 029

Page 201
Feb 1/09
The above materials are subject to a further reduction in shelf

life at room temperature. The limit is specified on the
manufacturer’s label on the material container. This limit is
usually shown in cumulative hours for the time that the
material is exposed to room temperature. The time the material
is exposed to room temperature must be tracked, and the
material replaced when the time has expired.
F. This procedure must be done by persons experienced in the same

repairs because of its critical nature.
G. The practices and processes referred to in the procedure by the

TASK numbers are in the SPPM.
VRS2262
VRS2263
Overhaul Processes Consumable Index
Standard Process and Procedure Manual
SAE ARP5143 Vacuum Bagging of Thermosetting Composite Repairs
NOTE: Equivalent materials and equipment can be used
Heat Blanket
Temperature Controller
Temperature Recorder
Thermocouples
Vacuum probes
Mechanics Tool Box
Analytical Balance
Router bit
18,000 -23,000 RPM drive motor
Heat Lamp (explosion proof)
Oven
Razor knife and scissors
B. Standard Equipment
Spray gun
Paint brush
V2500 54-30-00 REPAIR 029

Page 202
Feb 1/09
Disposable brush
Standard Equipment
C. Consumable Materials
Comat 01-076 Methyl Ethyl Ketone (MEK)

(Alternate to Comat (01-438)
CoMat 01-201 Deionized water
CoMat 01-438 MIBK/MEK
CoMat 02-107 Plastic, kraft paper
(320 grit)
CoMat 02-161 Teflon tape (2 in. /50,8 mm)
CoMat 02-167 Fiberglass fabric type 181
CoMat 02-178 Masking Tape, #250
(240 grit)
CoMat 08-021 Adhesive, Hysol EA934NA
CoMat 12-046 Proseal 899, B-2 area sealant
CoMat 12-024 Tacky Tape
CoMat 01-452 Turco W0-1 phosporic acid
NOTE: 1. Use alternative materials only when specified

materials are not available.
2. To identify consumable materials, refer to Overhaul

Processes and Consumables Index.
D. Special tools - None required
V2500 54-30-00 REPAIR 029

Page 203
Feb 1/09
E. Expendable Parts - None
F. Component Material
PART IDENT MATERIAL

DynaRohr™ Panel Woven Wire, Perforated Aluminum
sheet, and Aluminum Honeycomb
core
G. Repair Parts
PART NO. PART IDENT

TP738-80 * Test panel, RMS059 Class 11, woven
wire cloth 12 X 12 in. (300 X 300 mm)
TP140 * Test panel, Perf., Aluminum
12 X12 inches (300 X 300 mm)
RMS059, Class 11 Woven wire cloth 48 X 96 in.
(1219 X 2438 mm)
RMS070 ** Adhesive, used to RMS059 to
perforated skin
RMS078 ** Liquid barrier, used around periphery
of the woven wire to prevent wire from
lifting
RMS0058, Type 5 ** Adhesive Primer, applied to bonding
surface (prepare the surface for
RMS070 adhesive application)
RMS0042, Type 2, Adhesive film, applied around
Grade B or perimeter of RMS059 woven wire and acts
(grade A) ** as barrier strip between wire edges and
perforated skin
H. * These items constitute the 740K9004-5 C-duct DynaRohr™

Repair Kit
** These items constitute the 740K9004-3 C-duct DynaRohr™
Repair Bulk Material Shelf Life Kit (adhesive, etc.)
V2500 54-30-00 REPAIR 029

Page 204
Feb 1/09
4. Identify Damaged Area
CAUTION: ADHESIVE BOND PARTS MUST BE HANDLED WITH EXTREME CARE.

CLEAN WHITE GLOVES SHALL BE WORN AT ALL TIMES WHILE
HANDLING AND WORKING WITH CLEANED PARTS.
A. Use the tap test method to find size of the Disbond area.
B. Mark perimeter of damaged area. Use a CoMat 06-131 different

color marking pen.
NOTE: The woven wire used in this repair is different from the
original class of woven wire. The acoustic rayl values
are equivalent when this repair is done with the repair
woven wire.
CAUTION: DO NOT CUT INTO PERFORATED ALUMINUM SHEET BENEATH

WOVEN WIRE.
C. Cut wire score the woven wire with a razor knife in 1.0 to 2.0
in. (25,4 to 50,8 mm) lengths.
CAUTION: USE EXTREME CARE TO MAKE SURE THAT ALL LOOSE WIRE MESH
PARTICLES ARE CLEANED AWAY. THE STAINLESS STEEL WIRE
HAS A STRONG ELECTROLYTIC REACTION WHEN IN CONTACT
WITH ALUMINUM ALLOYS. THIS CAUSES
GALVANIC CORROSION TO OCCUR.
D. Remove damaged or disbonded DynaRohr™ woven wire cloth from the

repair area. To facilitate removal, tear off in narrow strips
1.0 to 2.0 in. (25,4 to 50,8 mm)wide.
V2500 54-30-00 REPAIR 029

Page 205
Feb 1/09
5. Prepare Damage Area for the Repair
A. Mask perimeter of repair area with CoMat 02-161 Teflon tape (2

in. /50,8 mm) and CoMat 02-107 plastic, Kraft paper sufficient
to prevent any sanding particles outside of the repair area.
(See Figure 201 and 202)

PPE IS NECESSARY.
CAUTION: A VACUUM SOURCE MUST BE PRESENT WHILE SANDING IS IN

PROGRESS. SANDING PARTICLES WILL DEGRADE THE NOISE
ABSORBING ABILITY OF THE PANEL AND MUST BE PREVENTED FROM
FALLING THROUGH THE HOLES IN THE PERFORATED SHEET.
B. Wire brush and sand existing adhesive and primer from the
exposed repair area surfaces of the perforated sheet. Use CoMat
05-128 (240 grit) or CoMat 05-129 (320 grit) aluminum oxide
abrasive paper. Avoid sanding through the bare metal.
NOTE: Do not sand into metal.
C. Examine damaged area for corrosion. If minor corrosion exists

on the perforated skin, it may be possible to remove by lightly
sanding. Use CoMat 05-128 (240 grit) or
CoMat 05-129 (320 grit) aluminum oxide abrasive paper. If the
corrosion is still present on the perforated skin after lightly
sanding, do not continue sanding.
V2500 54-30-00 REPAIR 029

Page 206
Feb 1/09
A. Clean repair area perforated sheet with CoMat 01-438 MIBK/MEK

and CoMat 02-091 wiping cloth. Wipe the surfaces dry with
second clean lint-free CoMat 02-091 wiping cloth before the
Comat 01-438 MI(BK/MEK evaporates. Force air dry for 30 minutes
at 150° F to 170° F (66° C to 77° C).
7. Apply Phosphoric Acid to Repair Area
CAUTION: DO NOT ALLOW PHOSPHORIC ACID TO ENTER INTO HONEYCOMB CORE.
CAUTION: DO NOT ALLOW EXCESSIVE AMOUNTS OF WATER TO ENTER INTO

HONEYCOMB CORE.
V2500 54-30-00 REPAIR 029

Page 207
Feb 1/09
A. Remove corrosion from the repair area perforated sheet using a

clean CoMat 02-091 cleaning cloth moist in CoMat 01-452 Turco
Wo-1. Apply the phosphoric acid to all bare metal surfaces. Dab
on phosphoric acid, do not rub. When the color change is
evident, remove phosphoric acid using a clean CoMat 02-091
cleaning cloth fully moistened in CoMat 01-201 deionized water.
Do not let the repair surface to dry before rinse. If the
corrosion is still present, do the process again with a clean
CoMat 02-091 cleaning cloth moistened in CoMat 01-452 Turco W0-
1.
B. Allow repair area perforated sheet to dry for 60 minutes.
8. Remove Perforated Sheet Plug
CAUTION: DO NOT CUT OR DAMAGE THE HONEYCOMB CORE UNDER THE

PERFORATED SHEET WHEN REMOVING PERFORATED SHEET PLUG
A. Remove a 0.5 in (12,7 mm) diameter plug from the repair area
perforated sheet at the worst areas with corrosion with an
18,000 to 23,000 RPM motor and a router or equivalent. Sand any
residual adhesive from the honeycomb core side of the removed
plug and clean with a vacuum. Use CoMat 05-128 (240 grit) or
CoMat 05-129 (320 grit) aluminum oxide abrasive paper. Do not
removed parent material or perforated sheet plug. (Refer to Fig
203).
9. Clean Perforated Sheet Plug
A. Clean Perforated Sheet Plug with CoMat 01-438 MIBK/MEK and

CoMat 02-091 cleaning cloth. Wipe the surfaces dry with the
second clean lint-free CoMat 02-091 cleaning cloth before the
CoMat 01-438 MIBK/MEK dries.
V2500 54-30-00 REPAIR 029

Page 208
Feb 1/09
10. Inspect Perforated Sheet Plug
A. Measure the thickness of the removed perforated sheet plus. If

the removed plug thickness is less than minimum as shown in
Table 201, contact Goodrich Customer Support Representative for
evaluations and disposition. If the removed plug thickness is
more than minimum as shown in Table 201, continue with the rest
of the repair.
Minimum Perforation Sheet Original Perforated Sheet

Allowable Thickness Thickness
0.021 in. (0,53 mm) 0.025 inch (0,64 mm)
0.039 in. (0,98 mm) 0.045 inch (1,14 mm)
Table 201
11. Clean Perforated Sheet Plug Hole
A. Clean the repair area perforated sheet plug hole with CoMat 01-
438 MIBK/MEK and CoMat 02-091 cleaning cloth. Wipe the surfaces
dry with the second clean lint-free CoMat 02-091 wiping cloth
before the CoMat 01-438 MIBK/MEK dries. Force air dry for 30
minutes at 150° F to 180° F (66° C to 77° C).
B. Mask 0.06 to 0.12 in. (1,524 to 3,048 mm) from the perimeter of
perforated sheet plug hole with CoMat 02-161 Teflon tape (2
in./50,8 mm).
V2500 54-30-00 REPAIR 029

Page 209
Feb 1/09
12. Apply Adhesive (EA934NA) into Hole

PPE IS NECESSARY.
A. Mix CoMat 08-021 EA934NA adhesive in accordance with the

B. Put the CoMat 08-021 EA934NA adhesive into a clean disposable

CoMat 02-162 syringe. Inject the CoMat 08-021 EA934NA adhesive
into the 0.25 in. (6,35 mm) diameter perforated sheet plug hole
until the Comat 08-021 EA934NA adhesive is flush with the
perforated sheet surface. Make sure shrinkage does not form a
concave repair surface. Remove excess adhesive flush to tape.
Cover the plug hole with CoMat 02-168 non-porous parting film
and hold it in position with CoMat 02-161 Teflon tape (2 in./
50,8 mm).
C. Cure EA934NA adhesive. Position thermocouple(s) at the

perimeter of plug hole and tape in position. Use CoMat
02-161 Teflon tape (2 in. / 50,8 mm). Connect the
thermocouple(s) from the perimeter of the plug hole area to
temperature recorder. Cure at 180° F to 210° F (82.2° C to
98.8°C) for sixty minutes with an explosion proof heat lamp.
Remove all CoMat 02-161 Teflon tape (2 in./50,8 mm) and CoMat
02-168 non porous parting film from plug hole area and sand
smooth to surface. Use CoMat 05-129 (320 grit) aluminum oxide
abrasive paper.
V2500 54-30-00 REPAIR 029

Page 210
Feb 1/09
13. Clean Repair Area
A. Flush repair area perforated sheet with CoMat 01-438 MIBK/MEK.

Repeat flushing until all visual traces of oil water or dirt
are removed.
B. Wipe the repair area perforated surface dry with a clean lint-
free CoMat 02-091 cleaning cloth before the CoMat
01-438 MIBK/MEK dries. Remove CoMat 02-161 teflon tape (2 in./
50,8 mm) and CoMat 02-107 plastic, kraft paper at the
perimeter of repair area. Force air dry for 30 minutes at 150°
F to 170° F (66° C to 77° C).
14. Inspect for Residual Oil Contamination (See Figure 204)
A. Position a minimum of four thermocouples throughout perimeter

of repair area. Tape in place with CoMat
02-161 teflon tape (2 in./ 50.8 mm).
B. Cover the entire repair area with one layer of CoMat 02-167
fiberglass fabric type 181. Where possible, overlap the CoMat
02-167 fiberglass fabric 4.0 in. (101,6 mm) minimum from the
edges of repair area. Place one layer of CoMat
02-166 breather cloth RC3000-10 and one layer of CoMat
02-169 parting film to completely cover the CoMat 02-167
fiberglass cloth.
C. Position CoMat 12-164 tacky tape on the structure to completely

cover the CoMat 02-169 parting film. Where possible, overlap
6.0 in. (152,4 mm) minimum from the edges of repair area. Apply
CoMat 02-163 vacuum bag assembly. Position two vacuum probes at
opposite ends, under the vacuum bag and on the top of the
breather cloth.
V2500 54-30-00 REPAIR 029

Page 211
Feb 1/09
D. Attach a gauge and draw a vacuum of between 8 to 10 in. (203,3

to 254 mm) of Hg vacuum to check for leaks. Remove the vacuum
source and check if more than 5 in. (127 mm) of Hg vacuum is
lost in 5 minutes maximum. Rework the vacuum bag assembly
until less than 5 in. (127 mm) of Hg vacuum is achieved. Remove
the gauge after the vacuum check and apply the vacuum
maintaining a minimum of 20 in. (508 mm) Hg vacuum. Position
the repair area surface with perforated side with the face
down, if possible.
E. Connect the thermocouples from the perimeter of repair area to

temperature recorder. Increase the temperature to 230° F to
270° F (110° C to 132° C) for four hour with an oven. The rate
of heat increase is 2° F to 10° F (1,11° C to 5,55° C) for each
minute. Cool at a rate of 2° F to 20° F (1,11° C to 11,11° C)
for each minute. Keep a minimum vacuum of 20 in. (508 mm) Hg,
until 150° F to (66° C), or less is shown.
CAUTION: EXERCISE EXTREME CARE WHEN REMOVING BAGGING MATERIALS FROM

REPAIR. THE MATERIALS MAY BE HOT AND MAY CAUSE BURNS.
F. Remove bag assembly. Examine for evidence of oil on CoMat

02-166 breather cloth RC3000-10. If the evidence of oil still
exists, repeat Steps 13 A through 14 F.
NOTE: Alternate bagging procedures may be required to achieve

the desired vacuum.
CAUTION: DO NOT ALLOW WATER TO ENTER INTO CORE.
CAUTION: APPLICATION OF RMS058 ADHESIVE PRIMER (STEP 15) MUST

BE PERFORMED WITHIN 72 HOURS AFTER COMPLETION OF THE
DRYING CYCLE (STEP 14 E)
V2500 54-30-00 REPAIR 029

Page 212
Feb 1/09
15. Application of Adhesive Primer (RMS058)
A. Mask a perimeter of repair area with CoMat 02-161 Teflon tape

(2 in. / 50,8 mm) and CoMat 02-107 plastic. Kraft paper
sufficient to prevent any overspray of adhesive primer.
CAUTION: RMS058 IS FLAMMABLE AND VAPOR IS HARMFUL. INHALATION OF

SPRAY MIST MAY CAUSE SERIOUS BODILY HARM. AVOID SOURCES OF
IGNITION. USE ONLY IN AREAS WITH ADEQUATE VENTILATION.
THIS PRODUCT CONTAINS CHROMATES. OVER EXPOSURES MAY CAUSE
A GREATER CANCER RISK. WORK PERFORMED IN CONFINED AREAS
REQUIRES THE USE OF ADDITIONAL FORCED CONTACT WITH SKIN
AND EYES. USE REGULATORY APPROVED RESPIRATORY PROTECTION
FOR SPRAY APPLICATIONS. PROTECTIVE GLOVES SHOULD BE WORN
DURING USE; BUTYL RUBBER, NEOPRENE, OR NITRILE GLOVES ARE
RECOMMENDED. BEFORE YOU USE THIS PRODUCT, CAREFULLY READ
THE APPLICABLE “MATERIAL SAFETY DATA SHEET”, AND FOLLOW
ALL LISTED SAFETY AND HEALTH PRECAUTIONS.
B. Mix RMS058 adhesive primer in accordance with the

C. Weigh test panel TP140 and record weight.
D. Spray apply a dry film thickness of RMS058 adhesive primer

0.0001 to 0.0004 in. (0,0025 to 0,102 mm) thick on the repair
area of assembly. Thickness measurements can only be made after
the bake cycle. RMS058 adhesive primer must applied using box
coats on 6.0 in. (152,5 mm) centers.
E. Spray apply a coat of RMS058 adhesive primer 0.0001 to 0.0004

in. (0,0025 to 0,102 mm) thick on one side of the test panel
TP140 in the same manner as on the repair area.
NOTE: This reflects the proper RMS058 adhesive primer

deposition for peel testing (Step 27)
F. Weigh the test panel TP140. The test panel must increase in net
weight by 0.063 to 0.071 oz. (1,8 to 2,0 gm) when the coating
thickness is correct.
G. Air dry all RMS058 adhesive primer applications for a minimum

of 30 minutes at 65° to 90° (18,33° C to 32,22° C).
V2500 54-30-00 REPAIR 029

Page 213
Feb 1/09
H. Remove masking. Position a minimum of four thermocouples

throughout perimeter of repair area and tape in place using
CoMat 02-161 Teflon tape (2 in. / 50,8 mm).
I. Connect thermocouples from perimeter of repair area to

temperature recorder. Raise temperatures from 340° F to 360° F
(171° C to 182° C) for 65 ± 5 minutes by means of an oven. Rate
of heat rise is 2° to 10° F (1,11° C to 5,55° C) per minute.
Cool at a rate of 2° to 20° F (1,11° C to 11,11° C) per minute
until 150° F (66° C), or less is indicated.
CAUTION: A VACUUM SOURCE MUST BE PRESENT WHILE SANDING IS IN

PROGRESS. SANDING PARTICLES WILL DEGADE THE NOISE
ABSORBING ABILITY OF THE PANEL AND MUST BE PREVENTED FROM
FALLING THROUGH THE HOLES IN THE PERFORATED SHEET.
J. Lightly sand and repair area with CoMat 05-129 (320 grit)
aluminum oxide abrasive paper to remove any minor bumps in the
adhesive primer. Avoid sanding through to bare metal. Touch
application of adhesive primer is permitted for minor scratches
through the RMS058 adhesive primer. Allow 2 hours of air dry
following this type of application.
16. Cut Woven Wire
A. Prefit and cut new woven wire as necessary for the repair area.
Allow excess around perimeter (recommended 0.75 in. (18,0 mm),
trim before installation. (Refer to Fig. 205 to 206 and
reference Step 22).
NOTE: Repair woven wire warp and weft directions shall be cut
to conform with existing wire cloth orientation.
NOTE: Repair woven wire may be cut and spliced in order to fit
the contour without wrinking. (See Figure 206).
V2500 54-30-00 REPAIR 029

Page 214
Feb 1/09
17. Cut Adhesive Film (RMS042)
NOTE: Each woven wire splice must have an adhesive film barrier
strip. If the area of barrier strips reduce the total
acoustic area below the approved limit per SRM section
54-01-00, rearrange the woven wire splices to minimize
the use of barrier strips in an effort to minimize the
use of barrier strips hence reducing acoustic loss to
acceptable limits. Ideally, the barrier strips should be
placed over non-acoustic areas.
NOTE: The adhesive film barrier strips will be between the

woven wire and the perforated skin. The adhesive film
barrier strips used to prevent the sharp edges of the
woven wire from making contact with the skin. If the
woven wire repair section is to be bonded over the
fasteners, a 0.5 in. (12,7 mm)wide adhesive barrier
strips is to be between the fastener and woven wire.
NOTE: For the adhesive film barrier strips, use RMS042, Type 2,
Grade B adhesive film. If grade B is not available, Grade
A film can be used as an alternative. If the adhesive
film barrier strips are made from Grade B film, two
layers will be needed; if made from the alternative Grade
A, use only one layer.
NOTE: The RMS042 adhesive film can be used after the adhesive
film reaches room temperature. Use the adhesive film
within 14 days after reaching room temperature.
A. Cut the RMS042 adhesive film into barrier strips to fit along
all cut edges of the woven wire, including under any splices.
(Refer to Fig. 207).
B. Calculate the loss of acoustic area due to the adhesive film

barrier strips and acoustic area lost to previous repairs. The
total loss must not exceed allowable limits per the SRM,
section 54-01-00. If the total acoustic area lost exceeds the
allowable limit, it will be necessary to rearrange the woven
wire seams to minimize the acoustic loss. If it is impossible
to avoid exceeding the allowable limit, contact Goodrich
Customer Support Representative for evaluation and disposition.
V2500 54-30-00 REPAIR 029

Page 215
Feb 1/09
18. Perform Repair
A. Clean repair area perforated sheet with CoMat 01-438 MIBK/MEK

and CoMat 02-091 cleaning cloth. Wipe the surfaces dry with a
second clean lint-free CoMat 02-091 cleaning cloth before the
CoMat 01-438 MIBK/MEK dries. Force air dry for 30 minutes at
150° F to 170° F (66° C to 77° C).
19. Apply Adhesive (RMS070)
A. Mask perimeter of repair area with CoMat 02-161 teflon tape (2

in. / 50,8 mm) and CoMat 02-107 plastic, Kraft paper sufficient
to prevent any overspray of adhesive.

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 029

Page 216
Feb 1/09
B. Shake undiluted RMS070 adhesive for a minimum of 45 minutes.

Mix with an equal volume of CoMat 01-438 MIBK/MEK and shake for
5 minutes.
NOTE: In a hot environment, a large amount of MIBK/MEK can be

used, possibly as much as 250 per cent of initial
volume.
NOTE: The RMS070/MIBK/MEK adhesive mixture is usable until the

expiration date provided that the mixture is agitated
again prior to application.
C. Test spray the RMS070/MIBK/MEK adhesive mixture on a piece of

scrap material. If cob webbing occurs, add just enough CoMat
01-438 MIBK/MEK to the mixture to eliminate the cob webbing.
D. Weigh test panel TP140 and record weight.
CAUTION: INSTALLATION OF THE REPAIR WOVEN WIRE (STEP 23) MUST BE

PERFORMED WITHIN 72 HOURS AFTER APPLICATION OF THE RMS070
ADHESIVE (STEP 19 E).
E. Spray apply a coat of RMS070/MIBK/MEK adhesive mixture on the

repair area and on one side of the test panel. The RMS070/MIBK/
MEK adhesive mixture must be applied using box coats in 6.0 in.
(152,5 mm) centers. Allow 5 minutes air dry between coats.
F. Air dry test panel for 120 minutes at room temperature before
weighing. Weigh test panel to find the coating thickness. The
coating thickness is correct when the weight of the 12 X 12 in.
(300 X 300 mm) test panel has increased 0.15 to 0.16 oz/ft²
(51,67 to54,90 grams/m²). Continue to apply equal coats of
RMS070/MIBK/MEK adhesive on test panel and repair area until
the correct thickness, by weight, is achieved.
NOTE: Protect repair area surface from dust and debris during
air dry period. If repair area is covered, do not allow
cover to make contact with adhesive.
G. Allow the repair area surface to air dry for 120 minutes at
room temperature.
V2500 54-30-00 REPAIR 029

Page 217
Feb 1/09
20. Apply Adhesive Film (RMS042)
A. Remove CoMat 02-161 Teflon tape (2 in./ 50,8 mm) and CoMat 02-
107 plastic, kraft paper at perimeter of repair area. Use a
brush to wet perimeter of repair area (and splice joints, if
used) with CoMat 01-438 MIBK/MEK to provide a tacky
surface for the adhesive film barrier strips. The CoMat
01-438 MIBK/MEK application width should match that of the
adhesive film barrier strips. Do not soak with excessive
quantities of CoMat 01-438 MIBK/MEK.
B. Apply layers of RMS042, Type 2, Grade B (grade A) adhesive film

barrier strips where necessary.
21. Clean Pre-Cut Woven Wire
CAUTION: IT IS ESSENTIAL THAT THE PRECUT WOVEN WIRE AND TEST PANEL
WOVEN WIRE BE CLEAN AND REMAIN CONTAMINANT FREE DURING THE
REPAIR.
V2500 54-30-00 REPAIR 029

Page 218
Feb 1/09
A. Solvent flush precut repair woven wire and the test panel woven
wire TP738-70 with CoMat 01-438 MIBK/MEK. Repeat flushing until
all visual traces of oil, water or dirt are removed.
B. Force air dry for 30 minutes at 150° F to 170° F (66° C to 77°

C).
22. Cut Woven Wire
A. Put precut repair woven wire on a clean table. Put a piece of

CoMat 02-178 masking tape in the excess area of the precut
repair woven wire. Use CoMat 06-131 marking pen to mark the
centerline (FWD/AFT direction). Make sure wire warp and weft
directions are oriented.\
B. Roll the precut repair woven wire inward from each end to the
centerline, in the form of a scroll.
NOTE: Rolling facilitates the installation of large woven wire

sections; it may not be necessary for smaller repairs.
C. Apply CoMat 02-17 masking tape to the outside of the repair

area. Mark the ends of the FWD/AFT center line on the tape using
a CoMat 06-131 marking pen.
D. Lay the precut repair woven wire with the marked centerline on
the repair area and line up the centerline of woven wire with
centerline marks on masking tape.
23. Apply Woven Wire (See Figures 208 and 210)
CAUTION: INSTALLATION OF THE REPAIR WOVEN WIRE (STEP 23) MUST BE

PERFORMED WITHIN 72 HOURS AFTER APPLICATION OF THE RMS070
ADHESIVE (STEP 19 E)
A. Use the heat gun to apply the repair woven wire to the repair
area and the test panel woven wire TP738-70 to the TP140 test
panel. Work the woven wire from the center to the radial ends.
V2500 54-30-00 REPAIR 029

Page 219
Feb 1/09
NOTE: Woven wire can be moved for proper positioning before the
next step. Woven wire shall be located so that there is
excess material around the repair area that extends over
the existing woven wire and/or existing solid barrier.
NOTE: The following two steps (23 and 24) should be performed
simultaneously.
24. Mark and Trim Woven Wire
A. Mark around the perimeter where repair woven wire overlays the
existing woven wire, or where the repair woven wire goes over
existing fasteners. Use a CoMat 06-131 marking pen of different
color.
B. Mark excess repair woven wire where splice joints are needed to
avoid wrinkling using a CoMat 06-131 marking pen of contrasting
color.
CAUTION: DO NOT USE A RAZOR TO CUT WOVEN. USING A RAZOR CAN DAMAGE
THE EXISTING LAYER OF WOVEN WIRE.
C. Remove excess repair woven wire using scissors. Trim so that

the edges of the repair woven wire clear existing fasteners and
existing woven wire. Remove loose woven wire ends.
D. Complete smoothing out repair woven wire on the repair area

using heat gun. Make sure the repair woven wire is in
complete contact with the adhesive on the repair area.
25. Cure Repair (see Figure 210)
NOTE: The test panel (TP140 with TP738-70 shall be bagged and
cured using equivalent bagging, heating and pressure
application procedures as are used on the repair.
A. Position a minimum of four thermocouples along the perimeter of

the repair. Do not put the thermocouples on the repair area.
Tape thermocouples in position with CoMat 02-161 teflon tape (2
in./50,8 mm).
V2500 54-30-00 REPAIR 029

Page 220
Feb 1/09
B. Position CoMat 02-169 porous parting film over the repair area.
Where possible, overlap the CoMat 02-169 porous
parting film 4.0 in. (101,6 mm) minimum from the edges of
repair area. Put one layer of CoMat 02-166 breather cloth
RC3000-10 over the CoMat 02-169 parting film.
C. Position CoMat 12-024 tacky tape on the structure to

completely cover the CoMat 02-166 breather cloth. Where
possible, overlap 6.0 in. (152,4 mm) minimum from the edges of
repair area. Apply a CoMat 02-163 vacuum bag assembly and
position two vacuum probes at opposite ends, under the
vacuum bag and on top of the breather cloth.
D. To check for leaks, attach a gauge and draw a vacuum of between

8 to 10 in. (203,3 to 254 mm) of Hg vacuum. Remove vacuum source
and verify no more than 5 in. (127 mm) of Hg vacuum is lost in
5 minutes maximum. If the vacuum loss is more than 5 in. (127
mm) of HG vacuum in 5 minutes, then rework the vacuum bag
assembly until less than 5 in. (127 mm) of Hg vacuum is
achieved. Remove gauge after vacuum check, and apply vacuum
maintaining a minimum of 20 in. (508 mm) Hg Vacuum.
CAUTION: EXERCISE EXTREME CARE WHEN REMOVING BAGGING MATERIALS FROM

REPAIR. THE MATERIALS MAY BE HOT AND CAN CAUSE BURNS.
E. Connect thermocouples from perimeter of repair area to

temperature recorder. Raise temperatures from 340° F to 360° F
(171° C to 182° C) for 120 minutes by means of an oven. Rate of
temperature rise is 2° to 10° F (1,11° C to 5,55° C) per minute.
Cool at a rate of 2° to 20° F (1,11° C to 11,11° C) per minute
while maintaining vacuum until 150° F (66° C) or less is
reached. Remove bag assembly.
26. Inspect Repair
A. Visually inspect and do a tap test of the repaired area to make

sure that there are no areas of bond separation between the
repaired woven wire and the perforated sheet.
V2500 54-30-00 REPAIR 029

Page 221
Feb 1/09
27. Perform Peel Test
A. Peel test panel using bating Roller Test Arrangement per ASTM-
D-3167-76 (Reapproved 1986). Test speed is 3 in. (76 mm) per
minute. The minimum acceptable peel strength is 6 lbs/in. (1050
nm) width; minimum of 3 specimens.
(OPTIONAL METHOD)
Peel test for field can be performed in accordance with ASTM D-

903-49 peel test method. The test speed is 3 in. (76 mm) per
minute. The minimum acceptable peel strength is 9 lbs/in. (1576
nm) width; minimum of 3 specimens required.
28. Finalize Repair
A. Mask with CoMat 02-1178 masking tape the repair woven wire to
the original barrier dimension and mask woven wire splice
joints to a width of 5.0 in. (12,7 mm), centered on the splice.
(Refer to Fig. 211 and 212).

PPE IS NECESSARY.
B. Sand the masked off area until smooth. Use CoMat 05-128 (240
grit) and the CoMat 05-129 (320 grit) aluminum oxide
abrasive paper.
V2500 54-30-00 REPAIR 029

Page 222
Feb 1/09
C. Clean repair area woven wire CoMat 01-438 MIBK/MEK and CoMat
02-091 wiping cloth. Wipe the surfaces dry with second clean
lint-free CoMat 02-091 cleaning cloth before the CoMat
01-438 MIBK/MEK dries. Force air dry for 30 minutes at 150°F to
170° F (66° C to 77° C).
29. Apply RMS078 Liquid Barrier (See Figures 211 and 212)
NOTE: Apply RMS078 liquid barrier to butt splices and total

periphery of wire mesh sections 0.25 in. (6,35mm) wide on
each side. This allows for a 0.50 in. (12,7mm) barrier
total.
A. Apply RMS078 liquid barrier, 0.005 to 0.0 10 in. (0,127 to

0,254 mm) thick.
B. Air dry for 45 minutes. Immediately after air dry, remove CoMat
02-178 masking tape. Dry an additional one hour at 190° F to
210° F (87,4°C to 98,6°C).
30. Apply Aerodynamic Sealant (Proseal 889 B-2)
V2500 54-30-00 REPAIR 029

Page 223
Feb 1/09
A. Apply a Proseal 899 B-2 aerodynamic sealant 0.10 in. (2,5 mm)
wide around perimeter of repair and the butt splice area.
(Refer to Fig. 213 and 214)
B. Cure at 140° F (60°C) for eight hours using explosion proof

heat lamp, or equivalent.
31. Inspect Repair
A. Visually examine the repair. Make sure that there are no loose
ends of the woven wire mesh strands. Do a check to make sure
that all exposed surfaces of the repair are prepared and that
the edges of the faying surfaces have an adhesive coat. Check
sealant and woven wire interfaces to make sure it is
smooth.
32. Identify Repair
A. Use CoMat 06-131 marking pen of contrasting color to mark

VRS2263 adjacent to assembly number.
V2500 54-30-00 REPAIR 029

Page 224
Feb 1/09
R/H Fixed Duct Woven Replacement

Figure 201
V2500 54-30-00 REPAIR 029

Page 225
Feb 1/09
L/H Fixed Duct Woven Replacement

Figure 202
V2500 54-30-00 REPAIR 029

Page 226
Feb 1/09
Perforated sheet Plug Hole Repair Area

Figure 203
V2500 54-30-00 REPAIR 029

Page 227
Feb 1/09
Vacuum Bag Installation

Figure 204
V2500 54-30-00 REPAIR 029

Page 228
Feb 1/09
Repair Woven Wire Layup

Figure 205
V2500 54-30-00 REPAIR 029

Page 229
Feb 1/09
Repair Woven Wire Splice Detail Layup

Figure 206
V2500 54-30-00 REPAIR 029

Page 230
Feb 1/09
Adhesive Film Barrier strip Layup

Figure 207
V2500 54-30-00 REPAIR 029

Page 231
Feb 1/09
Repair Woven Wire Installation

Figure 208
V2500 54-30-00 REPAIR 029

Page 232
Feb 1/09
Repair Woven Wire Splice Detail

Figure 209
V2500 54-30-00 REPAIR 029

Page 233
Feb 1/09
Bagging Arrangement
Figure 210
V2500 54-30-00 REPAIR 029

Page 234
Feb 1/09
Liquid Barrier Application

Figure 211
V2500 54-30-00 REPAIR 029

Page 235
Feb 1/09
Liquid Barrier Splice Detail

Figure 212
V2500 54-30-00 REPAIR 029

Page 236
Feb 1/09
Aerodynamic Sealant Application

Figure 213
V2500 54-30-00 REPAIR 029

Page 237
Feb 1/09
Aerodynamic Sealant Splice Detail

Figure 214
V2500 54-30-00 REPAIR 029

Page 238
Feb 1/09
REFER TO SRM 54-02-00

V2500 54-30-00 REPAIR 030

Page 201
Feb 1/09
V2500 54-30-00 REPAIR 030

Page 202
Feb 1/09
REPAIR 031
EDGE SEALANT REPLACEMENT REPAIR
FOR THE 7TH AND 10TH STAGE BLEED VALVE CUTOUTS
RIGHT FIXED DUCT ACOUSTIC PANEL
(VRS2083)
1. General
A. This repair procedure is used to replace the edge sealant for

the 7th and 10th stage bleed valve cutouts on the right fixed
duct acoustic panel. (See Figure 201).
B. This repair can be done in conjunction with VRS2338 (the

perforated skin repair around the 7th and 10th stage bleed
valve cutouts), or it can also be done by itself to replace the
edge sealant only.
VRS2083
Heat blankets
Heat gun
Plastic spatula
Standard shop tools
Temperature controllers
Thermocouples

Consumables Index)

CoMat 01-438
V2500 54-30-00 REPAIR 031

Page 201
Aug 1/09

Comat 05-081 Waterproof silicon carbide abrasive paper
CoMat 08-143A Potting Compound, Epocast 1614-A1
CoMat 08-143B Potting Compound, Epocast 938-A2 (Alternate to
CoMat 08-143A)
PART IDENT MATERIAL

Acoustic Panel Woven wire (A1 Engines);
Perforated aluminum outer skin;
Aluminum honeycomb core;
Solid aluminum inner skin

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 031

Page 202
Aug 1/09
CONTAMINATION.
A. Clean the damage area with a CoMat 02-099 lint-free cloth made
B. Remove all loose sealant from the edges.
C. Do an inspection of the damage area. Do a tap test, if

necessary, to examine for disbonds.
NOTE: This repair can be used by itself to replace the edge

sealant only. If the perforated skin is disbonded or
is otherwise damaged, you must use this repair in
conjunction with the “Perforated skin repair around
the 7th and 10th stage bleed valve cutouts,
(VRS2338)”. Refer to VRS2338 to perform the necessary
steps.
D. Remove the sharp edges. Remove the cured bonding material from
the exposed edges of the honeycomb cells. Use the CoMat 05-020
and 05-081 abrasive papers. Do not damage the skin.
E. Use clean air blast to remove the sanding debris. Clean the
repair area with a CoMat 02-099 lint-free cloth made moist with
CoMat 01-438 solvent. Rub the surface clean before solvent
becomes dry.
V2500 54-30-00 REPAIR 031

Page 203
Aug 1/09
5. Remove Contamination from the Repair Area

PPE IS NECESSARY.
A. Use a vacuum bagging procedure to remove contamination from the

repair area. During this procedure, heat the repair area at
190-210ºF (88-99ºC) for 30 minutes. Repeat this applicable
sanding, cleaning, and vacuum bagging steps until the
contamination is completely removed.
NOTE: Do this procedure if there is evidence of

contamination in the repair area.
6. Apply the Potting Compound to the Edges, (See Figure 202)

PPE IS NECESSARY.
CAUTION: USE COMAT 02-097 LINT-FREE GLOVES WHEN YOU TOUCH THE
CONTAMINATION.
V2500 54-30-00 REPAIR 031

Page 204
Aug 1/09
A. If necessary, clean the repair area. Use a CoMat 02-099 lint

surface before the solvent becomes dry.
B. Make a border around the repair area. Use CoMat 02-161 teflon
tape.
NOTE: 1. If there is no damage to the structure, apply the

tape along the edge of the bleed valve cutout on the
two sides of the acoustic panel.
2. If there is damage to the structure, and the

perforated skin has been cut out because of another
repair, apply the tape on the exposed core 0.5 in.
(13 mm) from the edge of the bleed valve cutout. On
the solid skin side of the acoustic panel, apply the
tape along the edge of the bleed valve cutout.
C. Remove the frozen CoMat 08-143A potting compound from storage.

Let it thaw at room temperature for two hours.
NOTE: You must use the potting compound within 8 hours after
it reaches the room temperature.
D. Use a spatula to apply the potting compound to the area between

the teflon tapes. Add more potting compound to completely cover
the honeycomb edges, or fill the cells, as necessary. Make sure
there are no air pockets in the applied potting compound.
E. The applied potting compound must be level with the adjacent

surfaces. Remove the unwanted potting compound before it cures.
F. Put a piece of the CoMat 02-168 non-porous parting film above

the repair area and wrap it around the edge. The piece of film
must be a minimum of 2.0 in. (51 mm) larger than the repair area
all around.
G. Put a minimum of two thermocouples around the perimeter of the

repair area. Hold in place with CoMat 02-160 teflon tape.
H. Put a sheet of CoMat 02-170 silicone rubber above and around

the non-porous parting film in the repair area.
V2500 54-30-00 REPAIR 031

Page 205
Aug 1/09
I. Put heat blankets above and around the sheet of silicone

rubber.
J. Turn on the heat blankets. Cure the repair at room temperature

at the rate of 5-7°F (3-4°C) per minute plus one (1) hour at
350°F (177°C) or 90 minutes at 250°F (121°C). The cure
temperature refers to temperature of material as determined by
thermocouple. Slow heat rise at 5-7°F (3-4°C) per minute is
preferred to reduce shrinkage and minimize out-gassing during
the cure.
NOTE: If the rate of temperature rise is not as specified,

the potting compound can crack.
K. Let the repair area cool down to room temperature. Then remove
the curing materials.
7. Make the Repair Surfaces Smooth

PPE IS NECESSARY.
A. The cured potting compound must be level with the adjacent

surfaces. Remove the sharp edges and the unwanted cured potting
compound from the area. Use the CoMat 05-020 and 05-081
abrasive papers. do not cut into the metal surfaces or remove
the surface finish.
V2500 54-30-00 REPAIR 031

Page 206
Aug 1/09
B. Clean the surface with a CoMat 02-099 lint-free cloth made

NOTE: 1. If this repair is done along with another repair,

you must now continue with the applicable steps of
that repair.
2. If this repair is not done along with another

repair, go to the next step.
A. Visually examine the repair area and check records to make sure
that procedures in this repair were done. If necessary, do the
A. Make a mark VRS2083 adjacent to the assembly number. Use a

V2500 54-30-00 REPAIR 031

Page 207
Aug 1/09
Edge Sealant Replacement Repair

For the 7th and 10th Stage Bleed Valve Cutouts
Right Fixed Duct Acoustic Panel
Figure 201
V2500 54-30-00 REPAIR 031

Page 208
Aug 1/09
Edge Sealant Replacement Repair

For the 7th and 10th Stage Bleed Valve Cutouts
Right Fixed Duct Acoustic Panel
Figure 202
V2500 54-30-00 REPAIR 031

Page 209
Aug 1/09
V2500 54-30-00 REPAIR 031

Page 210
Aug 1/09
REPAIR 032
LEFT & RIGHT C-DUCT FIXED STRUCTURES TORQUE RING INNER FAIRING PATCH
REPAIR AND FORWARD FRAME REPAIR
(VRS2362/VRS2363)
1. Effectivity
Part No.: 740-0012

Refer to General B.2, C, and D
2. General
A. The purpose of this repair is to patch repair the torque ring

inner fairing and the forward frame on the left and right
C-Duct fixed structures.
B. This repair is applicable to the following:
(1) Damaged aluminum inner fairing and aluminum forward frame.
(2) Only to Pre SB78-230 Torque Rings. The inner fairing and
forward frame of these Torque Rings are mechanically
fastened by countersunk or flush rivets.
NOTE: Contact Goodrich for disposition if the damaged to

inner fairing and forward frame are mechanically
fastened by dome or button heads.
(3) If the width of the inner fairing cutout is less than 6.0
in. (152 mm). Refer to Figure 202.
(4) Torque rings assemblies whose inner fairing and forward

frames are made out of aluminum. It is not applicable to
the components made of composite material.
C. The thickness of the inner fairing repairable by this repair

are:
(1) 0.056 in. (1,42 mm) chem-milled to 0.036 in. (0,91 mm)
V2500 54-30-00 REPAIR 032

Page 201
Aug 1/09
D. The thickness of the forward frame repairable by this repair

are:
(1) 0.045 in. (1,1 mm)
(2) 0.063 in. (1,6 mm)
E. This procedure can be used to repair the damage inner fairing

and the forward frame of the torque ring, or if a piece of the
inner fairing and/or forward frame is missing. It is affected
by cutting out the damage parts of the inner fairing and the
forward frame and installing repair patches, fillers and
doublers.
F. The location of the cut lines for the inner fairing and forward
frame should be established only within area 2 as shown in
Figure 201. They should be no less than 2.0 in. (50,8 mm) from
the edge of the actuator fitting. The exact location of cut
lines shall be established in such a way that the final
installation of the repair pieces will not interfere with the
production hardware.
G. If damage is located in Area 1 or in Area 1 and 2 simultaneously

when VRS2363/VRS2362 is not applicable. For repair of damage in
Area 1 refer to SRM 54-30-00 REPAIR 034 (VRS2181/VRS2182).
H. Measure the thickness of the forward frame. Inspect the forward

frame for crack damage. Review SB V2500-NAC-78-0159 to
determine if it is applicable to your thrust reverser.
(1) If the forward frame thickness is equal to 0.045 in. (1,14

mm) thick, proceed to step 2.I.

mm) thick, proceed to step 2.J.
I. Perform a repair using VRS2181/VRS2182, VRS2362/VRS2363,

VRS2179/VRS2180 or SB V2500-NAC-78-0160. If VRS2181/VRS2182 or
VRS2363/VRS2362 is used, inspect the torque ring afterwards at
least once every 4th A-check or 1250 flight cycles per SB
V2500-NAC-78-0159. If it is cracked again replace the forward
frame per VRS2179/VRS2180 or SB V2500-NAC-78-160. If necessary,
replace the inner fairing as well.
V2500 54-30-00 REPAIR 032

Page 202
Aug 1/09
J. Perform a permanent repair using VRS2181/VRS2182 or VRS2363/

VRS2362 or replace the forward frame per VRS2179/VRS2180 or SB
V2500-NAC-78-160.
K. Identify the part number of the damaged inner fairing and/or

the forward frame. Order a spare component before starting the
repair if necessary.
L. To affect the repair, it is necessary to have the tools and

fixtures needed to fabricate and install the parts while
maintaining the original production contour.
M. If the forward frame, (new version only), is found to be

damaged report its extent to Airbus.
N. The practices and processes referred to in the procedure are in

the Goodrich SPPM.
VRS2362 and VRS2363

V2500 Thrust Reverser Component Maintenance Manual
Clamps
Cutting tools
Drilling tools
Grinding tools
Nylon brush
Palette knife
Rivet tools
Standard shop tools
Temporary fasteners
V2500 54-30-00 REPAIR 032

Page 203
Aug 1/09
CoMat 01-076 Methylethylketone (MEK)(Alt. to CoMat

01-438)
CoMat 02-097 Lint-free Gloves
CoMat 02-158 Release agent
CoMat 02-171 Aluminum alloy sheet
CoMat 02-178 Masking tape, #250
CoMat 02-257 Aluminum laminated shim
CoMat 02-360 Alum. Alloy sht, t=0.040 in. (1,016 mm)
CoMat 05-126 Scotch brite
CoMat 07-028 Coversion coating, Alternative for CoMat
07-106
CoMat 07-106 Coversion coating
CoMat 07-126 Water soluble primer, Alternative for
CoMat 08-093
V2500 54-30-00 REPAIR 032

Page 204
Aug 1/09
CoMat 07-127 Water soluble primer converter,

Alternative for CoMat 07-116
CoMat 07-128 Water soluble primer thinner,
CoMat 08-032 Primer
CoMat 08-093 I Primer class M

Processes and Consumable Index, PCI.
PART IDENT MATERIAL

Torque ring Fairing and forward frame:
fairing assembly 2024-T62 A1 per QQ-A-250/4
F. Price and Availability
Refer to Goodrich Aerospace, Aerostructures Group, (Formerly

Rohr, Inc.)
G. Repair Parts
Item No. Part No. Part Identification Qty

1 CR3213-5-02 Rivet A/R
AF3213-5-02 Rivet (Optional) A/R
HR3213-5-02 Rivet (Optional) A/R
NAS9301B5-02 Rivet, alternative A/R
V2500 54-30-00 REPAIR 032

Page 205
Aug 1/09

AF3243-5-02 Rivet, Oversize (Optional) A/R
HR3243-5-02 Rivet, Alternative oversize A/R
NAS9304B5-02 Rivet, Alternative oversize A/R
2 CR3524PR-5-02 Rivet A/R
NAS9309M5-02 Rivet, Alternative A/R
NAS9311M5-02 Rivet, Alternative oversize A/R
3 CR3524PR-5-03 Rivet A/R
HR3552-5-03 Rivet, Oversize (Optional) A/R
4 CR3555-4-02 Rivet A/R
5 CR3214-4-03 Rivet A/R
NAS9303B4-03 Rivet, Alternative A/R
CR3242-4-03 Rivet, Oversize (Note 6) A/R
V2500 54-30-00 REPAIR 032

Page 206
Aug 1/09

(Note 6)
(Note 6)
6 HL10V6-7 Pin A/R
HL110-6-7 Pin, First oversize A/R
7 HL10V6-8 Pin A/R
8 HL12V6-9 Pin A/R
9 HL70-6 Collar A/R
HL79-6 Collar, First oversize A/R
10 HL75V-6 Collar (For standard and A/R
first oversize pins)
NOTE: 1. These item numbers reference to the illustrations.
2. Gage thickness of the forward frame doubler and the

inner fairing doubler shall be the same thickness
or one gage thicker than the maximum thickness of
the forward frame and the inner fairing
respectively. Depending on whether you have an old
or new version, these could be as follows:
Frame doubler-CoMat 03-360 (t=0.045, 0.050, 0.063,

0.071 in.)
Inner Fairing doubler-CoMat 03-360 (t=0.050, 0.056,

0.063 in.)
CoMat 03-360 must be heat treated to the T62

condition after forming.
V2500 54-30-00 REPAIR 032

Page 207
Aug 1/09
3. If damage in contained only within Area 2 it is

recommended to cut the fairing patch from a spare
fairing. However, as an alternative, it is
acceptable to form and fabricate the fairing patch
from CoMat 02-321 or CoMat 02-360 Aluminum alloy
sheet (t=0.050 or 0.056 in. thick). CoMat 02-360
must be heat treated to the T62 condition after
forming. If damage is present in Area 1 then
VRS2363/VRS2362 is not applicable. Use VRS2181/
VRS2182 to repair damage in Area 1.
4. Form and fabricate the fairing filler from CoMat

02-214 aluminum alloy sheet (t=0.050 in. thick
2024-T3). It is acceptable to use CoMat 02-321
(t=0.050 in.) or CoMat 02-360 (t=0.050 or 0.056
in.) as an alternative. CoMat 02-321 and CoMat 02-
360 must be heat treated to the T62 condition after
forming. Do not heat treat CoMat 02-214 (2024-T3)
after forming.
5. It is recommended to cut the frame segment from a

spare forward frame. It is acceptable to form and
fabricate a frame from CoMat 02-360 Aluminum alloy
sheet (t=0.045 or 0.063 in. thick) as an
alternative. CoMat 02-360 must be heat treated to
the T62 condition after forming.
6. It can become necessary to use laminated shim to

fill some spaces, because of variations in the
thickness of the fairing and the chem-milling
requirements. If this is the case, use CoMat 02-257
Aluminum laminated shim.
7. If the existing fairing is not chem-milled, use the

flush head oversize rivet. If the existing fairing
is chem-milled, use the protruding head oversize
rivet.
8. Use the alternative and oversize fasteners only if

necessary. All fasteners are commercially
available.
V2500 54-30-00 REPAIR 032

Page 208
Aug 1/09
5. Examine the Damage Area

PPE IS NECESSARY.
A. Remove the torque ring seal. Pull the seal from the retainer.
Cut if necessary.
B. Remove the sharp edges from the damaged area using CoMat 05-128
Aluminum oxide abrasive paper.
C. Clean the repair area using CoMat 02-099 lint free cloth made
D. Examine the damage area on the inner fairing. If necessary,

penetrant inspect to check for cracks. Refer to the SPPM for
instructions. Make a mark of the crack ends.
V2500 54-30-00 REPAIR 032

Page 209
Aug 1/09
6. Cut the Inner Fairing, Refer to Figure 202, Figure 203 and Table 1

PPE IS NECESSARY.
A. Stop drill the crack ends if there are cracks on the inner
fairing. Use a hole between 0.125 and 0.150 in. (3,17 and 3,81
mm) in diameter. Use drills and drilling tools. Remove the
burrs.
B. Make a mark of the cutout on the inner fairing only in Area 2.
NOTE: The cutout must be a minimum of 0.50 in. (12,7 mm) more
than the edge of damage or stop drill holes, if any.
C. Remove the fasteners in the marked areas. Remove more

fasteners, if necessary, to make the damage removal necessary.
Use drills and drilling tools. Do not damage the holes. Remove
the burrs.
D. Cut the damaged fairing. Cut the inner fairing as marked. Use
cutting and grinding tools. Remove burrs.
V2500 54-30-00 REPAIR 032

Page 210
Aug 1/09
7. Examine the Forward Frame, Refer to Figure 202
A. Clean the repair area using CoMat 02-099 Lint free cloth made
B. Examine the forward frame in the damage area of the fairing

cutout. Penetrant inspect the frame, if necessary, to check for
cracks. Refer to the SPPM TASK 70-23-00-230-501 for
instructions. Make a mark at the crack ends.
8. Cut the Forward Frame, Refer to Figure 202, Figure 205 and Table 1

PPE IS NECESSARY.
A. Stop drill the crack ends if there are cracks in the forward
frame. Use a hole between 0.125 and 0.150 in. (3,17 and 3,81 mm
in diameter. Use drills and drilling tools. Do not drill into
the existing structure. Remove the burrs.
B. Make a mark of the cutout on the forward frame. Use a CoMat 06-
131 marking pen.
V2500 54-30-00 REPAIR 032

Page 211
Aug 1/09
C. Cut the forward damaged frame as marked. Use cutting and

grinding tools. Do not cut into the existing structure. Remove
the burrs.
NOTE: 1. Cut out a complete section of the forward frame that

includes the damage.
2. The cut lines must be a minimum of 5.0 in. (12,7 mm)

more than the edges of the damage or the stop drill
holes, if any.
3. The edges of the cutout on the inner fairing must be

a minimum of 3.5 in. (88.9 mm) from the applicable
edges of the cutout on the forward frame. This
prevents interference between the fairing repair
and the frame repair. If necessary to meet this
requirement, you must repeat the applicable steps
to make the cutout on the larger fairing.
9. Make the Repair Parts, Refer to Figure 203, 205 and Table 1

PPE IS NECESSARY.
A. Make a mark of the outline of parts, the repair parts on the

fairing and on the frame. Refer to the applicable figure for
dimensions. Use a CoMat 06-131 marking pen.
B. Remove the fasteners in the marked areas. Use drills and

drilling tools. Do not damage the holes. Remove the burrs.
C. Make the repair parts as marked. Refer to section 2.B. for

CoMat materials. Refer to the applicable figure for dimensions.
Remove the burrs.
NOTE: The inner fairing and the forward frame have complex
shapes. It is recommended to make the fairing patch
and frame segment from a spare fairing and spare
forward frame.
V2500 54-30-00 REPAIR 032

Page 212
Aug 1/09
D. Align the repair parts to the contour of the structure in the

repair area. The parts must fit the contour with light finger
pressure.
E. Heat treat the parts that are made from 2024-T0 aluminum alloy
to the T62 condition. Be careful not to heat treat parts that
are already in the 2024-T3 condition.
F. Make the CoMat 02-257 laminated shim, if necessary. Use clamps

to temporarily install the repair parts. Examine for spaces. If
you must use laminated shims, make the shims now.
NOTE: Liquid shim and/or laminated shims to fill the spaces

between the mating parts can be used. See Figure 208,
Note 3, for the limits.
G. Make a mark of the holes on the repair parts and the structure.
Refer to Figure 208 for spacing requirements.
H. Drill the pilot holes at the marked locations. Use drill and
drilling tools. Remove the burrs.
I. Temporarily install the repair parts. Use temporary fasteners

to hold the parts in position. Make sure all the holes are
aligned. Drill the holes to their final size. Use drills and
J. Countersink the holes. Use drills and drilling tools. Drill the
pilot holes at the marked locations. Remove the burrs. See
Table 1.
K. Remove the sharp edges. Use CoMat 05-128 Aluminum oxide

abrasive paper.
V2500 54-30-00 REPAIR 032

Page 213
Aug 1/09
10. Prepare the Repair Parts for Installation, Refer to Figure 203, 205
and Table 1

PPE IS NECESSARY.
CONTAMINATION.
A. Clean the repair area. Use a palette knife and CoMat 05-126
Scotch brite pads made moist with CoMat 01-438 solvent.
Carefully remove the bulk of the existing sealant and adhesive
from the repair area and from the inside of the retainer. Use
CoMat 02-099 lint free cloth. Rub the surfaces clean before the
B. All bare aluminum surfaces must be water break free surfaces.

Do a water break free test of these surfaces. Repeat the water
break free test until the surfaces are acceptable.
C. Clean the tested surfaces. Use CoMat 02-099 lint free cloth
made moist with CoMat 01-438 solvent. Rub the surfaces clean
D. Apply the CoMat 07-106 chromate conversion coating solution to

the tested surfaces. Use a nylon brush or a CoMat 02-099 lint
free cloth. Keep the surface wet with fresh solution for 3 to 5
minutes. Do not let the solution dry on the surface.
V2500 54-30-00 REPAIR 032

Page 214
Aug 1/09
E. Rinse the conversion coated surfaces thoroughly with

demineralized water. Air dry for 30 minutes. The surface must
be colorless with no visible difference between parts.
NOTE: The surfaces will have golden color if the alternative

conversion coating (CoMat 07-028) is used.
F. Prepare the primer. Use the manufacture’s instructions to mix

the CoMat 08-093 I Primer class M, and the CoMat 07-116
Thinner. Let the primer mixture cure for 30 minutes.
NOTE: The CoMat 08-093 I Primer Class M must be used with

CoMat 07-115 I Primer class M and the CoMat 07-116
thinner. The alternative CoMat 07-126 primer, CoMat
07-127 converter, and CoMat 07-128 thinner must be
mixed together. Do not mix the two primer systems.
G. Apply the primer mixture to the conversion coated surfaces.

Refer to the manufacturer’s instruction for application
procedure.
H. Cure the primer for one hour between 190° and 210°F (88° and
99° C). Use an explosion proof heat lamp.
11. Install the Repair Parts, Refer to Figure 203, 205 and Table 1

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 032

Page 215
Aug 1/09
CAUTION: 1. USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CONTAMINATION.

LUBRICATED. DO NOT REMOVE THE LUBRICANT.
NOTE: Go to step 10.E. if liquid or laminated shim is not

used. Use the liquid shim to bond it in place if
laminated shim is used. If only liquid shim is used,
you must cure it before the final assembly. (See Step
8.F. for shimming information).
A. Prepare the adhesive/liquid shim. Remove the CoMat 08-021

adhesive from cold storage and bring to room temperature. Use
the manufacturer’s instructions to mix the adhesive.
B. If laminated shim is used:
(1) Apply a thin layer of the CoMat 08-021 adhesive to the

mating surface of the structure. Put the laminated shim
into position. Use temporary fasteners as required to keep
the holes aligned.
(2) Remove the unwanted adhesive/liquid shim and the temporary

fasteners from the area before the adhesive cures. Use
solvent. Rub the surface clean before the solvent becomes
dry.
(3) Cure the adhesive/liquid shim for one hour between 190°
and 210°F (88° and 99°C). Use an explosion proof heat
lamp. Go to step 10.D.
C. If adhesive/liquid shim is used:
(1) At each location where necessary, apply the required

amount of adhesive/liquid shim to one of the two mating
surfaces.
(2) Apply the release agent to the other mating surface. Use
release agent.
V2500 54-30-00 REPAIR 032

Page 216
Aug 1/09
CAUTION: YOU WILL FORCE THE UNCURED LIQUID SHIM OUT OF THE JOINT IF
YOU APPLY TOO MUCH PRESSURE.
(3) Temporarily install the applicable repair parts. Use

temporary fasteners to keep the holes aligned. Use clamps
as required to apply pressure to the parts. Apply enough
pressure to make the repair parts level with the adjacent
existing parts.
(4) Remove the unwanted adhesive and the temporary fasteners

from the area before the adhesive cures. Use CoMat 02-099
lint free cloth made moist with CoMat 01-438 solvent if
necessary. Do not let the solvent go into the joints. Rub
the surface dry before the solvent becomes dry.
(5) Cure the adhesive/liquid shim at 190° and 210°F (88 and
99°C) for one hour. Use an explosion proof heat lamp
Remove the parts before the adhesive cures.
D. Temporarily install the repair parts. Examine to make sure that

the repair parts are level with the adjacent parts. Remove the
layers of the laminated shim, or use abrasive paper on the
liquid shim if necessary.
E. Clean the repair area. Use CoMat 02-099 lint free cloth made
F. Install the repair parts. Apply a thin layer of the CoMat

08-021 adhesive to the mating surfaces. Put the repair parts
into position. Use temporary fasteners as required to keep the
holes aligned. Wet install the rivets with the adhesive.
G. Remove the unwanted adhesive/liquid shim from the area before

it cures. Use CoMat 02-099 lint free cloth made moist with
becomes dry.
H. Use an explosion proof heat lamp. Cure the adhesive/liquid shim

at 190° and 210°F (88 and 99°c) for one hour.
V2500 54-30-00 REPAIR 032

Page 217
Aug 1/09
12. Install the Seal, Refer to Figure 205 and Table 1

PPE IS NECESSARY.
CONTAMINATION.
A. Abrade the mating surfaces of the seal and the seal retainer.
Use CoMat 05-128 aluminum oxide abrasive paper.
B. Use a CoMat 02-099 lint free cloth made moist with CoMat 01-438
solvent. Clean the mating surfaces of the seal and retainer.
Rub the surfaces clean before the solvent becomes dry.
CAUTION: DO NOT APPLY THE PRIMER TO THE RUBBER SURFACES.

primer. Apply a thin layer of the primer to the inside surface
of the retainer. Let the primer dry at room temperature for one
hour. If the primer forms a dull finish or dusty chalk on the
surface, wipe the surface with CoMat 02-099 lint free cloth.
D. Apply a uniform level of the CoMat silicone rubber compound to

the mating surfaces. The adhesive layer must be 0.005 to 0.010
in. (0,13 to 0,25 mm) thick.
V2500 54-30-00 REPAIR 032

Page 218
Aug 1/09
E. Insert the seal into the retainer. Use a CoMat 02-099 lint free
cloth to remove the unwanted adhesive from the area.
F. Air cure the adhesive for 8 hours at room temperature, but no

less than 59°F (15°C), before you handle the parts.
NOTE: It is not necessary to let the silicone rubber

compound fully cure under the repair conditions. The
uncured adhesive is functionally acceptable.
13. Apply the Sealant to the Spaces, Refer to Figure 203, 205 and Table 1
A. Clean the repair area. Use CoMat 02-099 lint free cloth made
B. Use CoMat 02-178 masking tape. Make a border along the edges of
the spaces between the fairing patch and existing fairing.Do
the same along the edges of open spaces.
C. Apply the sealant primer to the spaces. Use the manufacturer’s

instructions to mix the Comat 08-032 primer. Apply a thin layer
of the primer to the spaces between the pieces of masking tape.
Let the primer dry at room temperature for one hour. If the
primer forms a dull finish or a dusty chalk on the surface, wipe
the surface with a CoMat 02-099 lint free cloth.
D. Use the manufacturer’s instructions to mix the CoMat 08-033

sealant. Apply the sealant to the spaces between the pieces of
masking tape.
V2500 54-30-00 REPAIR 032

Page 219
Aug 1/09
E. Remove the unwanted sealant using CoMat 02-099 lint free cloth.
On the air wetted surfaces, the sealant must not be above the
surface, and must not be more than 0.010 in. (0,25 mm) below the
surface.
F. Cure the sealant for 10 hours at room temperature. The sealant

will be tack free in one hour. Remove the masking tape before
the cure cycle is complete.
NOTE: It is not necessary to let the sealant fully cure under

the repair conditions. The uncured sealant is
14. Examine the Completed Repair
A. Visually examine the repair area to make sure the procedures in

this repair are done. Do the applicable steps again if
necessary.
A. Make a mark VRS2363 (left C-duct) and VRS2362 (Right C-duct)

V2500 54-30-00 REPAIR 032

Page 220
Aug 1/09
Torque Ring Inner Fairing Patch Repair and Forward Frame Repair
Left & Right C-Duct Fixed Structure
Figure 201
V2500 54-30-00 REPAIR 032

Page 221
Aug 1/09
Figure 202
V2500 54-30-00 REPAIR 032

Page 222
Aug 1/09
Figure 203
V2500 54-30-00 REPAIR 032

Page 223
Aug 1/09
Figure 204
V2500 54-30-00 REPAIR 032

Page 224
Aug 1/09
Figure 205
V2500 54-30-00 REPAIR 032

Page 225
Aug 1/09
Figure 206
V2500 54-30-00 REPAIR 032

Page 226
Aug 1/09
Table 1: Hole and Countersink Diameters

(Sheets 1 of 2)
V2500 54-30-00 REPAIR 032

Page 227
Aug 1/09
Table 1: Hole and Countersink Diameters

(Sheets 2 of 2)
V2500 54-30-00 REPAIR 032

Page 228
Aug 1/09
REPAIR 033
LEFT & RIGHT C-DUCT FIXED STRUCTURES
TORQUE RING FORWARD FRAME AND INNER FAIRING REPLACEMENT REPAIR
(VRS2179/VRS2180)
1. Effectivity
Part No.: 740-0012

Refer to General C.1, C.2, D, and E
2. General
A. The purpose of this repair is to replace the torque ring

forward frame and inner fairing.
B. This repair requires that the C-Duct is removed from the wing,
and the cascades have been removed from the structure per the
applicable procedures.
C. This repair is applicable to the following:
(1) Damaged aluminum inner fairing and aluminum forward frame.
(2) Only to Pre SB78-230 Torque Rings. The inner fairing and
forward frame of these Torque Rings are mechanically
fastened by countersunk or flush rivets.
NOTE: Contact Goodrich for disposition if the damaged to

inner fairing and forward frame are mechanically
fastened by dome or button heads.
(3) Torque rings assemblies whose inner fairing and forward

frames are made out of aluminum. It is not applicable to
the components made of composite material.
D. The thickness of the inner fairing repairable by this repair

are:
V2500 54-30-00 REPAIR 033

Page 201
Aug 1/09
E. The thickness of the forward frame repairable by this repair

are:
(1) 0.045 in. (1,1 mm)
(2) 0.063 in. (1,6 mm)
F. Measure the thickness of the forward frame. Inspect the

forward frame for crack damage. Review SB V2500-NAC-78-0159 to

mm) thick, proceed to step 2.G.

mm) thick, proceed to step 2.H.
G. Perform a repair using VRS2181/VRS2182, VRS2362/VRS2363,

VRS2179/VRS2180 or SB V2500-NAC-78-0160. If VRS2181/VRS2182 or
VRS2363/VRS2362 is used, inspect the torque ring afterwards at
least once every 4th A-check or 1250 flight cycles per SB
V2500-NAC-78-0159. If it is cracked again replace the forward
frame per VRS2179/VRS2180 or SB V2500-NAC-78-160. If necessary,
replace the inner fairing as well.
H. Perform a permanent repair using VRS2181/VRS2182 or VRS2363/

VRS2362 or replace the forward frame per VRS2179/VRS2180 or SB
V2500-NAC-78-160.
I. Identify the part number of the damaged inner fairing and/or

J. To affect the repair, it is necessary to have the tools and

K. The practices and processes referred to in the procedure are in

the Goodrich SPPM.
V2500 54-30-00 REPAIR 033

Page 202
Aug 1/09
VRS2179 and VRS2180

Clamps
Cutting tools
Drilling tools
Grinding tools
Nylon brush
Palette knife
Rivet tools
Standard shop tools
Temporary fasteners
CoMat 01-076 Methylethylketone (MEK)(Alt. to

CoMat 01-438)
CoMat 07-028 Coversion coating, Alternative for
CoMat 07-106
V2500 54-30-00 REPAIR 033

Page 203
Aug 1/09

CoMat 08-093
CoMat 08-032 Primer

C. Special Tools
Torque ring forward frame locating tool, 1N20055, (5 off).
PART IDENT MATERIAL

Torque ring inner Aluminum alloy
fairing and forward
assembly

Rohr, Inc.)
G. Repair Parts

1 CR3524-5-06 Rivet A/R
NAS9309M5-06 Rivet, alternative A/R
V2500 54-30-00 REPAIR 033

Page 204
Aug 1/09

2 MS21076-04 Nutplate A/R
3 HL12V6-04 Pin A/R
HL75-06AW Collar A/R
4 MS24026AD5 Rivet A/R
5 CR3214-5-02 Rivet A/R
6 CR3214-5-04 Rivet A/R
7 CR3523-6-05 Rivet A/R
HR3523-6-05 Rivet,(Optional) A/R
NAS9310M6-05 Rivet, Alternative Oversize A/R
8 CR3524-5-02 Rivet A/R
9 CR3553-5-02 Rivet A/R
10 HL12V5-02 Pin A/R
11 HL75V05A Collar A/R
12 MS20427M3 Rivet A/R
13 CR3524-6-() Rivet A/R
NAS9309M6-() Rivet, Alternative A/R
CR3552-6-() Rivet, Oversize A/R
NAS9311M6-() Rivet, Alternative Oversize A/R
14 HL10-6-07 Pin A/R
HL110-6-07 Pin-1ST Oversize A/R
15 HL10-6-08 Pin A/R
HL110-6-08 Pin-1ST Oversize A/R
V2500 54-30-00 REPAIR 033

Page 205
Aug 1/09

16 HL12V-6-09 Pin A/R
HL112V-6-09 Pin-1ST Oversize A/R
17 HL70-06 Pin A/R
HL70D06 ST A/R
Pin-1 Oversize
HL79-06 Pin A/R
18 HL75V-06 ST A/R
Pin-1 Oversize
19 HL11VAZ6-25 Pin A/R
20 HL94LP06 Collar A/R
21 NAS6303U8 Bolt A/R
22 MS21043-3 Nut A/R
23 AN960C10L Washer A/R
24 CR3555-4-02 Rivet A/R
AF3555-4-02 Rivet A/R
25 745-0406-501 Shim, Solid A/R
26 745-0406-503 Shim, laminated A/R
27 CR2664-6-07 Blind Rivet A/R
CR3552-6-07 Blind Rivet (Oversize) A/R
AF3552-6-07 Blind Rivet (Oversize) A/R
(Optional)
HR3552-6-07 Blind Rivet (Oversize) A/R
(Optional)
28 HL12V-6-02 Pin A/R
HL112V-6-02 Pin-1ST Oversize A/R
29 CR2664-6-03 Blind Rivet A/R
CR3552-6-03 Blind Rivet (Oversize) A/R
(Optional)
AF3552-6-03 Blind Rivet (Oversize) A/R
(Optional)
HR3552-6-03 Blind Rivet (Oversize) A/R
(Optional)
30 MS21141U0610 Rivet A/R
V2500 54-30-00 REPAIR 033

Page 206
Aug 1/09
NOTE: 1. These item numbers reference to the illustrations.
2. Use a depth gage to find the correct grip length

fastener.
3. All fasteners are commercially available. Use

alternative or oversize fasteners only when
necessary.
5. Remove the Inner Fairing, Refer to Figure 201

PPE IS NECESSARY.
NOTE: Use drills and drilling tools to remove the following

fasteners or parts. Do not damage the holes. Remove
the burrs.
A. Remove the fasteners that attach the lower bifurcation forward

fairing to the adjacent structure. Remove the forward fairing
and keep for reinstallation.
B. Remove the fasteners that attach the upper track and lower
track block seals to the structure. Remove the seals to the
structure. Remove the seals and keep for reinstallation.
C. Remove the fitting fasteners that are common to the upper end
fitting and the inner fairing. Do the same for the lower end
fitting.
V2500 54-30-00 REPAIR 033

Page 207
Aug 1/09
D. Remove the fasteners that are common to the upper end fitting
and the adjacent bracket. Do the same for the lower end fitting
and the adjacent bracket.
NOTE: You must install the brackets on the inner fairing. If

the old brackets are serviceable, and the holes can be
aligned, it is acceptable to used the old bracket
E. Remove the fasteners that are common to the actuator fitting

and the inner fairing.
F. Remove the fasteners that are common to the upper actuator

fitting and the adjacent bracket. Do the same for the lower
actuator fitting and bracket.
NOTE: Do not remove the brackets from the inner fairing. If

you reinstall the existing inner fairing, you can
install the existing brackets along with it. If you
install a new inner fairing, it is recommended to use
new brackets. The old brackets can be used only if the
fastener holes of the brackets aligns with the
fastener holes of the new fairing.
G. Remove the rivets and the nutplates common to the inner fairing
and the torque ring cone.
H. Remove the fasteners that are common to the forward frame and
the inner fairing.
I. Examine the mating surfaces of the inner fairing with adjacent

parts. Make sure all the applicable fasteners are removed.
J. Apply pressure to separate the inner fairing from the adjacent

structure. Remove the inner fairing. Do not damage the adjacent
structure.
K. Use CoMat 05-128 Aluminum oxide abrasive paper to remove the

sharp edges from the repair area. Do not remove the liquid shim
that is not loose.
L. Use CoMat 02-099 lint free cloth made moist with CoMat 01-438
solvent to clean the area. Rub the surface clean until the
V2500 54-30-00 REPAIR 033

Page 208
Aug 1/09
6. Remove the Forward Frame, Refer to Figure 201 thru Figure 208 and
Table 1

PPE IS NECESSARY.
NOTE: Use drills and drilling tools, when necessary, to

remove the following fasteners or parts. Do not damage
the holes. Remove the burrs.
A. Pull the seal from the seal retainer. Cut the seal if
necessary. Remove the fasteners that attach the retainer to the
forward frame. Remove the retainer. Keep the retainer for
reinstallation, if serviceable.
NOTE: You can remove the seal retainer. Keep the retainer
for reinstallation, if serviceable.
B. Remove the frame fasteners (9 off) in the station plane. These

fasteners are common to the upper actuator fitting and the
v-blade. Do the same for the lower fitting.
C. Remove the remaining fasteners that attach the forward frame to

the adjacent structure.
NOTE: The two Hi-lok pins at the lower end of the assembly
are difficult to remove. It is recommended that you
cut off these pins.
V2500 54-30-00 REPAIR 033

Page 209
Aug 1/09
D. Examine the mating surfaces of the forward frame. Some of the

fasteners at the upper and lower ends of the torque ring
assembly are difficult to see. Make sure you have removed all
the applicable fasteners.
E. Apply pressure to separate the forward frame from the existing

structure and liquid shim. Remove the forward frame. Do not
damage the adjacent structure.
F. Immediately install the temporary fasteners in some of the

holes. This is necessary to keep the holes aligned.
G. Use CoMat 05-128 aluminum oxide abrasive paper to remove the

sharp edges from the repair. Do not remove the liquid shim that
is not loose.
H. Use CoMat 02-099 lint free cloth made moist with CoMat 01-438
solvent to clean the area. Rub the surface clean before the
7. Examine the Repair Area, Refer to Figure 201 thru Figure 208 and
Table 1
A. Make sure that adjacent structure is not damaged. Penetrant

inspect the area, if necessary, to check for cracks. Refer to
SPPM for instructions. Do the applicable repairs, if necessary.
V2500 54-30-00 REPAIR 033

Page 210
Aug 1/09
8. Locate the New Forward Frame, Refer to Figure 202 and Figure 208

PPE IS NECESSARY.
A. Refer to Figure 208, View P, for tool installation. Install the

tools on the V-blade. At each of the tool locations install the
clamp. Make sure the tools and the V-blade are in contact along
the A and B surfaces. If necessary, use shims to fill the space
at the C surface. Tighten the clamp.
NOTE: You must use the forward frame locating tools at five
locations along V-blades.
B. Put the new forward frame into position on the tools. At each of
the tool locations install the clamp. Make sure the tool and
the forward frame are in contact along the D and E surfaces.
Tighten the clamp.
C. Examine the F surface. Fill the space between the mating

surfaces of the forward frame and torque ring cone with shims.
Use the solid shim and/or laminated shim. Remove the
laminations if necessary. Maximum thickness of shims is not to
exceed 0.110 in. (2.794 mm).
D. Remove the repair parts. Remove the sharp edges. Use CoMat
05-128 aluminum oxide abrasive paper.
V2500 54-30-00 REPAIR 033

Page 211
Aug 1/09
9. Prepare the Repair Area and the Adjacent Parts for Forward Frame
Installation, Refer to Figure 201 thru Figure 208 and Table 1

PPE IS NECESSARY.
CONTAMINATION.
A. Clean the repair area and the repair part. Use CoMat 02-099
lint free cloth made moist with CoMat 01-438 solvent. Use a
palette knife and CoMat 05-126 Scotch brite pads made moist
with CoMat 01-438 solvent. Carefully remove the loose liquid
shim from the repair area. Rub the surface clean before the
NOTE: If you use the existing seal retainer, you must clean
the inside of the retainer at this time.
B. All bare aluminum surfaces must be water break free surfaces.

Do a water break free test of these surfaces.
C. Clean the tested surface. Use CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent to clean the area. Rub the
surface clean before the solvent becomes dry.
V2500 54-30-00 REPAIR 033

Page 212
Aug 1/09
D. Use a nylon brush or CoMat 02-099 lint free cloth. Apply CoMat
07-106 conversion coating to the tested surfaces. Do not let
the solution dry on the surface. Keep the surfaces wet with
fresh solution for 2 to 5 minutes.
E. Rinse the surfaces thoroughly with de-mineralized water. Air

dry for 30 minutes. The surface must be colorless with no
visible difference between parts.
NOTE: If the CoMat 07-028 alternative conversion coating is

used, the surfaces will have a golden color.
F. Prepare the primer. Use the manufacturer’s instructions to mix

the CoMat 08-093 I Primer class M, the CoMat 07-115 I Primer
class M, and the CoMat 07-116 Thinner. Let the primer mixture
stay for 30 minutes until it makes a paste.
NOTE: The CoMat 08-093 I primer class M must be used with the
CoMat 07-115 I Primer Class M and the CoMat 07-116
Thinner. The alternative CoMat 07-126 Water soluble
primer must be used with CoMat 07-127 Water soluble
primer converter and the CoMat 07-128 Water soluble
primer thinner. Do not mix the two primer systems.
G. Apply the primer. Use the manufacturer’s instructions to apply

a thin layer of the primer mixture to the conversion coated
surfaces.
H. Use and explosion proof heat lamp. Cure the primer for one hour
at 190° to 210° F (88 to 99°C).
V2500 54-30-00 REPAIR 033

Page 213
Aug 1/09
10. Install the New Forward Frame, Refer to Figure 203 and Figure 205

PPE IS NECESSARY.
CONTAMINATION.
2. DO NOT SOLVENT CLEAN THE FASTENERS. SOME FASTENERS CAN

BE LUBRICATED. THE LUBRICANT MUST NOT BE REMOVED.
A. Prepare the adhesive. Remove the CoMat 08-021 adhesive from

cold storage and bring to room temperature. Use the
manufacturer’s instructions to mix the adhesive.
B. Apply a thin layer of the adhesive to the mating surfaces. Put

the locating tools, the forward frame, and the applicable shims
into position. See Step 7C. Make sure the installation is
correct then tighten the clamps.
C. Cure the adhesive. Use an explosion proof heat lamp. Cure the
adhesive for one hour at 190° to 210°F (88 to 99° C). As an
alternative, you can cure the adhesive for eight hours at room
temperature.
V2500 54-30-00 REPAIR 033

Page 214
Aug 1/09
D. Drill the holes. Use the existing holes common to the V-blade
and the torque ring cone to drill holes in the forward frame. Do
not damage the existing holes. Use temporary fasteners as
necessary to keep the holes aligned.
NOTE: If you must move the tools to drill more holes, remove
and reinstall only one tool at a time.
E. Clean the repair area. Remove the drilling pieces. Use dry air
blast and CoMat 02-099 lint free cloth made moist with CoMat
01-438 solvent. Rub the surfaces clean before the solvent
becomes dry.
F. Install the forward frame fasteners. Wet install with CoMat 08-
021 the fasteners that attach the forward frame to the V-blade
and torque ring cone.
NOTE: In place of the two Hi-lok pins at the lower end that
were cut off, install the bolts. Refer to Figure 207,
View N, Flag note 4, for fastener callout.
G. Install The adjacent parts. Remove the locating tools. Apply a

thin layer of the CoMat 08-021 to the mating surfaces. Install
in the applicable order. Put the adjacent parts in position and
align the holes. Wet install the fasteners with a CoMat 08-021.
Use original type fasteners, or the fasteners that are
specified in this repair.
H. Remove the unwanted adhesive with a CoMat 02-099 lint free

cloth made moist with CoMat 01-438 solvent. Do not let the
solvent go in the joint. Rub the surface clean before the
I. Cure the primer for one hour between 190° and 210°F (88° and 99°
C). Use an explosion proof heat lamp.
NOTE: The cure cycle can be eliminated under repair

conditions. The uncured adhesive is functionally
acceptable.
V2500 54-30-00 REPAIR 033

Page 215
Aug 1/09
11. Prepare the New Inner Fairing and the Adjacent Parts for
Installation, Refer to Figure 203 and Figure 205

PPE IS NECESSARY.
CONTAMINATION.
A. Trim the new inner fairing if applicable. Use the imprint of

the old inner fairing on the existing torque ring cone to put
the new inner fairing into the correct position. Trim the
unwanted edges, only if necessary. Remove the burrs.
B. Make a mark of the existing holes. Put the fairing into

position. Put the applicable adjacent parts into position. Use
clamp to keep the parts in place. Make a mark of the applicable
existing holes on the new fairing.
NOTE: 1. Install the brackets on the new inner fairing. If

the old brackets are serviceable, and the holes can
be aligned, it is acceptable to use the old
brackets.
2. Use the dimensional information in Figure 207,

Section L-L and Detail N, to find the fastener
locations.
V2500 54-30-00 REPAIR 033

Page 216
Aug 1/09
C. Drill some of the holes in the new inner fairing. Use clamps and
temporary fasteners as necessary to keep the holes aligned.
Drill the remaining holes. These include holes for the
nutplates attach rivets Do not damage the existing holes in the
structure. Remove the burrs.
NOTE: Examine the assembly from time to time. This is to make

sure that the holes common to the forward frame and the
inner fairing stay aligned.
D. Use drills and drilling tools. Countersink the holes on the air
wetted surfaces. Remove the burrs. See Table 1.
E. Remove the sharp edges. Use CoMat 05-128 aluminum oxide

abrasive paper.
F. Clean the repair area. Use a palette knife and CoMat 05-126
Carefully remove the loose liquid shim from the repair area.
Use CoMat 02-099 lint free cloth. Rub surfaces clean before the
G. All bare aluminum surfaces must be water break free surfaces.

Do a water break free test of these surfaces.
H. Clean the tested surfaces. Use a CoMat 02-099 lint free cloth
made moist with CoMat 01-438 solvent. Rub the surface clean
I. Use a nylon brush or CoMat 02-099 lint free cloth. Apply CoMat
07-106 conversion coating to the tested surfaces. Do not let
the solution dry on the surface. Keep the surfaces wet with
fresh solutions for 2 to 5 minutes.
J. Rinse the conversion coated surfaces thoroughly with

demineralized water. Air dry for 30 minutes. The surfaces must
be colorless with no visible difference between parts.
NOTE: If the CoMat 07-028 alternative conversion coating is

used the surfaces will have a golden color.
V2500 54-30-00 REPAIR 033

Page 217
Aug 1/09
K. Prepare the primer. Use the manufacturer’s instructions to mix

stay for 30 minutes until it makes a paste.
NOTE: The CoMat 08-093 I Primer class M must be used with the
CoMat 07-115 I Primer class M and the CoMat 07-116
Thinner. The alternative CoMat 07-126 Water soluble
primer must be used with CoMat 07-127 Water soluble
primer converter and CoMat 07-128 Water soluble primer
thinner. Do not mix two primer systems.
L. Apply the primer. Use the manufacturer’s instructions to apply

surfaces.
M. Cure the primer. Use an explosion proof heat lamp. Cure the
primer for one hour at 190° to 210°F (88° to 99°C).
12. Install the New Inner Fairing, Refer to Figure 201 thru Figure 208
and Table 1

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 033

Page 218
Aug 1/09
CONTAMINATION.
2. DO NOT SOLVENT CLEAN THE FASTENERS. SOME FASTENERS

CAN BE LUBRICATED. THE LUBRICANT MUST NOT BE
REMOVED.
A. Examine the installation. Temporarily install the new inner

fairing and the applicable adjacent parts. Make sure that the
parts are in correct position. Remove the parts.
B. Clean the repair area. Use Comat 08-021 lint free cloth made
C. Prepare the adhesive. Remove the CoMat 08-021 adhesive from

cold storage and bring to room temperature. Use the
manufacturer’s instructions to mix the adhesive.
D. Install the parts in the applicable order. Apply a thin layer

of the adhesive to the mating surfaces. Put the parts in
position and align the holes. Wet install the fastener with the
adhesive. Use the original type fasteners, or the fasteners
that are specified in this repair.
NOTE: 1. Install the brackets on the new inner fairing.
2. Reinstall the upper and lower track block seals.
3. Install the nutplates.
E. Install the lower bifurcation forward fairing. Apply a thin

layer of the adhesive to the mating surfaces. Put the lower
bifurcation forward fairing parts in position and align the
holes. Wet install the rivets with the adhesive.
F. Remove the unwanted adhesive before it cures. Use CoMat 02-099

lint free cloth made moist with CoMat 02-099 lint free cloth
made moist with CoMat 01-438 solvent. Do not let the solvent go
in the joint. Rub the surfaces clean before the solvent becomes
dry.
G. Cure the adhesive. Use an explosion proof heat lamp. Cure for
one hour at 190° to 210°F (88° to 99°C)
V2500 54-30-00 REPAIR 033

Page 219
Aug 1/09
13. Apply the Sealant to the Spaces, Refer to Figure 203 and 205
A. Abrade the mating surfaces. Use CoMat 05-128 abrasive paper to

abrade the mating surfaces of the seal and the retainer.
B. Clean the repair area. Use CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Clean the mating surface of
the seal and the retainer. Rub the surface clean before the
CAUTION: DO NOT APPLY THE SEAL TO THE RUBBER SURFACES.
C. Apply the primer. Use the manufacturer’s instructions to mix

the Comat 08-032 primer. Apply a thin layer of the primer to the
inside of the retainer. Let the primer dry at room temperature
for one hour. If the primer forms a dull finish or a dusty chalk
on the surface, wipe the surface with a CoMat 02-099 lint free
cloth.
D. Apply the silicone rubber compound. Apply a uniform layer of

CoMat 08-031 silicone rubber compound to the mating surfaces.
The adhesive layer must be 0.005 to 0.010 in. (0,13 to 0.25 mm)
thick.
E. Install the seal. Insert the seal into the retainer. Use a
CoMat 02-099 lint free cloth to remove the unwanted adhesive
compound from the area.
V2500 54-30-00 REPAIR 033

Page 220
Aug 1/09
F. Cure the adhesive. Air cure for 8 hours at not less than 59°F
(15°C) before you handle the parts.

compound fully cure under the repair conditions. The
uncured compound is functionally acceptable.
G. Clean the areas around the joints and the spaces between the
adjacent parts before you do the next step. Use CoMat 02-099
lint free cloth made moist with CoMAt 01-438 solvent. Rub the
surfaces clean before the solvent becomes dry.
14. Apply the Sealant to the Spaces, Refer to Figure 201 thru Figure 208
and Table 1
CONTAMINATION.
A. Make a border along the sides of the spaces between the

adjacent parts and along the edges of the open spaces. Use
CoMat 02-178 masking tape.
B. Apply the sealant primer to the spaces. Use the manufacturer’s

instructions to mix the CoMat 08-032 primer. Apply a thin layer
of the primer to the spaces between the pieces of masking tape.
C. Cure the sealant primer. Let the primer dry at room temperature
for one hour. If the primer forms a dull finish or dusty chalk
on the surface, remove it with a CoMat 02-099 lint free cloth.
V2500 54-30-00 REPAIR 033

Page 221
Aug 1/09
D. Apply the sealant to the spaces. Use the manufacturer’s

instructions to mix the CoMat 08-033 sealant. Apply the sealant
to the spaces between the pieces of masking tape. Use CoMat
02-099 lint free cloth made to remove the unwanted sealant.
E. Cure the sealant for 10 hours at room temperature. Use an

explosion heat lamp. The sealant will be tack free in one hour.
Remove the masking tape before the cure cycle is complete.


necessary.
A. Make a mark VRS2179/VRS2180 adjacent to the assembly number.

V2500 54-30-00 REPAIR 033

Page 222
Aug 1/09
Torque Ring Inner Fairing and Forward Frame Replacement Repair

Figure 201
V2500 54-30-00 REPAIR 033

Page 223
Aug 1/09

Figure 202
V2500 54-30-00 REPAIR 033

Page 224
Aug 1/09

Figure 203
V2500 54-30-00 REPAIR 033

Page 225
Aug 1/09

Figure 204
V2500 54-30-00 REPAIR 033

Page 226
Aug 1/09

Figure 205
V2500 54-30-00 REPAIR 033

Page 227
Aug 1/09

Figure 206
V2500 54-30-00 REPAIR 033

Page 228
Aug 1/09
Figure 207
V2500 54-30-00 REPAIR 033

Page 229
Aug 1/09

Figure 208
V2500 54-30-00 REPAIR 033

Page 230
Aug 1/09
ITEM NO. FASTENERS HOLE DIAMETER 100º COUNTERSINK DIA.

10 HL12V5 0.1640 TO 0.1670 IN. N/A
(4,166 TO 4,242 MM)
6 HL11VAZ6 0.1900 TO 0.1930 IN. 0.2966 TO 0.3016 IN.
(4,826 TO 4,902 MM) (7,534 TO 7,661 MM)
14,15,16 HL10-6 0.1900 TO 0.1930 IN. N/A
HL12V6 (4,826 TO 4,902 MM)
14,15,16 HL110-6 0.2031 TO 0.2061 IN. N/A
HL112V6 (5,159 TO 5,235 MM)
24 CR3555-4 0.129 TO 0.132 IN. 0.160 TO 0.170 IN.
NAS9312M4 (3,28 TO 3,35 MM) (4,06 TO 4,32 MM)
6,8 CR3524-5 0.160 TO 0.164 IN. 0.239 TO 0.247 IN.
NAS9309M5 (4,06 TO 4,17 MM) (6,07 TO 6,27 MM)
CR3214-5
8 CR3552-5 0.176 TO 0.180 IN. 0.282 TO 0.290 IN.
NAS9312M5 (4,47 TO 4,57 MM) (7,16 TO 7,37 MM)
24 CR3555-5 0.176 TO 0.180 IN. 0.203 TO 0.213 IN.
NAS9312M5 (4,47 TO 4,57 MM) 5,16 TO 5,41 MM
21 NAS6303 0.199 TO 0.202 IN. N/A
(5,05 TO 5,13 MM)
4 MS20426AD5 0.161 TO 0.165 IN. 0.282 TO 0.290 IN.
(4,09 TO 4,19 MM) (7,16 TO 7,37 MM)
7 CR3523-6 0.192 TO 0.196 IN. N/A
NAS9307M6 (4,88 TO 4,98 MM)
7 CR3553-6 0.205 TO 0.209 IN. N/A
NAS9310M6 (5,21 TO 5,31 MM)
12 MS20427M3 0.098 TO 0.106 IN. 0.160 TO 0.170 IN.
(2,49 TO 2,69 MM) (4,06 TO 4,32 MM)
TABLE 1. HOLE AND COUNTERSINK DIAMETERS

(Sheet 1 of 2)
V2500 54-30-00 REPAIR 033

Page 231
Aug 1/09
ITEM NO. FASTENERS HOLE DIAMETER 100º COUNTERSINK DIA.

13,29 CR3524-6 0.192 TO 0.196 IN. 0.295 TO 0.303 IN.
NAS9309M6 (4,88 TO 4,98 MM) (7,49 TO 7,70 MM)
CR2664-6
13 CR3552-6 0.205 TO 0.209 IN. 0.349 TO 0.357 IN.
NAS9311M6 (5,21 TO 5,31 MM) (8,86 TO 9,07 MM)
30 MS21141 0.199 TO 0.202 IN. N/A
(5,05 TO 5,13 MM)
NOTE: 1. Minimum edge distance for holes is 2X diameter unless

otherwise specified.
2 Apply CoMat 08.033 sealant to spaces and exposed edges.
3 Use CoMat 02.257 Laminated shims to fill in the space. Bond

in place with adhesive.
4 If there is no bracket or fitting at this location, install

pin (14). If there is a bracket at this location, install pin
(15). If there is no actuator fitting at this location,
install pin 16. At the lower end only, install two bolts (21).
5. Not to Scale.
6. Unless other wise Specified, use existing hole sizes

(Sheet 2 of 2)
V2500 54-30-00 REPAIR 033

Page 232
Aug 1/09
REPAIR 034
LEFT & RIGHT C-DUCT FIXED STRUCTURES
TORQUE RING INNER FAIRING AND FORWARD FRAME SEGMENT REPAIR
(VRS2181/VRS2182)
1. Effectivity
Part No.: 740-0012

Refer to General C, D, and E.
2. General
A. The purpose of this repair is to repair the damaged segments of

the torque ring inner fairing and forward frame on the left and
right C-duct fixed structures.
B. This segment repair is applicable to damaged aluminum inner

fairing and aluminum forward frame.
C. The thickness of the inner fairing repairable by this repair

are:
D. The thickness of the forward frame repairable by this repair

are:
(1) 0.045 in. (1,1 mm)
(2) 0.063 in. (1,6 mm)
E. This segment repair is applicable only if the inner fairing and

forward frame are mechanically fastened by countersunk or flush
rivets.
NOTE: Contact Goodrich if the damaged to the inner fairing

and forward frame are mechanically fastened by dome or
button head rivets.
V2500 54-30-00 REPAIR 034

Page 201
Feb 1/09
F. This procedure can be used to repair the damaged inner

fairing and the forward frame of the torque ring, or if a piece
of the inner fairing and/or forward frame is missing. It is
affected by cutting out the damage parts of the inner fairing
and the forward frame and installing repair
segments, fillers, and doublers.
G. The location of the cut lines for the inner fairing and
forward frame should be established only within area 2 as shown
in Figure 201. It should be no less than 2.0 in. (50,8 mm) from
the edge of the actuator fitting. The exact location of cut
lines shall be established in such a way that the final
installation of the repair pieces will not interfere with the
production hardware.
H. If damage is located in Area 1 or in Area 1 and 2

simultaneously only one cut line in area 2 needs to be made. In
this case, a fairing segment and/or frame segment shall be
fabricated from a spare inner fairing and forward frame
respectively. The length of the segment shall extend from the
cut line to the end of the spare. Refer to REPAIR 033 (VRS2179/
VRS2180) for parts, removal and installation information.
I. If damage is located in Area 2 only then two cut lines in Area

2 will need to be made.
J. Measure the thickness of the forward frame. Inspect the

forward frame for crack damage. Review SB V2500-NAC-78-0159 to

mm) thick, proceed to step 2.K.

mm) thick, proceed to step 2.L.
K. Perform a repair using REPAIR 034 (VRS2181/VRS2182), REPAIR 032

(VRS2362/VRS2363), REPAIR 033 (VRS2179/VRS2180) or
SB V2500-NAC-78-0160. If REPAIR 034 (VRS2181/VRS2182) or REPAIR
032 (VRS2362/VRS2363) is used, inspect the torque ring
afterwards at least once every 4th A-check or 1250 flight
cycles per SB V2500-NAC-78-0159. If it is cracked again replace
the forward frame per REPAIR 033 (VRS2179/VRS2180) or SB V2500-
NAC-78-160. If necessary, replace the inner fairing as well.
V2500 54-30-00 REPAIR 034

Page 202
Feb 1/09
L. Perform a permanent repair using REPAIR 034 (VRS2181/VRS2182)

or REPAIR 032 (VRS2363/VRS2362) or replace the forward frame
per REPAIR 033 (VRS2179/VRS2180) or SB V2500-NAC-78-160.
M. This repair is only applicable to those torque ring assemblies

whose inner fairing and forward frames are made out of
aluminum. It is not applicable to the components made of
composite material.
N. Identify the part number of the damaged inner fairing and/or

O. To affect the repair, it is necessary to have the tools and

P. If the forward frame, (new version only), is found to be

damaged report its extent to Airbus.
Q. The practices and processes referred to in the procedure are in

the Goodrich SPPM.
VRS2181 and VRS2182

Clamps
Cutting tools
Drilling tools
Grinding tools
Nylon brush
Palette knife
Rivet tools
Standard shop tools
Temporary fasteners
V2500 54-30-00 REPAIR 034

Page 203
Feb 1/09

01-438)
CoMat 02-360 Aluminum alloy sheet (t = 0.040 in.)
07-106
CoMat 08-093
CoMat 08-031 Silicone Rubber Compound
CoMat 08-032 Primer
V2500 54-30-00 REPAIR 034

Page 204
Feb 1/09

01-438)
07-106
CoMat 08-093
CoMat 08-032 Primer
V2500 54-30-00 REPAIR 034

Page 204
Feb 1/09

C. Special Tools-None
PART IDENT MATERIAL

Torque ring fairing Fairing and forward frame:
assembly 2024-T62 A1 per QQ-A-250/4

Rohr, Inc.)
G. Repair Parts

1 CR3213-5-02 Rivet A/R
NAS9301B5-02 Rivet, alternative A/R
2 CR3524PR5-02 Rivet A/R
3 CR3524PR5-03 Rivet A/R
V2500 54-30-00 REPAIR 034

Page 205
Feb 1/09

4 CR3555-4-02 Rivet A/R
AF3555-4-02 Rivet, (Optional) A/R
5 CR3214-4-03 Rivet A/R
NAS9303B4-03 Rivet, Alternative A/R
HR3242-4-03 Rivet, Oversize A/R
(Optional)(Note 6)
(Note 6)
6 HL10V6-7 Pin A/R
HL110-6-7 Pin, First Oversize A/R
7 HL10V6-8 Pin A/R
HL110-6-8 Pin, First Oversize A/R
8 HL12V6-9 Collar A/R
HL120-6-9 Collar, First Oversize A/R
9 HL70V6-9 Collar A/R
HL79-6-9 Collar, First Oversize A/R
10 HL75V6 Collar (For standard and first A/R
oversize pins)
13 MS20427M3 Rivet A/R
V2500 54-30-00 REPAIR 034

Page 206
Feb 1/09

14 NAS6303U2 Bolt A/R
15 NAS1587-3C Washer A/R
16 CR3524-5-06 Rivet A/R
NAS9309M5-06 Rivet, alternative A/R
NAS9311M5-06 Rivet, alternative oversize A/R
NOTE: 1. The item numbers reference to the illustrations in

this repair section.
2. Forward frame doubler and the inner fairing doubler

shall only be installed in Area 2. Gage thickness of
both shall be the same thickness or one gage thicker
than the maximum thickness of the forward frame and
the inner fairing respectively, these could be as
follows:
Frame doubler-CoMat 03-360 (t=0.045, 0.050, 0.063,

0.071 in.)
Inner Fairing doubler-CoMat 03-360 (t=0.050, 0.056,

0.063 in.)
CoMat 03-360 must be heat treated to the T62

condition after forming.
3. If damage in contained only within Area 2 it is

recommended to cut the fairing segment from a spare
fairing. However, as an alternative, it is
acceptable to form and fabricate the fairing
segment from CoMat 02-321 or CoMat 02-360 Aluminum
alloy sheet (t=0.050 or 0.056 in. thick). CoMat 02-
360 must be heat treated to the T62 condition after
forming. If damage extends into Area 1 then the
fairing segment must be cut from a spare fairing.
For this case, the fairing segment shall extend from
the cut line in Area 2 all the way to the end of the
spare fairing. See VRS2179/VRS2180 for removal and
installation of the inner fairing.
V2500 54-30-00 REPAIR 034

Page 207
Feb 1/09
4. Fairing filler must be installed in Area 2. Form and

fabricate the fairing filler from CoMat
02-214 aluminum alloy sheet (t=0.050 in. thick
2024-T3). It is acceptable to use CoMat 02-321
(t=0.050 in.) or CoMat 02-360 (t=0.050 or 0.056 in.)
as an alternative. CoMat 02-321 and CoMat 02-360
must be heat treated to the T62 condition after
forming. Do not heat treat CoMat 02-214 (2024-T3)
after forming.
5. If damage is contained only within Area 2, it is

recommended to cut the frame segment from a spare
forward frame. It is acceptable to form and
fabricate a frame from CoMat 02-360 Aluminum alloy
sheet (t=0.045 or 0.063 in. thick) as an
alternative. CoMat 02-360 must be heat treated to
the T62 condition after forming. If damage extends
into Area 1 then the fairing segment must be cut
from a spare forward frame. For this case, the frame
segment shall extend from the cut line in Area 2 all
the way to the end of the spare forward frame. See
VRS2179/VRS2180 for removal and installation of the
forward frame.
6. It can become necessary to use laminated shim to

fill some spaces, because of variations in the
thickness of the fairing and the chem-milling
requirements. If this is the case, use CoMat
02-257 Aluminum laminated shim.
7. If the existing fairing is not chem-milled, use the

flush head oversize rivet. If the existing fairing
is chem-milled, use the protruding head oversize
rivet.
8. Use the alternative and oversize fasteners only if

necessary. All fasteners are commercially
available.
V2500 54-30-00 REPAIR 034

Page 208
Feb 1/09
5. Examine the Damaged Area, See Figure 201 and Figure 202

PPE IS NECESSARY.
A. Remove the torque ring seal. Pull the seal from the retainer.
Cut if necessary.
B. Remove the sharp edges. Use CoMat 05-128 Aluminum oxide

abrasive paper to remove the sharp edges from the damaged area.
C. Clean the repair area with CoMat 02-099 lint free cloth made
D. Examine the damaged area on the inner fairing. Penetrant

inspect to check for cracks if necessary. Refer to the SPPM for
instructions. Make a mark on the crack events.
V2500 54-30-00 REPAIR 034

Page 209
Feb 1/09
6. Cut the Inner Fairing, See Figure 202 and Figure 203

PPE IS NECESSARY.
A. Stop drill the crack ends if there are cracks on the inner
fairing. Use a hole between 0.125 and 0.150 in. (3,17 and 3,81
mm) in diameter. Use drills and drilling tools. Remove the
burrs.
B. Make a mark on the cut lines on the inner fairing.
NOTE: 1. Cut out a complete section of the inner fairing that

includes the damage.
2. The cut lines must be a minimum of 0.50 in. (12.7

mm) from the edges of the damage or the stop drill
holes, if any.
3. The inner fairing cut lines should be more than 2.0

in. (50.8 mm) from the edge of the actuator fitting.
See Figure 201 and Figure 202. Cut lines should only
be made within Area 2.
C. Remove the fasteners in the marked areas. Remove more

fasteners if necessary, to make the damage removal easy. Use
drills and drilling tools. Do not damage the holes. Remove the
burrs.
V2500 54-30-00 REPAIR 034

Page 210
Feb 1/09
D. Cut the damaged fairing as marked. Use cutting and grinding

tools. Remove the damage segment. Remove burrs.
7. Examine the Forward Frame, See Figure 202
A. Clean the repair area with CoMat 02-099 lint free cloth made
B. Examine the forward frame in the damage area. Penetrant inspect

the frame, if necessary, to check for cracks. Refer to the SPPM
for instructions. Make a mark on the crack ends.
8. Cut the Forward Frame, Refer to Figure 202 and Figure 207

PPE IS NECESSARY.
A. Stop drill the crack ends if there are cracks in the forward
frame. Use a hole between 0.125 and 0.150 in. (3,17 and 3,81 mm)
in diameter. Use drill sand drilling tools. Do not drill into
the existing structure. Remove the burrs.
B. Make a mark of the cutout on the forward frame. Use a CoMat 06-
131 marking pen.
C. Cut the damage frame as marked. Use cutting and grinding tools.
Do not cut into the existing structure. Remove the burrs.
V2500 54-30-00 REPAIR 034

Page 211
Feb 1/09
NOTE: 1. You must cut out a complete section of the forward

frame that includes the damage.
2. The cut lines must be a minimum of 0.50 in. (12,7

mm) more than the edges of the damage or the stop
drill holes.
3. The edges of the cutout on the inner fairing must be

a minimum of 3.5 in. (88,9 mm) from the applicable
edges of the cutout on the forward frame. This
prevents interference between the fairing repair
and the frame repair. You must repeat the applicable
steps to make the cutout on the fairing larger if
necessary.
9. Make the Repair Parts, See Figure 203 and Figure 207

PPE IS NECESSARY.
A. Make a mark on the outline of the repair parts on the fairing

and on the frame. Refer to the applicable figure for
dimensions. Use CoMat 06-131 marking pen.
B. Remove the fasteners in the marked areas. Use drills and

drilling tools. Do not damage the holes. Remove the burrs.
V2500 54-30-00 REPAIR 034

Page 212
Feb 1/09
C. Make the repair parts as marked. Refer to section 2.E for

repair materials. Refer to the applicable figure for
dimensions. Remove the burrs.
NOTE: Because the inner fairing and the forward frame have
complex shapes, it is recommended to make the fairing
segment and frame segment from a spare fairing and a
spare forward frame, respectively. This is not
required if the repair is contained only within Area
2. However, if damage is contained in Area 1 or Area 1
and 2 simultaneously it is necessary to make these
from spare components. Use laminated shim if necessary
to fill the spaces. Refer to VRS2179/VRS2180 for
removal and installation information of the forward
frame and inner fairing.
D. Make the repair parts to align with the contour of the

structure in the repair area. The parts must fit the contour
with light finger pressure.
E. Heat treat the parts that are made from 2024-T aluminum alloy
to the T62 condition. Be careful not to heat treat parts that
are already in the 2024-T3 condition.
F. Use clamps to temporarily install the repair parts. Examine for

spaces. If you must use CoMat 02-257 laminated shims, make the
shims now.
NOTE: You can use liquid shim and/or laminated shims to fill
the spaces between the matting parts. See Figure 210,
Note 3, for the limits.
G. Make a mark of the holes on the repair parts and the structure.
Refer to Figure 210 for spacing requirements.
H. Use drill and drilling tools. Drill the pilot holes at the
marked locations. Remove the burrs.
V2500 54-30-00 REPAIR 034

Page 213
Feb 1/09
I. Temporarily install the repair parts. Use temporary fasteners

to hold the parts in position. Make sure all the holes are
aligned. Drill the holes to their final size. Use drills and
J. Use Drills and drilling tools. Countersink the holes on the air
wetted surfaces. Remove the burrs.
K. Remove the sharp edges. Use CoMat 05-128 aluminum abrasive

paper.
10. Prepare the Repair Parts for Installation, Refer to Figure 203 and
Figure 207

PPE IS NECESSARY.
CONTAMINATION.
A. Clean the repair area. Use a palette knife and CoMat 05-126
Carefully remove the bulk of the existing sealant and adhesive
from the repair area and from the inside of the retainer. Use
CoMat 02-099 Lint free cloth. Rub the surface clean before the
V2500 54-30-00 REPAIR 034

Page 214
Feb 1/09
B. All bare aluminum surfaces must be a water break free test of

these surfaces. Do a water break free test of these surfaces.
Repeat water breakfree test until the surfaces are acceptable.
C. Clean the tested surfaces. Use CoMat 02-099 Lint free cloth
D. Apply the CoMat 07-106 chromate conversion coating solution to

the tested surfaces. Use a nylon brush or a CoMat 02-099 lint
free cloth. Keep the surface wet with fresh solution for 3 to 5
minutes. Do not let the solution dry on the surface.
E. Rinse the conversion coated surfaces with demineralized water.

Air dry for 30 minutes. The surface must be colorless with no
visible difference between parts.
NOTE: If the alternative CoMat 07-028 conversion coating is

used, the surface will have a golden color.
F. Prepare the primer. Use the manufacturer’s instructions to mix

cure for 30 minutes.
NOTE: The CoMat 08-093 I Primer class M must be used with the
CoMat 07-115 I Primer class M and the CoMat
07-116 thinner. The alternative CoMat 07-126 primer,
CoMat 07-127 converter, and CoMat 07-128 thinner must
be mixed together. Do not mix the two primer systems.
G. Apply the primer. Use the manufacturer’s instructions to apply

surfaces.
H. Cure the primer at 190° and 210°F (88° and 99°C) for one hour.
V2500 54-30-00 REPAIR 034

Page 215
Feb 1/09
11. Install the Repair Parts, See Figure 203 and Figure 205

PPE IS NECESSARY.
CONTAMINATION.

NOTE: If liquid or laminated shim is not used, go to step

10.C. If laminated shim is used, you must use the
liquid shim to bond it in place. If only liquid shim is
used, you must cure it before the final assembly. (See
Step 8.F for shimming information.)
A. Prepare the adhesive/liquid shim. Remove the CoMat 08-021

adhesive from cold storage and bring to room temperature. Use
the manufacturer’s instructions to mix the adhesive.
V2500 54-30-00 REPAIR 034

Page 216
Feb 1/09
B. If laminated shim is used:
(1) Install the laminated shim. Apply a thin layer of the

CoMat 08-021 adhesive to the mating surface of the
structure. Put the laminated shim into position. Use
temporary fasteners as required to keep the holes aligned.
(2) Remove the unwanted adhesive and the temporary fasteners

from the area before the adhesive cures. If necessary, use
a CoMat 02-099 lint free cloth made moist with CoMat 01-
438 solvent. Rub the surface clean before the solvent
becomes dry.
(3) Cure the adhesive at 190° and 210°F (88° and 99°C) for one
hour. Use an explosion heat lamp. Go to step 10.D
C. If only adhesive/liquid shim is used:
(1) Apply the adhesive/liquid shim at each location where

necessary. Apply the required amount of the adhesive to
one of the two mating surfaces.
(2) Use CoMat 02-099 lint free cloth made moist with CoMat 02-
158 release agent. Apply the release agent to the other
mating surface.
CAUTION: IF YOU APPLY TOO MUCH PRESSURE, YOU WILL FORCE THE UNCURED
LIQUID SHIM OUT OF THE JOINT.
(3) Temporarily install the applicable repair parts. Use

temporary fasteners to keep the holes aligned. Use clamps
as required, to apply pressure to the parts. Apply enough
pressure to make repair parts level with the adjacent
existing parts.
(4) Remove the unwanted adhesive/liquid shim and the temporary

fasteners from the area before the adhesive cures. Use a
solvent. Do not let the solvent go into the joints. Rub
the surface dry before the solvent becomes dry.
(5) Cure the adhesive/liquid shim at 190° and 210°F (88° and
99°C) for one hour. Use an explosion proof heat lamp.
Remove the parts before the adhesive cures.
V2500 54-30-00 REPAIR 034

Page 217
Feb 1/09
D. Temporarily install the repair parts. Examine to make sure that

the repair parts are level with the adjacent parts within
limits. If necessary, remove the layers of the laminated shim,
or use abrasive paper on the liquid shim.
E. Clean the repair area. Use CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surfaces clean before
F. Apply a thin layer of the CoMat 08-021 adhesive to the mating

surfaces. Be careful not to get adhesive on the threads. Put
the nutplates into position. Wet install the rivets with the
adhesive.
G. Install the repair. Apply a thin layer of the CoMat 08-021

adhesive to the mating surfaces. Put the repair parts into
position. Use temporary fasteners as required to keep the holes
aligned. Wet install the rivets with the adhesive.
H. Remove the unwanted adhesive from the area before it cures. If

necessary, use CoMat 02-099 lint free cloth made moist with
becomes dry.
I. Cure the adhesive/liquid shim at 190° and 210°F (88° and 99°C)
for one hour. Use an explosion proof heat lamp.
12. Install the Seal, See Figure 205

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 034

Page 218
Feb 1/09
CONTAMINATION.
A. Abrade the mating surfaces of the seal and the seal retainer.
Use CoMat 05-128 aluminum oxide abrasive paper.
B. Clean the repair area. Use Comat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Clean the mating surface of
the seal and retainer. Rub the surface dry before the solvent
becomes dry.
CAUTION: DO NOT APPLY THE PRIMER TO THE RUBBER SURFACES.

primer. Apply a thin layer of the primer to the inside surface
of the retainer. Let the primer dry at room temperature for one
hour. If the primer forms a dull finish or dusty chalk on the
surface, clean the surface with CoMat 02-099 lint free cloth.
D. Apply a uniform layer of the CoMat 08-031 silicone rubber

compound to the mating surfaces. The adhesive layer must be
0.005 to 0.010 in. (0,13 to 0,25 mm) thick.
E. Insert the seal into the retainer. Use a CoMat 02-099 lint free
cloth to remove the unwanted adhesive from the area.
F. Air cure the adhesive for 8 hours at room temperature but no

less than 59 °F (15°C), before you handle the parts.

compound fully cure under the repair condition. The
uncured adhesive is functionally acceptable.
V2500 54-30-00 REPAIR 034

Page 219
Feb 1/09
13. Apply the Sealant to the Spaces, Refer to Figure 203 and 205
A. Clean the repair area. Use CoMat lint free cloth made moist
with CoMat 01-438 solvent. Rub the surface clean before the
B. Apply CoMat 02-178 masking tape. Make a border along the edges
of the spaces between the fairing patch and the existing
fairing. Do the same along the edges of the open space.
C. Apply the primer. Use the manufacturer’s instructions to mix

the Comat 08-032 primer. Apply a thin layer of the primer to the
spaces between the pieces of masking tape. Let the primer dry
at room temperature for one hour. If the primer forms a dull
finish or a dusty chalk on the surface, wipe the surface with a
CoMat 02-099 lint free cloth.
D. Use the manufacturer’s instructions to mix the CoMat 08-033

sealant. Apply the sealant to the spaces between the pieces of
masking tape.
E. Use Comat 02-099 lint free cloth to remove the unwanted

sealant. On the air wetted surfaces, the sealant must not be
above the surface and must not be more tan 0.010 in. (0,25 mm)
below the surface.
V2500 54-30-00 REPAIR 034

Page 220
Feb 1/09
F. Cure the sealant for 10 hours at room temperature. The sealant

will be tack free in one hour. Remove the masking tape before
the cure cycle is complete.


necessary.
A. Make a mark VRS2181/VRS2182 adjacent to the assembly number.

V2500 54-30-00 REPAIR 034

Page 221
Feb 1/09
Figure 201
V2500 54-30-00 REPAIR 034

Page 222
Feb 1/09
Figure 202
V2500 54-30-00 REPAIR 034

Page 223
Feb 1/09
Figure 203
V2500 54-30-00 REPAIR 034

Page 224
Feb 1/09
Figure 204
V2500 54-30-00 REPAIR 034

Page 225
Feb 1/09
Figure 205
V2500 54-30-00 REPAIR 034

Page 226
Feb 1/09
Figure 206
V2500 54-30-00 REPAIR 034

Page 227
Feb 1/09
Figure 207
V2500 54-30-00 REPAIR 034

Page 228
Feb 1/09
Figure 208
V2500 54-30-00 REPAIR 034

Page 229
Feb 1/09
Figure 209
V2500 54-30-00 REPAIR 034

Page 230
Feb 1/09
Figure 210
V2500 54-30-00 REPAIR 034

Page 231
Feb 1/09
V2500 54-30-00 REPAIR 034

Page 232
Feb 1/09
REPAIR 035
LEFT & RIGHT C-DUCT HEAT SHIELD WELD PATCH REPAIR
(VRS2003/2004)
1. Effectivity
The following table contains the top assemblies related to the

following repair procedure.
LH SIDE RH SIDE
PART NO. PART NO.
740-0012-515 740-0012-517
740-0012-603 740-0012-605
740-0012-611 740-0012-607
740-0012-613 740-0012-609
740-0012-615 740-0012-635
740-0012-617 740-0012-639
740-0012-637 740-0012-647
740-0012-641 740-0012-659
740-0012-643
740-0012-645
740-0012-649
740-0012-651
740-0012-661
2. General
A. The purpose of this repair is to repair a large hole in the C-

Duct heat shield.
B. Weld repairs cannot be performed while the part is attached to

the aircraft. The heat shield must be removed in order to
perform this repair.
V2500 54-30-00 REPAIR 035

Page 201
Feb 1/09
C. Weld a foil patch over the holes or cracks more than 0.50 in.
(12,7 mm) can be repaired by.
D. Maximum dimension of foil patch is 2 by 10 in. (50,8 by 254 mm)

and must overlap undamaged foil a minimum of 0.375 in. (9,5
mm).
E. The practices and processes referred to in the procedure are in

the SPPM.
VRS2003
VRS2004
V2500 Thrust reverser Component Maintenance Manual
Fine wire stainless steel brush
Hand held probe
Hand punch, 0.250 in. (6,35 mm) diameter
Power supply
Palette knife
Stored energy spot welder
Standard shop tools
CoMat 01-457 Methylisobutylketone (alternative for
CoMat 01-438)
CoMat 08-032 Primer
CoMat 12-028 Thermal insulating material
CoMat 12-030 Foil (plain)
V2500 54-30-00 REPAIR 035

Page 202
Feb 1/09

Processes and Consumables Index, PCI.
PART IDENT MATERIAL

Heat shield skin Rigidized CRES foil, 0.003 in. (0,076
mm) thick type 3XX
Fiber filler Min-K insulation material
F. Price and availability - None
G. Repair Parts - None
5. Prepare the Damaged Surface for Repair
A. Cut away torn skin pieces
(1) Use metal cutters to cut away torn skin pieces.
B. Clean debris from insulation material.
(1) Do a check for lost or contaminated fiber fill.
6. Prepare the Patch, Figure 201 through Figure 204 and Tables 1
and 2
A. Find the size of the repair
(1) Find the size and the amount of repair materials required.
B. Make a mark for the size of the patch
(1) Make a mark all around the damage. Maintain an overlap of

V2500 54-30-00 REPAIR 035

Page 203
Feb 1/09
C. Cut out the patch
(1) Use CoMat 12-030 foil (plain). Use the mark in paragraph
5.B. to find the dimensions of the patch.
D. Punch a vent hole through the patch, if necessary
(1) Use a hand punch to punch the hole.
NOTE: Punch vent hole in patch only if patch is to cover an

area where an initial vent hole was located. Vent
holes will be centered under vent shields. Refer to
Figure 203 and Figure 204 for vent hole locations.
7. Make and Install the Vent Shield, Figures 201 through 204 and Tables
1 and 2

PPE IS NECESSARY.
CONTAMINATION.
NOTE: Install a vent shield only if a vent hole has been punched
in the patch. If it is not necessary to punch a vent hole
in the patch, ignore Paragraph 6 and continue to Paragraph
7.
V2500 54-30-00 REPAIR 035

Page 204
Feb 1/09
A. Cut out the vent shield
(1) Use CoMat 02-030 foil (plain). Cut the vent shield 1.0 in.
(25,4 mm) by 2.25 in. (57,15 mm). Fold back one of the
longer edges 0.25 in. (57,15 mm). Fold back one of the
longer edges 0.25 in. (6,35 mm) to prevent a sharp edge.
This edge will become the open side of the vent.
B. Clean the repair area
(1) Clean the repair area with CoMat 02-099 lint free cloth
made moist with CoMat 01-438 solvent. Rub the surface
clean before the solvent becomes dry.
C. Make the clean area rough
(1) Lightly rub the foil with a stainless steel, fine wire
brush.
D. Put the vent shield on the patch
(1) Center the shield over the hole. point the open side of
the shield down towards the lower edge of the heat shield,
except in area 6. In area 6, point the open side of the
heat shield towards the aft edge.
E. Spot weld the vent shield to the patch
(1) Stored energy spot weld three sides only. Refer to weld
Data below.
WELD DATA
Type of weld Stored energy spot weld (poke)
with power supply.
Materials CoMat 12-030 foil (plain).
V2500 54-30-00 REPAIR 035

Page 205
Feb 1/09
WELD DATA
Weld setting Do a test of the weld procedure
for good welds. Join a patch and
two pieces of repair foil the
same as the part to be repaired.
Pull apart the pieces. Weld is
good if portions of the weld
nugget are torn out when pulled
apart.
Weld sequence Start the weld at one of the two
tack welds. Continue at
intervals of 0.063 in. (1,60
mm). Keep the probe of the
welder on the edge of the part.
Do the same procedure on the
second and third sides.
F. Visually examine
(1) Examine the weld joints carefully to detect any deformed

corners or edges, which could be caught. Any such defect
should be rewelded.
8. Prepare the Faying Surfaces of the Heat Shield

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 035

Page 206
Feb 1/09
CONTAMINATION.
A. Clean the faying surface of the patch and the repair area of the
heat shield
(1) Clean the repair area with Comat 02-099 lint free cloth
B. Make the cleaned area rough
(1) Lightly rub the foil with a stainless steel, fine wire
brush.
9. Assembly the Repair Materials
A. Put in place or replace insulation material as required
(1) Use CoMat 12-028 thermal insulation material.
B. Put the patch in position on the damaged area of the heat shield
(1) Center the patch over the damaged area. Point the open end
of the vent shield toward the open end of the heat shield.
C. Hold the patch in position
(1) Use at least two pieces of CoMat 02-134 masking tape

applied to opposite edges.
V2500 54-30-00 REPAIR 035

Page 207
Feb 1/09
10. Spot Weld the Patch, Figure 201 and 202
A. Spot weld the patch to the heat shield
(1) Refer to the Weld Data below
WELD DATA
Type of weld Stored energy spot weld (poke)
with power supply.
Materials CoMat 12-030 foil (plain).
Weld setting Do a test of the weld procedure
for good welds. Join a patch and
two pieces of repair foil the same
as the part to be repaired. Pull
apart the pieces. Weld is good if
portions of the weld nugget are
torn out when pulled apart.
Weld sequence Start the weld at one of the two
edges of the patch that have no
tape. Weld from the center of this
edge to a corner. Poke wield at
0.063 to 0.125 in. (1,60 to 3,18
mm) intervals. Keep the probe of
the welder on the edge of the
patch. Finish the first edge by a
start at the center and poke weld
to the other corner with the same
intervals. Do the same procedure
on the second and third sides.
Before the weld procedure of the
tape edge is started, carefully
remove the hold down tape. Start
from the folded corner of the tape
and peel gradually with a pull
away from the patch.
V2500 54-30-00 REPAIR 035

Page 208
Feb 1/09
11. Visually Examine the Patch

NECESSARY.
A. Visually examine the patch
(1) Examine the patch carefully for any deformed corner or

unclosed edge that could be caught. Any defect in weld
finish should be rewelded.
B. Clean the repair area
(1) Clean the repair area with CoMat 02-099 lint free cloth
12. Mix and Apply Sealant

NECESSARY.
V2500 54-30-00 REPAIR 035

Page 209
Feb 1/09
A. Mix the sealant
(1) Use manufacturer’s instructions to mix the CoMat 08-030

sealant.
B. Prime the repair area
(1) Apply a thin coat of CoMat 08-032 primer around the outer
edge of the patch and to the welded edge of the vent
shield (if necessary). Let the primer dry for a minimum of
30 minutes before you apply the CoMat 08-030 sealant.
C. Apply the sealant
(1) Apply the sealant to the edges of the patch and to the
vent shield (if necessary).
D. Cure the sealant
(1) Cure the sealant for 2 hours at room temperature, 72ºF

(22ºC), before it is moved. Allow 24 hours at room
temperature to cure fully.
NOTE: Fully cured silicone sealant may not be necessary

under repair conditions. The uncured sealant is
V2500 54-30-00 REPAIR 035

Page 210
Feb 1/09
A. Examine the repair
(1) Visually examine the repair to make sure all requirements

of this repair are done. Make sure the upper edges of the
weld patch are sealed.
A. Make a mark VRS2003 (left C-duct) or VRS2004 (right C-duct)

adjacent to the assembly number
(1) Use a CoMat 06-131 marking pen of a color that contrasts.
V2500 54-30-00 REPAIR 035

Page 211
Feb 1/09
EDGE OF DAMAGE
PATCH TO CONFORM
TO REPAIR SURFACES
APPROX. 0.50 in. (12,7 mm)
ALL AROUND
CLEAN AREA
ALL AROUND
1.0 in. (25,4 mm)
PATCH (Foil)
PREPARATION STRAIGHTEN OR
REMOVE TORN FOIL
HEAT SHIELD
SECOND EDGE START HERE-
WELD TO CORNERS
START WELD HERE-
AFTER REMOVAL OF
MASKING TAPE MASKING TAPE
(2 off)
(TO HOLD PATCH IN
PLACE FOR WELDING)
NOTE: A CORNER IS
TO BE TURNED UNDER
FOR EASY REMOVAL
FIRST EDGE
START HERE-
WELD TO CORNERS
WELDING
PATCH (Foil)
A5S120
Heat Shield Weld Patch Repair

Figure 201
V2500 54-30-00 REPAIR 035

Page 212
Feb 1/09
FOLD BACK
(Open edge) VENT SHIELD
REPAIR PATCH
1.00 in.
0.125 in. (3,18 mm) (25.4 mm)
0.250 in. (6.35 mm)

DIAMETER VENT
HOLE IN PATCH
2.00 in.
(50.8 mm)
SEAL
(3 sides only)
POKE WELD
(3 sides)
POKE TACKWELD
(2 places)
A5S121

Figure 202
V2500 54-30-00 REPAIR 035

Page 213
Feb 1/09
1 2 8
3
6
5 4
VENT LOCATIONS 7 10
(OPEN SIDE DOWN)
A5S122

Figure 203
V2500 54-30-00 REPAIR 035

Page 214
Feb 1/09
8 2 12 2 1
11
3
6
VENT LOCATION
5
4 (OPEN SIDE AFT)
9 7 VENT LOCATIONS
10 (OPEN SIDE DOWN)
A5S123

Figure 204
V2500 54-30-00 REPAIR 035

Page 215
Feb 1/09
Table 1, Reference Figure 203 Looking Outboard
ITEM NO. PART NUMBER NOMENCLATURE

1 740-0220-343 Heat Shield, Aft LH
2 740-0220-347 Heat Shield, Fwd LH
3 740-0220-265 Heat Shield, LWR LH Bifur
4 740-0220-309 Heat Shield, Bottom LH
8 740-0220-233 Heat Shield, UPPR Bifur
9 740-0220-243 Heat Shield, Exp Bifur
Table 2, Reference Figure 204 Looking Outboard
ITEM NO. PART NUMBER NOMENCLATURE

1 740-0220-345 Heat Shield, Aft RH
2 740-0220-111 Heat Shield, Pan Down
3 740-0220-267 Heat Shield, LWR RH Bifur
4 740-0220-17 Heat Shield, Bottom RH
7 740-0220-15 Heat Shield, Bottom FWD RH
8 740-0220-234 Heat Shield, UPPR Bifur
11 740-0220-111 Heat Shield, Pan Down
12 740-0220-285 Pre-cooler, Pan
V2500 54-30-00 REPAIR 035

Page 216
Feb 1/09
REPAIR 036
FULL PENETRATION DAMAGE REPAIR OF COMPOSITE CONE AND OUTER FAIRING
C-DUCT FIXED STRUCTURE - LEFT AND RIGHT TORQUE RING ASSEMBLIES
(REPAIR WITH M20 PREIMPREGNATED FABRIC)
(VRS2176)
1. General
A. This repair scheme gives the procedure to repair full

penetration damage to the composite cone (P/N 740-0055) and the
outer fairing (P/N 740-0053) on the C-Duct fixed structure
torque ring assemblies. See Figure 201. This repair is not
applicable to inner fairing damage.
B. This repair is applicable only in the areas shown in Figure

201. The damage cannot be more that 6.0 in. (152 mm) wide, or
6.0 in. (152 mm) long. The distance between the edges of the
adjacent repairs cannot be less than 18.0 in. (457 mm). Each
repair can be used for single or multiple damages in an area
that is not more than 6.0 in. (152 mm) wide and 6.0 in. (152 mm)
long.
C. This repair must be done in a room with controlled temperature

of between 68° and 77°F (20° and 25°C). The humidity must be
kept at 50 percent or less.
D. This type of damage is repaired by removal of the damaged

material and installation of pre-impregnated graphite fabric
repair plies.
TASK 78-30-00-200-029 Insp/Check V2500 CMM
V2500 54-30-00 REPAIR 036

Page 201
Feb 1/09
3. Equipment And Material
A. Standard Tools

Heat blanket, range 32° to 260°F (0° to 127°C)
Heat lamp, explosion proof, range 32° to 212°F (0° to 100°C)
Nylon brush
Steel roller 2.0 in. (51 mm) diameter, 2.0 in. (51 mm) long
Suction cleaner
Temperature probes, range 32° to 260°F (0° to 127°C)
Vacuum pump, range 0 to 31 in, (0 to 762 mm) of mercury
18,000 - 23,000 RPM drive motor
B. Consumable Material (Reference Overhaul Processes and

Consumable Index)

CoMat 08-136 Film adhesive
CoMat 08-138 Graphite prepreg fabric
CoMat 08-139 Fiberglass prepreg fabric
PART IDENT MATERIAL

Torque Box Cone and Composite structure made from graphite
Outer Fairing fabric
V2500 54-30-00 REPAIR 036

Page 202
Feb 1/09
4. Prepare the damaged area for repair (See Figures 202 thru 204)

PPE IS NECESSARY.
PREIMPREGNATED FABRICS, FILM ADHESIVES OR CLEANED
SURFACES. THIS PREVENTS CONTAMINATION.
CAUTION: WHEN YOU ABRADE THE COMPOSITE SURFACE, DO NOT TAPPER OR

A. If the C-duct is removed from the nacelle, make sure it is held

satisfactorily for the repair procedure. The damaged area must
be horizontal.
B. Use a CoMat 02-099 lint free cloth made moist with CoMat
01-438 solvent to clean the damaged area. Rub the surface dry
V2500 54-30-00 REPAIR 036

Page 203
Feb 1/09
C. Find the type of repair that you will do. (See Note 1 below.)
Make a mark of the cutouts (stepped or tapered) on the surface,
as applicable. Use a CoMat 06-131 marking pen.
(1) There are to types of repair for this damage, “Step

Repair” and “Scarf or Taper Repair”. It is important to
maintain the exact taper requirements in a “Scarf or Taper
Repair”. If not, the repair will fail later. If you can
maintain these exact requirements, do a “Scarf or Taper
Repair”. If not, do a “Step Repair”.
(2) The steps or tapers must be 0.5 in. (13 mm) wide for each
graphite ply.
D. Cut the damage out in a geometric shape. Cut and remove the
plies of graphite from the repair area in a stepped or scarf
(tapered) shape, as applicable. Remove the minimum amount of
material that will remove the damage completely. Use cutters or
routers, and CoMat 05-020 and CoMat 05-021 waterproof silicon
carbide abrasive papers. Do not damage the adjacent structure.
Remove sharp edges.
NOTE: 1. If the backside of the repair area is accessible, the

cutout can be circular or rectangular. If not, the
cutout must be rectangular. If rectangular, you must
have a minimum radius of 0.25 in. (6,4 mm) at all
corners.
2. This repair is not applicable if, after damage removal,

the damage area is larger that the given limits.
E. Make a border for the repair area with CoMat 02-161 teflon
tape. Apply the tape 1.5 in. (38 mm) from the mark of the
largest cutout all around.
F. Remove the surface finish and lightly make the surface rough in
the repair area within the border. Use CoMat 05-020 and 05-021
waterproof silicon carbide abrasive papers. Do not damage the
graphite fibers.
NOTE: If there is an existing fiberglass sanding ply in the

repair area, you must also remove the sanding ply from
the repair area within the border.
V2500 54-30-00 REPAIR 036

Page 204
Feb 1/09

PPE IS NECESSARY.
G. On the backside of the repair area, remove the surface finish

and lightly make the surface rough in an area approximately 0.5
to 1.0 in. (13 to 25 mm) larger that the smallest cutout all
around. Use CoMat 05-020 and 05-021 waterproof silicon carbide
abrasive papers. Do not damage the graphite fibers.
H. Use dry air blast to remove the sanding particles. Clean the
two surfaces in the repair area. Use a CoMat 02-099 lint free
cloth made moist with CoMat 01-438 solvent. Rub surfaces dry
V2500 54-30-00 REPAIR 036

Page 205
Feb 1/09
I. The repair surface must be a water break free surface. Do a

water break free test of the repair surface.
NOTE: A surface is water break free if a thin, unbroken film of

water can stay on it for at least 30 seconds. Repeat the
sanding and cleaning steps. (It is not necessary for the
backside surface to be water break free.).
CAUTION: DO NOT TOUCH THE HOT PARTS WITHOUT PROTECTIVE GLOVES. HOT
PARTS CAN CAUSE REDDENING AND BLISTERING OF THE SKIN IF
THE HANDS ARE NOT PROTECTED. PUT THE CONTACTED AREA IN
COLD WATER FOR 10 MINUTES IF THE SKIN IS BURNED. GET
MEDICAL AID IF PAIN OR BLISTERING CONTINUES.
J. Refer to SRM 54-02-00 REPAIR 002 (VRS2371), Moisture Removal

Process to remove moisture or other contamination from the
repair area.
K. Let the area cool down to room temperature. Cover the repair
area to prevent contamination.
5. Make the repair plies (See Figures 202 - 204)
V2500 54-30-00 REPAIR 036

Page 206
Feb 1/09
A. Cut the repair and doubler plies from CoMat 08-138 graphite
prepreg fabric. The repair plies must have the same warp
directions as the removed plies. Refer to SRM 54-30-00 Thrust
Reverser Structural Identification for warp directions.
(1) For each graphite ply of the original skin that was cut
out, you must make two plies. The size of the repair plies
is different for the step repair and the taper repair.
Refer to applicable illustrations.
(2) Make two more plies to use as doubler. Each ply must be
0.5 in. (13 mm) larger that the previous ply all around.
B. Cut a sanding ply from the CoMat 08-139 fiberglass prepreg

fabric. Cut the ply 0.5 in. (13 mm) larger the last doubler ply
all around.
6. Make a back-up plate
A. Refer to SRM 54-02-00 REPAIR 008 (VRS2377), Fabrication and

Installation of a back-up plate.
7. Install the repair plies (See Figure 204 and 205)
A. Cut a piece of the CoMat 08-136 film adhesive. Remove one of the
protective parting films from the piece and apply the film
adhesive top the repair area. Press into position and remove
the wrinkles. Use the roller if necessary.
V2500 54-30-00 REPAIR 036

Page 207
Feb 1/09
B. Remove the remaining protective parting film from the film

adhesive. Put all repair and doubler plies and the sanding ply
in place. Press the plies into positions and remove wrinkles.
Use the roller if necessary.
NOTE: 1. Make sure the repair and doubler plies have the same
warp directions ad the original.
2. To remove the trapped air pockets, lightly tap each

installed ply from the center outward in all directions
before you install the ply.
8. Vacuum bag and cure the repair area
A. Refer to SRM 54-02-00 REPAIR 004 (VRS2370), Vacuum Bagging

Procedures.
CAUTION: DO NOT TOUCH THE HOT PARTS WITHOUT PROTECTIVE GLOVES. HOT
PARTS CAN CAUSE REDDENING AND BLISTERING OF THE SKIN IF
THE HANDS ARE NOT PROTECTED. PUT THE CONTACTED AREA IN
COLD WATER FOR 10 MINUTES IF THE SKIN IS BURNED. GET
MEDICAL AID IF PAIN OR BLISTERING CONTINUES.
B. Let the repair area cool down to room temperature. Disconnect

the heat blankets and the vacuum source. Remove the bagging
materials and the teflon tapes.
9. Make the repair surface smooth

PPE IS NECESSARY.
A. Remove the sharp edges. Make the surface ion the repair area
smooth with the adjacent surfaces. Use CoMat 05-020 and 05-021
V2500 54-30-00 REPAIR 036

Page 208
Feb 1/09
B. Use dry air blast to remove the sanding particles. Clean the
repair area. Use a CoMat 02-099 lint free cloth made moist with
CoMat 01-438 solvent. Rub surface dry before the solvent
evaporates.
10. Examine the repair

there are no delamination or disbonds. If necessary, do the
11. Identify the repair

V2500 54-30-00 REPAIR 036

Page 209
Feb 1/09
Composite Cone and Outer Fairing Full Penetration Repair

(With M20 prepreg graphite fabric)
C-Duct Structure, Left and Right Torque Ring Assemblies
Figure 201
V2500 54-30-00 REPAIR 036

Page 210
Feb 1/09

Figure 202
V2500 54-30-00 REPAIR 036

Page 211
Feb 1/09

Figure 203
V2500 54-30-00 REPAIR 036

Page 212
Feb 1/09

Figure 204
V2500 54-30-00 REPAIR 036

Page 213
Feb 1/09

Figure 205
V2500 54-30-00 REPAIR 036

Page 214
Feb 1/09
REPAIR 037
DOUBLER REPAIR AROUND RH C-DUCT 7TH AND 10TH-STAGE BLEED VALVES
(VRS2338)
1. General
A. This repair is applicable to damage to the acoustic panel at

approximately the 7th stage bleed port valve cutout on the right
fixed duct. The repair is applicable to P/N 740-0515 bonded
panel of the C-duct fixed structure inner barrels.
B. The heat damage can be repaired by adding a slot to separate the

damage from the unaffected perforated skin (See Figure 4). A
repair doubler is installed above the damaged area.
C. The perforated skin penetration is repaired by replacing or

filling the damaged core area, installing filler(s), if
required and doubler(s) over the perforated skin.
D. A crack is repaired by adding a stop drill and routing out the

crack. A repair doubler is installed over the damaged area.
(See Figure 3, Sheet 3.)
E. This repair causes blockage to the perforated skin in the

Limits.
F. If a repair filler and doubler have complex shapes they can be

formed using 2219-0 per QQ-A-250/30 (bare) then heat-treated to
the T62 or T81 condition after forming.
G. This repair can be performed only in areas shown in Figure 1,

Sheet 1 and 2. Contact Goodrich for repairs outside of these
areas. No fasteners allowed at the edge of the bleed port where
the doubler sits, see Figure 3, Sheets 1 and 2, View
C-C. An engine seal sits in this area.
H. This repair is applicable on V2500-A1 and V2500-A5 right hand

Thrust Reverser halves prior to CUM Serial Number 8521001.
I. It is recommended to perform Service Bulletin V2500-NAC-78 0218

after completion of this repair.
V2500 54-30-00 REPAIR 037

Page 201
Feb 1/09
Damage Tolerance Inspection Requirement

Category Initial Repetitive Replacement
B 6000 Flight 6000 Flight None
Hours, 4500 Hours, 4500
Flight Cycle Flight Cycle
or 20 months or 20 months
whichever whichever
comes first. comes first.
Reference Title
54-01-01 Damage Removal Methods
54-01-00 Acoustic Treatment Blockage Area Limits
54-02-00 Paste and Liquid Adhesive Mixing and Curing
VRS2373
54-02-00 Stop Drill of Cracks
54-02-00 Moisture removal process
VRS2371
54-02-00 Core Replacement
54-30-00 Thrust Reverser, Structure Identification
Composite standard tools and equipment
V2500 54-30-00 REPAIR 037

Page 202
Feb 1/09
CoMat 01-275 Chromate conversion coating

CoMat 02-168 Non-porous release film
CoMat 05-074 Aluminium oxide abrasive
paper, 180 grit
CoMat 08-140 PR1995B primerless sealant
D. Repair Parts
Item Part Material
(1) External Repair 0.050 in. (1,27 mm) thick,

Doubler, QQ-A-250/30. Heat treated to T62 or
Perforated skin T81. 2219 bare aluminium alloy sheet
(2) Splice doubler 0.050 in. (1,27 mm) thick,
QQ-A-250/30. Heat treated to T62 or
T81. 2219 bare aluminium alloy sheet
(3) Skin Filler 0.045 in. (1,14 mm) thick,
QQ-A-250/30. Heat treated to T62 or
T81. 2219 bare aluminium alloy sheet
(3A) Skin Filler 0.045 in. (1,14 mm) thick, AMS 4037 &
AMS-QQ-A-250/4. 2024-T3 Bare
Aluminium Alloy
Fastener CR3524-5 Cherry-Max Countersunk
(Grip length to suit at assembly)
Fastener CR3523-5 Cherry-Max Universal Head
(Grip length to suit at assembly)
Fastener HL10VAZ-6 Hi-lok
Washer NAS1149D0316K
Nut MS21043-6
V2500 54-30-00 REPAIR 037

Page 203
Feb 1/09
E. Material of component
NOTE: To identify the specific material in the area of the

damage, refer to SRM 54-30-00 for Structural
Identification.

PPE IS NECESSARY.
A. Cleaning Instructions.
(1) Clean damaged area with a CoMat 02-099 lint free cloth
B. Locate the damaged area.
(1) Verify and map damaged area as necessary per INSPECTION

402. Refer to Figure 1 and 2 for location. Refer to Figure
2 for typical damage.
NOTE: There must be a minimum distance of 1.3 in. (33 mm)

between the edge of the blocker door link fitting and the
edge of the skin cutout. If the distance is less, make a
mark for a larger cutout to include the fitting area.
C. Repair Procedure. (Refer to Figure 3, Sheets 1-7.)
V2500 54-30-00 REPAIR 037

Page 204
Feb 1/09
(1) Based on inspection findings, identify which repair should

be performed in accordance with Table 1.
(2) If applicable, remove the fasteners that attach the

Blocker Door Link Fitting to the panel. Remove and retain
the Fitting (and the related shims, if applicable).
Measure and record shim thickness. The shim will need to
be readjusted with repair part thickness at Fitting re-
installation. Refer to SRM
54-30-00, REPAIR 042 (VRS2052/2057).
NOTE: Location of existing blocker door pivot fittings is

critical. If shims are present between the existing
fitting and the existing skin, make sure that the
shims and the fitting are carefully removed and
properly identified. The shims are re-used in their
original stacking order and orientation after
taking into account the repair parts thickness when
the fitting is reinstalled. The total shimming
thickness requires adjustment to compensate for the
repair parts thickness at installation. Failure to
accomplish adjustment will result into impinged
blocker door operation.
NOTE: There is an underlying doubler under the perforated

skin in the blocker door pivot fittings area. If the
doubler is still bonded to the core, and the bond is
good, do not remove it. If the bond is not good, or
if the doubler is attached to the removed skin,
remove the doubler and keep it for re-installation.
(3) If applicable, cut and remove the wire mesh in the area to
be reworked in accordance with SRM 54-30-00, REPAIR 004
(VRS2011/2012).
(4) If applicable, stop drill the crack as per SRM 54-02-00

Para 2. Rout out the crack with a 0.250 in. (6,35 mm) dia.
router bit.
V2500 54-30-00 REPAIR 037

Page 205
Feb 1/09
(5) If applicable, cut and remove the damaged skin in

accordance with Figure 3 using best shop practice. Make
sure that a minimum corner radius of 0.5 in. (12,7 mm)
Remove the burrs.
NOTE: Do not remove the high density core located under

the blocker door link fitting.
(6) If applicable, remove the damaged core in the rework area

(except at hinge location, if applicable) using best shop
practice. DO NOT REMOVE REMAINING ADHESIVE AT THE BOTTOM
OF CUTOUT. Refer to SRM 54-02-54, Core Replacement.
NOTE: If underlying doubler is disbonded under blocker

door link fitting, comat 08-104 adhesive will be
used to fill higher density core later in the
repair.
(7) If applicable, perform a .125 in. (3,18 mm) slot around

the heat-affected area, in accordance with Figure 4 using
best shop practice. Make sure a minimum corner radius of
0.5 in. (12,7 mm) Remove the burrs.
See Figure 4.
(8) Examine the sealant around the edge of the bleed valve
cutout for looseness and cracks. If necessary remove all
loose or cracked sealant.
(9) Remove the sharp edges. Use clean air blast to remove the
debris. Clean with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface dry
(10) Perform an inspection of the repair area to make sure all

damage has been removed. Repeat the applicable steps if
necessary. Verify size of repair in accordance with Figure
1 and 2.
(11) Using CoMat 02-161 Teflon tape, make a border around the
cutout on the perforated skin 3 in. (76,2 mm) larger than
the cutout or slotted skin.
D. Prepare repair parts.
V2500 54-30-00 REPAIR 037

Page 206
Feb 1/09
NOTE: Determine repair parts dimensions based on damage size,

type and location. Refer to Figure 3.
(1) Fabricate a Repair Doubler –1 in accordance with Figure 3,

for the applicable repair type. Form to contour, corner
radius of 0.5 in. (12,7 mm) minimum.
NOTE: It is acceptable to use 2 repair doublers and a

splice doubler, if required due to skin contour as
per Figure 3, Sheet 7.
(2) If required, fabricate a Repair Splice Doubler –2 in

accordance with Figure 3, Sheet 7. Form to contour, corner
radius of 0.5 in. (12,7 mm) minimum.
(3) Taper the edges of the Repair Doubler –1 and, if required

the Splice Doubler -2 as per Figure 3, Sheet 6. Remove the
sharp edges.
(4) If required, fabricate Repair Skin Filler –3 in accordance

with Figure 3. Form to contour, corner radius of 0.5
in.(12,7 mm) minimum. Deburr.

EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.
(5) Clean the parts with a CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surface dry
E. Remove contamination from the repair area.
(1) Dry and remove contaminant from part as per

SRM 54-02-52, Moisture Removal Process.
V2500 54-30-00 REPAIR 037

Page 207
Feb 1/09
(a) Repeat Moisture Removal Process if the part is still

contaminated. Desiccant salt can also be used in
series with vacuum line to detect water vapor. To
prevent damage, repeat drying procedure until no
trace of contaminant remains on the bleeder cloth.
F. Core replacement, if applicable.
(1) If core damage is less than 3 in. (76,2 mm) diameter or

located within 3 in. (76,2 mm) of the 7th stage cutout or
underlying doubler is disbonded under Blocker Door Link
Fitting, repair core per method 3 (filling with adhesive)
in accordance with SRM 54-02-00 VRS2372, Core Replacement.
(2) If core damage is more than 3 in. (76,2 mm) diameter,

repair per method 2 (Core replacement) in accordance with
SRM 54-02-00 (VRS2372), Core Replacement. Core ribbon
direction to match existing part. Use same core as
existing. Refer to SRM, 54-30-00 for Structural
Identification.
G. Drill fastener holes through existing part and repair parts.
(1) Install repair parts, as required. Use Teflon tape or

equivalent to secure their location.
NOTE: Countersunk blind fasteners are required at the

splice location and at fully deployed blocker door
location.
NOTE: Verify for any interference with surrounding

structures on inner and outer skin before proceeding
with drilling.
NOTE: No fasteners allowed at the edge of the bleed port

where the doubler sits. Refer to Figure 3, Sheets 1
and 2, View C-C. An engine seal sits in this area.
(1) Drill 0.160/0.164 in. (4,06/4,17 mm) diameter holes thru

the repair parts and existing skin for CR3523-5 blind
protruding fastener. It is acceptable to use CR3524-5
countersink blind fasteners as an alternative. Refer to
Figure 3.
V2500 54-30-00 REPAIR 037

Page 208
Feb 1/09
(2) Locate the through fastener location. Drill 0.189/0.192

in. (4,80/4,88 mm) diameter holes for HL10VAZ-6 Hi-Lok
thru the assembly. Refer to Figure 3. Make sure that a
proper spacing between through fasteners.
(3) Remove the sharp edges. Clean with a CoMat 02-099 lint
surface dry before the solvent becomes dry.
H. Fill insert for through fastener installation.
(1) Locate the area to be filled with epoxy paste for through
fastener installation.
(2) Fill the area per SRM 54-02-00 (VRS2372), Core Replacement
Method 3 for through fastener installation. Refer to
Figure 3, Sheet 6.
(3) Re-open holes as required, after cure is complete.
I. If applicable, repair the 7th stage edge sealant.
(1) Repair the 7th stage existing edge sealant in accordance

with VRS2083.
J. Surface preparation of repair parts.
(1) Prepare bonding surface on the repair parts and existing

part bonding surfaces per SRM 54-02-00 (VRS2369), PANTA
method.
V2500 54-30-00 REPAIR 037

Page 209
Feb 1/09
K. Install the repair parts.

EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP AND
DISCARD CHEMICALS.
(1) Mix CoMat 08-104 adhesive per manufacturer’s

instructions.
(2) Using a plastic spatula, apply a thin layer of paste

adhesive to the bonding surface of the repair doubler and
existing skin.
(3) If required, using a plastic spatula, apply a thin layer

of paste adhesive to the bonding surface of all other
repair details and open core surface.
(4) Install repair parts. Locate repair doubler and all other
repair details using pre-drilled holes. Temporary bolts
can be used to locate parts properly. Refer to Figure 3.
NOTE: The installation of all permanent fasteners must be

done during the working life (pot life) of the
adhesive.
(5) Install the through fasteners (grip length to suit).

Torque the nut to 10 – 20 lbs-in. (1,13 – 2,26 Nm). Refer
to Figure 3.
(6) Install the blind fasteners in accordance with Figure 3.
(7) Remove excess adhesive from filler periphery.
V2500 54-30-00 REPAIR 037

Page 210
Feb 1/09
L. Cure repair.
(1) If a heat lamp is to be used, install at least 3

thermocouples to monitor cure. Cure CoMat 08-104 adhesive
1 hour at 160×F +/- 10×F (71×C +/- 5.5°C).
(2) If a heat blanket is to be used, do the following.
(a) Install at least 3 thermocouples to monitor cure.
(b) Apply CoMat 02-168 non-porous release film over the

repair area exceeding at least 3 in. (76,2 mm) of the
repair doubler.
(c) Install a heat blanket over the non-porous release

film. Add dead weight to make sure the proper heat
blanket contact and to prevent hot spot or heat sink.
Add insulation over the heat blanket.
(d) Cure CoMat 08-104 adhesive 1 hour at 160×F +/- 10×F

(71×C +/- 5.5°C). Monitor cure using thermocouples.
M. Post cure repair instructions
(1) Apply the CoMat 01-275 chromate conversion coating to the

bare aluminum surfaces of the existing and replacement
parts.
(2) If required, re-install the blocker door link fitting as

per CMM 78-30-00-350-102, REPAIR 023. Adjust shim to
compensate for the repair parts thickness. If previous
thickness cannot be matched, contact Goodrich
engineering.
(3) Seal the through pin nut with CoMat 08-140 sealant or
equivalent as per manufacturer’s instruction.
V2500 54-30-00 REPAIR 037

Page 211
Feb 1/09
N. Inspection of repair area.
(1) After repair has cured, remove any cure equipment. Sand
edges of patch lightly using CoMat 05-074 abrasive paper.
Remove dust by wiping with clean, dry lint free cloth.
(2) Visual inspect the repair area. Perform tap test of

reworked area for any disbond. Verify process.
O. If applicable, seal the edges of existing wire mesh per

SRM 54-30-00, REPAIR 004.
P. Perform a manual functional test of the blocker door located in

the repair area. If any interference occurs, trim the blocker
doors up to 0.100 in. (2,54 mm) to prevent any interference.
Q. Identify repair VRS2338 adjacent to the assembly number. Use a

CoMat 06-131 marking pen of contrasting color.
V2500 54-30-00 REPAIR 037

Page 212
Feb 1/09
DAMAGE TYPE APPLICABLE REPAIR

Type 1 Figure 3, Sheet 1
Disbond, Heat Damage less than
3 in. (76,2 mm)
Crack
Disbond, Heat damage greater than
3 in. (76,2 mm)
Large heat damage and other damage
Multiple doubler large area damage
Table 1
V2500 54-30-00 REPAIR 037

Page 213
Feb 1/09
Damage Location
V2500 54-30-00 REPAIR 037

Page 214
Feb 1/09
Repairable Damage Area

V2500 54-30-00 REPAIR 037

Page 215
Feb 1/09
Typical Damage and Type Location

Figure 2
V2500 54-30-00 REPAIR 037

Page 216
Feb 1/09
Repair for Damage of Type 1

Damage Less Than 3 in. (76,2 mm) Diameter
V2500 54-30-00 REPAIR 037

Page 217
Feb 1/09
Repair Parts Installation

V2500 54-30-00 REPAIR 037

Page 218
Feb 1/09

Crack Repair
V2500 54-30-00 REPAIR 037

Page 219
Feb 1/09

Damage Greater Than 3 in. (76,2 mm) Diameter
V2500 54-30-00 REPAIR 037

Page 220
Feb 1/09

Large Heat Damage Area and Other Damage
V2500 54-30-00 REPAIR 037

Page 221
Feb 1/09

V2500 54-30-00 REPAIR 037

Page 222
Feb 1/09

Multiple Doubler Large Area Repair
V2500 54-30-00 REPAIR 037

Page 223
Feb 1/09
Affected Skin Contour Slot

Figure 4
V2500 54-30-00 REPAIR 037

Page 224
Feb 1/09
REPAIR 038
C-DUCT, PAN-DOWN ENGINE BUMPER REPAIR
(VRS2365)
1. General
A. This repair procedure is used tot repair worn areas in the pan-
down area of the C-Duct caused by engine bumper.
B. This type of damage is repaired by blending the worn area of the

engine bumper pan-down panel and adding a titanium doubler.
C. This repair is applicable to P/N 740-0160 titanium pan-down

panel where the engine bumper contacts the panel.
D. Cracks in the engine bumper pan-down are not allowed.
E. Damage must be less than 0.025 inch (0,64 mm) deep.
F. NAS1200M4 Monel solid rivets are acceptable substitutes for the

blind rivets if the pan-down has been removed from the C-Duct.
VRS2365
PCI-V2500-11A Overhaul Processes and Consumables Manual
V2500 Standard Practices/Processes Manual
A. Standard tools
Cutting tools
Drilling tools
Temporary fasteners
Rivet tools

Consumable Index)

CoMat 01-457 Solvent, Alternate for CoMat 01-438
V2500 54-30-00 REPAIR 038

Page 201
Feb 1/09

CoMat 08-032 Primer base, DC1200
D. Expendable tools - None
Part Ident Material

Engine Bumper Pan-Down Titanium Ti-6AL-4V Sheet AMS
4911.
Repair Doubler Titanium Ti-6AL-4V Sheet AMS
4911 0.040 inch (1,02 mm) thick.
F. Repair Parts

CR3524-4-03 Blind Rivet 6
NAS1200M4-3 Alternate Solid Rivet 6
V2500 54-30-00 REPAIR 038

Page 202
Feb 1/09

PPE IS NECESSARY.
CAUTION: USE THE CORRECT PROCEDURE AND EQUIPMENT WHEN YOU MOVE THE
C-DUCT. MAKE SURE THE C-DUCT IS SECURED CORRECTLY DURING
THE REPAIR PROCEDURE.
CAUTION: BE CAREFUL NOT TO CAUSE DAMAGE TO THE EDGES AND CORNERS OF

THE C-DUCT ASSEMBLY.
solvent dries.
B. Find the extent of the damage. Perform a Dye Penetrant

Inspection of the damage in accordance with the
SPPM 70-23-00-230-501. If a crack is found, the part must be
rejected.
C. Measure the thickness of the remaining material of the worn

area. If the depth of the worn area is greater than 0.025 inch
(1,27 mm) deep, the part must be rejected.
D. Use CoMat 05-074 aluminum oxide abrasive paper to blend the

damage. Blend the damage into contour of the surrounding area.
Use CoMat 05-73 aluminum oxide abrasive paper to radius all
corners to a 0.020 inch (0,5 mm) minimum radius. Do not
increase the depth od the damaged area. Remove all burrs and
sharp edges.
E. Clean sanding debris from the surface with CoMat 02-099 lint
surface dry before the solvent dries.
F. Visually inspect for cracks using 10x magnifying glass.
V2500 54-30-00 REPAIR 038

Page 203
Feb 1/09
5. Fabricate the Repair Doubler
A. Fabricate repair doubler from 0.040 inch (1,02 mm) thick AMS
4911 6AL-4V titanium sheet. Remove all burrs. Refer to figure
201 for dimension.
B. Drill six (6) #40 (0.098 inch/2,5 mm) pilot holes into the
doubler. Refer to figure 201 for location of the fasteners.
6. Locate the Doubler onto the Pan-Down
A. Center the repair doubler over the chafed area. Secure the
doubler using appropriate clamps.
B. Using drilling equipment, back drill the six pilot holes into
the pan-down. Use temporary fasteners as required to secure the
doubler.
C. Step drill the pilot holes to the final hole size. Drill the
holes up to 0.129 - 0.132 inch (3,27 - 3,35 mm) diameter. Use
temporary fasteners as required to keep the doubler from
moving.
D. Remove the doubler from the pan-down. Remove all burrs.
E. Countersink the holes in the doubler. Make 100° countersinks

0.188 - 0.196 inch (4,47 - 4,97 mm) in diameter.
7. Apply the Primer and Sealant
V2500 54-30-00 REPAIR 038

Page 204
Feb 1/09

PPE IS NECESSARY.
CLEANED OR PREPARED SUFACES. THIS PREVENTS CONTAMINATION.
A. Clean the repair area and the mating surface of the doubler
with CoMat 02-099 lint free cloth made moist with
CoMat 01-438 solvent. Clean the surface before the solvent
dries.
B. Apply the CoMat 08-032 primer to the mating surfaces of the

doubler and the repair area on the pan-down. Allow the primer
to dry for 30 minutes.
C. Apply a thin layer of CoMat 08-031 RTV sealant to the primed

areas of the doubler and the repair area on the pan-down.
8. Install the Doubler
A. Install the doubler onto the pan-down. Use CR3524-4 blind

rivets. Install the rivets wet using the CoMat 08-031 RTV
sealant.
NOTE: NAS1200M4 solid rivet can be used if the pan-down has

been removed from the C-Duct.
B. Put a fillet seal using 08-031 RTV sealant around the edge of
the doubler. Remove excess sealant after all the fasteners are
installed.
V2500 54-30-00 REPAIR 038

Page 205
Feb 1/09
9. Remove Shims from the Radial Bumper
A. Remove the appropriate thickness in the shims under the radial

bumper on the engine case. Remove a minimum thickness that is
equal to the thickness of the doubler. Refer to Task V2500 78-
30-00-991-158 of the AMM to re-shim and rig the radial bumper
in order to provide the correct gap between the pan-down and
the radial bumper.
A. Visually examine the repair area. Make sure that the procedures
in this repair have been completed. If necessary do the
application steps again.
A. Make a mark VRS2365 adjacent to the assembly number. Use CoMat

06-131 marking pen of a color that contrasts.
V2500 54-30-00 REPAIR 038

Page 206
Feb 1/09
C-Duct Pan-Down - Engine Bumper Repair

Figure 201
V2500 54-30-00 REPAIR 038

Page 207
Feb 1/09
V2500 54-30-00 REPAIR 038

Page 208
Feb 1/09
REPAIR 039
COMPOSITE CONE AND COMPOSITE OUTER FAIRING PARTIAL PENETRATION REPAIR
C-DUCT FIXED STRUCTURE - LEFT AND RIGHT TORQUE RING ASSEMBLIES
(REPAIR WITH M20 PRE-IMPREGNATED FABRIC)
(VRS2175)
1. General
A. This repair scheme gives the procedure to repair scratches,

gouges, nicks, and other surface damage to composite plies of
the cone (P/N 740-0055) and the outer fairing
(P/N 740-0053) on the c-duct fixed structure torque ring
assemblies (See Figure 201).
B. This repair is applicable only in the areas shown in Figure

201. The distance between the edges of adjacent repairs cannot
be less 18.0 in. (457 mm). Each repair can be used for single or
multiple damages in an area that is not more than 6.0 in. (152
mm) wide and 6.0 in. (152 mm) long. Damage cannot be deeper than
the limits given in Figure 201.
C. This repair must be done in a room with a controlled

temperature of between 68° and 77°F (20° and 25°C). The
humidity must be kept at 50% or less.
D. This type of damage is repaired by removal of the damaged

material, and installation of pre-impregnated graphite fabric
repair plies.
E. The illustrations in this repair show only two damaged plies,

but the procedure can also be used if more plies are damaged.
Refer to the limits given in Figure 201.
Task 78-30-00-200-014 Torque Ring Inspection CMM
V2500 54-30-00 REPAIR 039

Page 201
Feb 1/09
NOTE: Equivalent materials can be used.
A. Standard tools
Explosion proof heat lamp, range 32 to 212°F (0 to 100°C)
Heat blanket, range 32 to 260°F (0 to 127°C)
Nylon brush
Steel roller 2.0 in. (51 mm) diameter, 2.0 in. (51 mm) long
Suction cleaner
Vacuum suction pump, range 0 to 30 in (0 to 762 mm) of mercury

Consumable Index)
01-438 Solvent
02-037 Lint free gloves
02-099 Lint free cloth
02-161 Teflon tape
05-020 Waterproof silicon carbide abrasive paper
05-021 Waterproof silicon carbide abrasive paper
06-131 Marking pen
08-136 Film adhesive
08-138 Graphite prepreg fabric
08-139 Fiberglass prepreg fabric
12-024 Sealant
E. Component material
Part Identification Material

Torque box cone and Composite structure made
outer fairing from graphite fabric
V2500 54-30-00 REPAIR 039

Page 202
Feb 1/09

PPE IS NECESSARY.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH PRE-
IMPREGNATED FABRICS, FILMS, OR CLEANED SURFACES. THIS
PREVENTS CONTAMINATION.
A. If the C-duct is removed from the nacelle, make sure it is held

such that the damaged area is horizontal when you do the
repair.
B. Clean the damaged area. Use a CoMat 02-099 lint free cloth made
C. Use the CoMat 05-020 and CoMat 05-021 waterproof silicon

carbide abrasive papers. Remove the minimum amount of material
that will remove the damage completely. do not damage the
adjacent structure. Do not make the damage area deeper. remove
the sharp edges.
NOTE: The cutouts can be circular or rectangular. If

rectangular, you must have a minimum radius of 0.25 in.
(6,4 mm) at all corners.
V2500 54-30-00 REPAIR 039

Page 203
Feb 1/09
(1) Cut and remove the plies of graphite from the repair area
in a “stepped” shape. The steps must be a minimum of 0.5
in. (13 mm) wide for each ply. Make sure you do not cut
into the remaining plies. Remove the burrs. See figure
202.
NOTE: This repair is not applicable if, after damage
removal, the damage area is larger than the given
limits.
D. Make a border for the repair area with CoMat 02-161 teflon
tape. Apply the tape 1.5 in. (38 mm) from the edge of the larger
cutout all around.
E. Remove the surface finish and lightly make the surface rough in
the repair area within the border. Use the CoMat 05-020 and
CoMat 05-021 waterproof silicon carbide abrasive papers. Do not
damage the graphite fibers.
NOTE: If there is an existing fiberglass sanding ply in the

repair area, you must also remove the sanding ply from
the area within the border.
F. Use dry air blast to remove the sanding particles. Clean the
CoMat 01-438 solvent. Rub the surface clean before the solvent
becomes dry.
G. The repair surface must be water break free. do a water break

free test of the surface.
NOTE: A surface is water break free if a thin, unbroken film

of water can stay on it for at least 30 seconds. If the
water breaks, repeat the sanding and cleaning steps.
H. If necessary, refer to SRM 54-02-00 REPAIR 002, (VRS2371),

Moisture Removal process to remove moisture or other
contamination from the repair area.
I. Let the area cool down to room temperature. Cover the repair
area to prevent contamination.
V2500 54-30-00 REPAIR 039

Page 204
Feb 1/09
5. Make and Install The Repair Plies, (See Figure 203)

NECESSARY.
CAUTION: USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH PRE-
IMPREGNATED FABRICS, FILM ADHESIVES, OR CLEANED SURFACES.
THIS PREVENTS CONTAMINATION.
A. Cut the repair doubler plies from the CoMat 08-138 graphite
prepreg fabric. the repair plies must have the same warp
directions as the removed plies. refer to SRM 54-30-00 Thrust
Reverser Structural Identification for warp directions.
(1) For each graphite ply of the original skin that was cut
out, you must make two repair plies. The repair plies must
be the same size as the related cutout.
(2) Make two more plies to use as a doubler. Each ply must be
0.5 in. (13 mm) larger than the previous ply all around.
B. Cut a sanding ply from CoMat 08-139 fiberglass prepreg fabric.

Cut the ply 0.5 in. (13 mm) larger than the last doubler ply all
around.
C. If the cutout is rectangular, trim the corners of all plies 45°

by 0.5 in. (13 mm).
D. Cut a layer of the CoMat 08-136 film adhesive the same size as
the repair area. Remove one of the protective parting films
from the film adhesive and apply it to the repair area. Press
firmly into position and remove the wrinkles. Use the roller if
necessary.
V2500 54-30-00 REPAIR 039

Page 205
Feb 1/09
E. Remove the remaining protective parting film from the film

adhesive. Put all repair and doubler plies and sanding ply in
place. Press the plies into position and remove the wrinkles.
Use a roller if necessary.
NOTE: Make sure the repair and doubler plies have the same
warp directions as the original plies.
Remove the protective parting films from the plies
before you install them.
To remove trapped air pockets, lightly tap each
installed ply from the center outward in all directions
before you install the next ply.
6. Vacuum Bag the Repair Area

NECESSARY.
NOTE: Refer to SRM 54-02-00 REPAIR 004, (VRS2370) Vacuum Bagging

Procedures and Cure.
A. Turn on the heat blanket and raise the temperature to 250° to

270°F (121° to 132°C). increase the temperature at a rate of 2°
to 5°F (-17° to -15°C) per minute. Cure the repair at this
temperature for 120 to 135 minutes. Keep a minimum vacuum
pressure of 22 in. (559 mm) of mercury during the cure.
B. Let the repair area cool down to room temperature. Disconnect

the heat blankets and the vacuum source. Remove the bagging
materials and the teflon tapes.
V2500 54-30-00 REPAIR 039

Page 206
Feb 1/09

NECESSARY.
A. Remove sharp edges. make the surface in the repair area smooth
with the adjacent surface. Use CoMat 05-020 and CoMat 05-021
B. Use dry air blast to remove the sanding particles. clean the
CoMat 01-438 solvent. Rub the surface clean before solvent
becomes dry.
8. Examine the Repair Area

there are no delaminations.
A. Make a mark VRS 2175 adjacent to the assembly number. Use a

V2500 54-30-00 REPAIR 039

Page 207
Feb 1/09
Composite cone and Outer Fairing Partial Penetration Repair

(with M20 prepreg graphite fabric)
C-Duct Fixed Structure, Left and Right Torque Ring Assemblies
Figure 201
V2500 54-30-00 REPAIR 039

Page 208
Feb 1/09
Composite cone and Outer Fairing Partial Penetration Repair

Figure 202
V2500 54-30-00 REPAIR 039

Page 209
Feb 1/09
Composite Cone and Outer Fairing Partial Penetration Repair

Figure 203
V2500 54-30-00 REPAIR 039

Page 210
Feb 1/09
REPAIR 040
BLEED PORT CLOSURE INSTALLATION UPPER 7TH STAGE BLEED VALVE
(VRS2368)
1. General
A. This repair is applicable to damage that occurs to the closure

edge around the 7th stage bleed port valve cutout on the right
fixed duct. The repair is applicable to bonded panel of the c-
duct fixed structure inner barrels.
B. Repair parts are made from CRES 321 annealed, 0.020 and 0.032
in. (0.51 and 0.81 mm) thick.
C. This repair may be performed in conjunction with

SRM 54-30-00 Repair 31 Sealant Replacement Repair (VRS2083)
and/or REPAIR 037 Doubler Repair (VRS2338).
D. This repair cannot be fitted to units that are post

V2500-NAC-78-0204 Service Bulletin. This repair can be fitted
to right hand Thrust reverser halves prior to CUM serial Number
8521001.
Reference Title
54-01-00 Acoustic Treatment Blockage Area Limits
54-30-00 Thrust Reverser, Structure Identification
EC02VN317A Customer Approval
NOTE: This Repair can be performed only in areas shown in Figure 201.
Contact Goodrich for repairs outside these areas.
NOTE: Equivalent materials can be used.
A. Standard Tools
V2500 54-30-00 REPAIR 040

Page 201
Feb 1/09
B. Consumable materials.
01-438 Solvent
02-099 Lint free cloth
05-074 Aluminum oxide abrasive paper 180
05-129 Aluminum oxide abrasive paper 320
06-131 Marking pen
08-140 Sealant
NOTE: To identify consumable materials, refer to the PCI.
C. Repair parts.
Item Part Material

-1 to -8 Closure sections 321 CRES sheet annealed, SAE AMS
5510,.032 in.(0,81mm) thick
-9 Cover plate 321 CRES sheet annealed, SAE AMS
5510,.020 in.(0,51mm) thick or
same as -1
Fastener CR3524-4 Cherry-Max
Sealant PR1995B
NOTE: All fasteners are commercially available.
D. Material of component.
NOTE: To identify the specific material in the area of

damage, refer to SRM 54-30-00 for Structural
Identification.
A. Cleaning instructions.
(1) Solvent clean repair area using MEK or other approved

solvent and clean lint free cloth. Allow to air dry.
V2500 54-30-00 REPAIR 040

Page 202
Feb 1/09
B. Identify if a repair has to be used in conjunction with this

installation.
(1) If another repair has to be used in conjunction with this

repair, make sure to follow proper installation sequence.
Filler may be required if a doubler is installed partially
around the bleed port. Refer to Figure 203, sheet 2.
C. Fabricate the repair closures.
(1) Fabricate repair closure sections -1 to -8. Refer to

Figure 202. Use best shop practices.
(2) Fabricate 8 cover plates -9. Refer to Figure 2. use best

shop practices.
(3) Visually inspect part for cracks. If cracks are suspected,

liquid penetrant inspect part in accordance with SPPM Task
70-23-00-230-501 or equivalent.
D. Prepare installation of the repair closure sections.
(1) Verify fit of repair sections on existing structure. Make

sure that repair parts are formed to contour and conform
only using light finger pressure. Rework as required using
best shop practices.
(2) Assemble the upper repair closure sections -1 to -4 on

existing structure. Identify their location using a
marker. Locate a cover plate -9 over the repair closure
sections.
(3) Locate the lower repair closure sections -5 to -8 on

existing structure. Identify their location using a
marker. Locate a cover plate -9 over the repair closure
sections. Secure repair parts in place using clamps or
equivalent.
(4) Drill the necessary fastener holes as shown in Figure 203.

Temporary bolts can be used to locate parts properly and
prevent movement during drilling.
(5) Disassemble the repair parts. Break and deburr all sharp
edges.
V2500 54-30-00 REPAIR 040

Page 203
Feb 1/09
(6) Remove unwanted materials and clean the repair area and
the repair parts. Use a clean lint free cloth made moist
with solvent. Rub the area dry before solvent evaporates.
E. Install repair closure sections.
(1) Mix PR1995B primerless high temperature sealant

(CoMat 08-140) or equivalent as per manufacturer’s
instructions. If repair is performed in conjunction with
VRS2083, it is acceptable to substitute sealant with
adhesive called out in VRS2083.
(2) Using a plastic spatula, apply a thin layer of sealant to

the mating surface of the repair parts.
(3) Install repair parts. Locate repair closure sections -1 to

-8 and cover plates -9 using pre-drilled holes. Temporary
bolts can be used to locate parts properly. Refer to
figure 203.
NOTE: The installation of all permanent fasteners must be
done during the working life (pot life) of the
adhesive. Knife edge conditions are acceptable in the
closure and cover plate only.
(4) Install repair fasteners in accordance with Figure 203.

(5) Remove excess adhesive from periphery of repair.
F. Cure repair.
(1) Cure sealant as per manufacturer’s instruction. If another

adhesive is used, cure as specified in the applicable
repair.
G. Inspection of the repair.

(1) After the repair has cured, sand the edges of closures
lightly using 180 grit abrasive paper (CoMat 05-074).
Remove dust by wiping clean with clean, lint free cloth.
(2) Visually inspect the area. Report any discrepancy to

Goodrich Aftermarket Services.
H. If applicable, restore surface finish in accordance with

appropriate Maintenance Manual.
V2500 54-30-00 REPAIR 040

Page 204
Feb 1/09
Figure 201
V2500 54-30-00 REPAIR 040

Page 205
Feb 1/09
Figure 202
V2500 54-30-00 REPAIR 040

Page 206
Feb 1/09

Figure 203, Sheet 1
V2500 54-30-00 REPAIR 040

Page 207
Feb 1/09

Figure 203, Sheet 2
V2500 54-30-00 REPAIR 040

Page 208
Feb 1/09

Figure 203, Sheet 3
V2500 54-30-00 REPAIR 040

Page 209
Feb 1/09
V2500 54-30-00 REPAIR 040

Page 210
Feb 1/09
REPAIR 041
LEFT C-DUCT FIXED STRUCTURE
REPLACE THE LOWER TRACK NUTPLATE WITH A BLIND NUT ASSEMBLY
(VRS2195/2196)
1. General
A. VRS2195 is applicable to replacement of the lower track

nutplate with a blind nut on the left and right c-duct fixed
structure.
B. Repair is done by removal of each damaged nutplate and

installation of a blind nut assembly.
2. Effectivity
Fig/Item Part No.

01-001 740-0012-603, -611, -613, -615, -617
01-001 740-0012-637, -641, -643, -645
01-001 740-0012-605, -607, -609
01-001 740-0012-635, -639
NOTE: Equivalent materials or equipment can be used.
Blind nut hand tool (high-shear) BH120-632-M2
Crow foot wrench
B. Consumable materials

CoMat 07-067 Primer converter
CoMat 08-029 Primer base
CoMat 08-043 Cold curing silicone compound
V2500 54-30-00 REPAIR 041

Page 201
Feb 1/09

E. Repair parts
Fig/Item Part No. Part Identification Qty

10-585 BN360-632-2 Blind nut assembly 1
10-340 740-0422-507 Retention block 1
10-345 NAS1189-06P8 Screw 1
NOTE: For price and availability refer to Goodrich

Aerospace, Aerostructures group (formerly Rohr, Inc.).
4. Remove the Damaged Nutplate, (Figure 201, Left Hand), (Figure 202,
Right Hand)

PPE IS NECESSARY.
A. Remove the retention block
(1) Remove and discard the screw and retention.
B. Put in sealant.
(1) Put in CoMat 08-043 cold curing silicone sealant into the
existing hole through the damaged nutplate.
V2500 54-30-00 REPAIR 041

Page 202
Feb 1/09
NOTE: The sealant will keep the nutplate from moving around after
you remove the attaching rivets.
C. Remove the damaged nutplate.
(1) Drill out the rivets attaching the damaged nutplate to the
track. Use drill and drilling equipment.
5. Install the Blind Nut

PPE IS NECESSARY.
A. Mix the primer
(1) Use the manufacturer’s instructions to mix the CoMat 07-

067 primer converter. and the CoMat 07-066 thinner. Wait
30 minutes before using primer mix.
B. Enlarge hole
(1) Enlarge the existing hole for the retention block screw to
0.219 to 0.222 in. (5,56 to 5,64 mm) and countersink to
0.280 to 0.284 in. (7,11 to 7,21 mm) diameter x 100
degrees. Use drill and drilling equipment.
V2500 54-30-00 REPAIR 041

Page 203
Feb 1/09
B. Enlarge hole
(1) Enlarge the existing hole for the retention block screw to
0.219 to 0.222 in. (5,56 to 5,64 mm) and countersink to
0.280 to 0.284 in. (7,11 to 7,21 mm) diameter x 100
degrees. Use drill and drilling equipment.
C. Clean the repair area
076 methlethylketone. Rub the surface dry before the
cleaning fluid evaporates.
D. Install the blind nut
(1) Using the primer mix wet install the blind nut assembly
(Figure 203, 10-585). Use a blind nut hand tool and a crow
foot wrench.
E. Check that the screw head is not above the retention block
(1) Install the replacement retention block (Figure 203, 10-

340) and the attaching NAS1189-06P8 screw (Figure 203, 10-
345). If the screw head is above the retention block,
remove the screw and block. Countersink the blind nut
sleeve until the screw head is not above the retention
block. Do not countersink more than 0.015 in. (0,38 mm)
deep.
F. Remove the sharp edges
(1) Remove the screw and retention block. Remove any sharp
edges.
G. Clean the repair
076 methylethylketone. Rub the surface dry before the
cleaning fluid evaporates.
H. Apply the primer
(1) Touch up exposed surfaces with primer and cure at 140º to

180ºF for 40 minutes.
V2500 54-30-00 REPAIR 041

Page 204
Feb 1/09
I. Fill the attach holes
(1) Fill the holes that were used for the attach rivets with
CoMat 08-043 cold curing silicone compound.
J. Install the retention block
(1) Install the replacement retention block (Figure 203, 10-

340) and the NAS1189-06P8 attaching screw (Figure 203, 10-
345).
A. Visually examine the repair
(1) Examine the completed repair to make sure all requirements

of this repair procedure are done.
A. Make a mark VRS2195 adjacent to the assembly number.
(1) Use CoMat 06-131 marking pen of color that contrasts.
V2500 54-30-00 REPAIR 041

Page 205
Feb 1/09
Nutplate Removal
Figure 201
V2500 54-30-00 REPAIR 041

Page 206
Feb 1/09
Nutplate Removal
Figure 202
V2500 54-30-00 REPAIR 041

Page 207
Feb 1/09
Nutplate Removal
Figure 203
V2500 54-30-00 REPAIR 041

Page 208
Feb 1/09
REPAIR 042
C-DUCT FIXED STRUCTURE
REPLACE THE PIVOT FITTING
(VRS2052/2057)
1. General
A. VRS2052/2057 is applicable to replacement of the pivot fitting

on the left and right C-duct fixed structure.
B. Repair is done by removal of the damaged pivot fitting and

installation of a replacement pivot fitting.
C. The practices and processes referred to in the procedure are in

the Goodrich SPPM.
D. The material for pivot fitting is 2054-T851 AL.
2. Effectivity
NOTE: See the Illustrated Parts List (IPL), Figure 31, or 32, for
item locations of specific part numbers.
NOTE: Equivalent materials or equipment can be used.
Drill bushing
B. Consumable materials.
CoMat 01-076 Methylethylketone (alternative to

CoMat 01-438)
CoMat 07-140 Epoxy prime
CoMat 08-021 Silicone rubber compound
V2500 54-30-00 REPAIR 042

Page 201
Feb 1/09
E. Repair parts
NOTE: To identify repair or replacement parts, refer to the

IPL section.
F. Material of Component
PART IDENT RELATED DATA

Pivot fitting 2024-T851 AL
4. Remove the Damaged Pivot Fitting, (Figure 201)
A. Remove the link assembly from the pivot fitting
(1) Remove the attaching hardware and the link assembly from
the pivot fitting.
NOTE: If there are shims under the fitting, do not remove the
shims.
5. Prepare the New Pivot Fitting, (Figure 202)
A. Put the pivot fitting into positions
(1) Put the pivot fitting into position with its one hole over
the applicable hole in the inner barrel assembly and
install a temporary fastener.
B. Make the drill bushing
(1) Make the drill bushing
V2500 54-30-00 REPAIR 042

Page 202
Feb 1/09
C. Drill the mounting holes in the pivot fitting
(1) Use the drill bushing to hold the drill straight and use
the existing holes in the inner barrel as guide. Drill the
guide holes in the pivot fitting. Remove the inner fitting
from the inner barrel. Use drill and drilling equipment.
Drill the mounting holes in the pivot fitting between
0.190 and 0.194 in. (4,83 and 4,93 mm) diameter).
D. Countersink the mounting holes in the pivot fitting.
(1) Countersink the mounting holes in the pivot fitting

between 0.296 and 0.306 in. (7,52 and 7,77 mm) diameter
with a 100 degree countersink.
E. Remove the burrs
(1) Remove the burrs from the drilled holes.
6. Install the New Pivot Fitting, (Figure 201)

PPE IS NECESSARY.
NOTE: Do steps A and B only if the shims (if any) are not fully
bonded to the C-duct surfaces.
V2500 54-30-00 REPAIR 042

Page 203
Feb 1/09
A. Mix the adhesive
(1) Use the manufacturer’s instructions to mix the CoMat 08-

021 adhesive.
B. Apply the adhesive to the inner barrel
(1) Remove the shim. Apply a thin layer of CoMat 08-021

adhesive to the mating surface of the inner barrel. Put
the shim into position on the inner barrel.
C. Apply the release agent
(1) Apply a layer of CoMat 02-158 release agent on the mating

surface of the pivot fitting.
D. Mix the primer
(1) Use the manufacturer’s instructions to mix, the CoMat 07-

140 epoxy primer and the CoMat 07-139 thinner. Let the
primer mix stand for 30 minutes.
E. Install the pivot fitting
(1) Put the pivot fitting into position. Wet install the pins,
the collars and the sleeves with the primer mix. Refer to
Figure 201 for the fastener locations. Remove any unwanted
primer with a CoMat 02-099 lint free cloth made moist with
CoMat 01-438 solvent. Rub the surface dry before the
F. Clean the repair surface
(1) Clean the repair surface with a CoMat 02-099 lint-free

cloth made moist with CoMat 01-438 solvent. Rub the
surface dry before the solvent becomes gas.
A. Visually examine
(1) Examine the completed repair to make sure all requirements

of this repair are done.
V2500 54-30-00 REPAIR 042

Page 204
Feb 1/09
A. Make a mark VRS2057 (left C-duct) or VRS2052 (right C-duct)

adjacent to the assembly number
(1) Use a CoMat 06-131 marking pen of a color that contrasts
V2500 54-30-00 REPAIR 042

Page 205
Feb 1/09
Pivot Fitting Fastener Locations

Figure 201
V2500 54-30-00 REPAIR 042

Page 206
Feb 1/09
0.190 - 0.194 in.(4.83 - 4.93 mm) DIA HOLES

COUNTERSINK
0.296 - 0.306 in.(7.52 - 7.77 mm) DIA X 100
A-A (4 off) A-A (1 off)
A A
LAMINATED SHIM PIVOT FITTING
gc00a5s008
Pivot Fitting
Figure 202
V2500 54-30-00 REPAIR 042

Page 207
Feb 1/09
0.303-0.323 in.
(7.70-8.20 mm) DIA.
0.178-0.198 in.
(4.52-5.03 mm)
45 CHAMFER
(4 off)
UNDERCUT
0.678-0.698 in.
(17.22-17.73 mm)
0.0981-0.0984 in.
(2.492-2.499 mm) DIA.
0.1873-0.1875 in.
(4.757-4.763 mm) DIA.
CONCENTRICITY
0.0005 in. (0.013 mm)
MAXIMUM INDICATOR
READING
DRILL BUSHING
gc00a5s009
Drill Bushing Specifications

Figure 203
V2500 54-30-00 REPAIR 042

Page 208
Feb 1/09
REPAIR 043
THRUST REVERSER TRANSLATING SLEEVE
BLISTER FAIRING CRACK REPAIR
(VRS2323)
1. General
A. This procedure is used to repair crack damage on the left and

right hand Blister Fairing on the translating sleeve of the
thrust reverser. This type of damage is repaired by trimming
out the damaged area on the blister fairing and installing a
filler and repair doubler over the damaged area.
B. This repair is applicable to crack damage of up to 2.00 in.

(50,8 mm) maximum in length. For typical damage, refer to
Figure 201 and 202 sheet 1.
C. The Blister Fairing is made from 2024 Aluminum Alloy and is

0.50 in. (1,27 mm) thick.
D. This repair is only applicable to Blister Fairings that are

made of Aluminum.
PCI-V2500-11A (PCI) Overhaul Processes and Consumable Index
Drill and drilling Equipment
B. Consumable materials (Ref Overhaul Processes and Consumable

Index)
CoMat 01-076 Methylethylketone (Alternate)

V2500 54-30-00 REPAIR 043

Page 201
Feb 1/09

CoMat 02-171 Aluminium Alloy Sheet 0.063 in. (1,60 mm)
CoMat 02-214 Aluminium Alloy sheet 0.050 in. (1,27 mm)
CoMat 02-367 Non Porous Release Film
CoMat 05-020 Waterproof Abrasive Paper
CoMat 05-081 Waterproof Abrasive Paper
CoMat 07-106 Chromate Conversion Coating
CoMat 08-141 Two Part Polysulfide Sealant
C. Repair Materials
Filler (CoMat 02-214) 1.050 in. (1,27 mm), 2024-T3 PER

QQ-A-250/4, QQ-A-250/5
Doubler (CoMat 02-171) 0.063 in (1,60 mm), 2024-T3 PER
QQ-A-250/4, QQ-A-250/5
D. Component material
PART IDENT MATERIAL

Fairing Blister Aluminium Sheet, 0.50 in. (1,27 mm),
Translating Sleeve 2024-T42
V2500 54-30-00 REPAIR 043

Page 202
Feb 1/09
A. Determine the size of the crack
(1) Verify the part number of the fasteners used to install

the blister fairing.
(2) Remove the fairing. Refer to the illustrations given in

CMM Task 78-30-00 Figure 23 and 24.
(3) Remove the existing paint on the blister fairing.
(4) Do a High Frequency Eddie Current Inspection (HFEC) to

find the length of the crack. Refer to SPPM Task
70-025-01-250-501.
(5) Optional: Do a Fluorescent Penetrant Crack Inspection of

the damaged area. Refer to SPPM Task 70-023-02-230-501.
B. Remove the damaged area for repair

UNDERSTAND AND OBEY ALL INSTRUCTIONS FOR ITS USE.
MANUFACTURER, YOUR EMPLOYER AND GOVERNMENT
REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH
PPE IS NECESSARY.
CAUTION: WHEN YOU CUT OUT THE CRACK, MAKE SURE THAT YOU REMOVE
THE CRACKED MATERIAL COMPLETELY AND PREVENT DAMAGE
TO THE ADJACENT STRUCTURES.
(1) Cut out the crack, remove a minimum of 0.30 in. (7.6 mm)
past all sides of the crack. Keep a minimum of 0.25 in
(6,3 mm) corner radius and minimum of 2 times diameter
edge margin to adjacent fastener locations.
(2) Do an H F Eddy Current inspection of the cut edges to make

sure that there is no other damage. Refer to SPPM
Task 70-25-01-250-501.
V2500 54-30-00 REPAIR 043

Page 203
Feb 1/09

DISCARD CHEMICALS.
(3) Remove burrs from all edges. If necessary, clean the

surface with a lint free cloth (Comat 02-099) moist with
solvent (CoMat 01-438). Wipe the surface dry before the
solvent evaporates.
C. Prepare the repair material
(1) Make a filler of 0.050 in. (1,27 mm) thick from CoMat 02-
214 Aluminum Sheet to fit the contour of the cutout area.
Make sure that the gap between the cutout and filler is
0.050 in. (1,27 mm). Remove burrs from all edges.
(2) Make a repair doubler of 0.063 in. (1,60 mm) thick from
CoMat 02-171 Aluminum Sheet. Chamfer all edges of doubler
by 0.030 in. (0,76 mm) times 30 degrees. Form the repair
doubler to fit the contour surface of the blister fairing.
Remove burrs from all edges.
D. Locate and drill holes on repair parts
(1) Place the filler into the cutout sections. Assemble the
repair doubler over the filler and use temporary clamps to
hold in position.
(2) Mark the repair and existing fastener holes on the doubler
surface using a marking pen (CoMat 06-131). Maintain 4
times diameter fastener spacing and a minimum of 2 times
diameter edge margin. Refer to Figure 202.
V2500 54-30-00 REPAIR 043

Page 204
Feb 1/09

UNDERSTAND AND OBEY ALL INSTRUCTIONS FOR ITS USE.
MANUFACTURER, YOUR EMPLOYER AND GOVERNMENT
REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH
PPE IS NECESSARY.
CAUTION: WHEN YOU DRILL THE FASTENER HOLES, MAKE SURE YOU DO
NOT ENLARGE OR DAMAGE EXISTING FASTENER HOLES AND
THAT YOU DO NOT DAMAGE ADJACENT TRANSLATING SLEEVE
STRUCTURES.
(3) Locate and drill 0.160 - 0.164 in. (4,06 - 4,17 mm)
diameter holes through the doubler, filler and blister
fairing. Drill 100 degrees countersink holes on the repair
doubler to a diameter of 0.239 - 0.247 in.
(6,07 - 6,27 mm). Refer to Table 1.
(4) Disassemble the repair parts. Remove nicks, gouges,

scratches and burrs.
E. Inspect and clean the repair area
(1) Do an H F Eddy Current inspection of all the existing and

repair fastener holes to make sure there is no damage.
Refer to SPPM Task 70-25-01-250-001.

DISCARD CHEMICALS.
(2) Clean the repair parts and repair area with a lint free
cloth (CoMat 02-099) moist with solvent (CoMat 01-438).
Wipe the surfaces dry before the solvent evaporates.
V2500 54-30-00 REPAIR 043

Page 205
Feb 1/09
F. Application of chemical coating and primer

DISCARD CHEMICALS.
(1) Apply one layer of chemical conversion coating (CoMat 07-

106 to the bare surfaces of the blister fairing, the
repair doubler and the filler. Allow coating to dry per
manufacturer instructions.

DISCARD CHEMICALS.
(2) Apply one layer of sealant (CoMat 08-141) to the inner

surface of the doubler, the filler and the bare surfaces
of the blister fairing.
G. Install the repair doubler and the filler
(1) Place the filler in the cutout area and put the repair
doubler over the repair area of the blister fairing and
use temporary fasteners to hold it in position.
(2) Fill with the original countersink holes on the blister

fairing with AD rivet head material (2117-T4 Aluminum
Alloy).
V2500 54-30-00 REPAIR 043

Page 206
Feb 1/09
(3) Install the NAS1097AD5 repair fasteners wet with CoMat 08-
104 adhesive. Refer to Detail B, C or D of Figure 202 and
Table 1.
(4) Place the blister fairing onto the translating sleeve

using temporary clamps and fasteners to hold in position.
(5) Install the NAS9303E-5 original fastener locations wet

with CoMAt 08-104 adhesive at the repair area. Increase
grip length as required.
(6) Re-install the remaining original fasteners on the blister

fairing per illustrations given CMM Task
78-30-00 Figure 23 and 24.
(7) Seal gap and fair the doubler and the fairing edges with
Polysulfide Sealant (CoMat 08-141).
A. Inspect the completed repair to make sure that the repair is

done in reference to the procedure.
A. Mark the VRS2323 adjacent to the repair on the panel edge. Use
CoMat 06-131 marking pen for high color contrast.
Fastener Hole and CounterSink Diameter
Fastener P/N Hole Diameter Countersink

Diameter
NAS9303E5 0.160 -0.164 in. 0.239 -0.247 in.

(4,06 - 4,17 mm) (6,07 - 6,27 mm)
NAS1097AD5 0.160 -0.164 in. 0.239 -0.247 in.

(4,06 - 4,17 mm) (6,07 - 6,27 mm)
TABLE 1
V2500 54-30-00 REPAIR 043

Page 207
Feb 1/09
Location of Blister Fairing on Translating Sleeve

Figure 201
V2500 54-30-00 REPAIR 043

Page 208
Feb 1/09
Location of Crack Damage on Blister Fairing

V2500 54-30-00 REPAIR 043

Page 209
Feb 1/09
Location of Doubler and Filler on Blister Fairing

V2500 54-30-00 REPAIR 043

Page 210
Feb 1/09

V2500 54-30-00 REPAIR 043

Page 211
Feb 1/09

V2500 54-30-00 REPAIR 043

Page 212
Feb 1/09
REPAIR 044
THRUST REVERSER, C-DUCT, PRE-COOLER DUCT
LEADING EDGE EROSION REPAIR
(VRS2324)
1. General
A. This repair procedure is used to repair erosion damage caused

by rain or grit on the leading edge (see Figure 201) of the
composite Pre-cooler Duct.
B. This is a four step process and includes: 1) removing the

erosion damage on the leading edge of the composite Pre-cooler
Duct 2)applying Potting Compound, 3) applying Ceramic-Epoxy
Coating and; 4) applying Polyurethane Clear Coat.
C. This repair is applicable only if the damage is located on the

edge highlight of the leading edge, the length of the damage is
not more than 0.50 in. (12,70 mm), and the remaining thickness
on the damage area is not less than 0.053 in. (1,35 mm). Refer
to Figure 202.
D. This repair is also applicable to Pre-cooler Ducts that were

previously coated with Ceramic Coating.
None
A. Standard Tools
Paint brush
Spray tools
Standard shop tools
V2500 54-30-00 REPAIR 044

Page 201
Feb 1/09

Consumable Index)
CoMat 01-076 Solvent; Alternate for CoMat 01-438
CoMat 07-098 Clear Polyurethane
CoMat 08-050 Epoxy Paste Adhesive (EA9390)
PART IDENT MATERIAL

Pre-Cooler Duct Composite Material, Graphite Fabric
F. Repair Parts - none
4. Prepare and Examine the Damaged Area (See Figure 202)

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 044

Page 202
Feb 1/09
CONTAMINATION.
CAUTION: CLEAN THE SURFACE WITH A COMAT 02-099 LINT FREE CLOTH
MOISTENED WITH COMAT 01-076 SOLVENT. RUB THE SURFACE CLEAN
AND DRY BEFORE THE SOLVENT DRIES.
CAUTION: REMOVE THE PAINT, PRIMER AND ANY REMAINING AERODYNAMIC

SEALANT BY LIGHTLY SANDING FROM THE ENTIRE LEADING EDGE
AREA WITH COMAT 05-081 SILICON CARBIDE ABRASIVE PAPER. DO
NOT ABRADE INTO THE GRAPHITE FIBERS UNDERNEATH THE PRIMER.
NOTE: The CoMat 07-160 Ceramic Coating will not adhere to

surfaces contaminated with Silicone. It is important to
remove all residues of Silicone from the aerodynamic
surfaces.
NOTE: If there is damage to the Graphite Fibers then repair the

damage as described in Step 5.
NOTE: Perform a water break test to the repair areas. A surface

is water break free if a thin unbroken film of water can
stay on the surface for at least 30 seconds. If the water
breaks free from the surface, repeat the sanding and
cleaning procedures in this step until a thin, unbroken
film of water can remain on the surface for at least 30
seconds.
A. Clean the repair area with a CoMat 02-099 lint free cloth
moistened with CoMat 01-076 Solvent. Clean the surfaces before
the solvent dries.
V2500 54-30-00 REPAIR 044

Page 203
Feb 1/09
B. Measure the remaining thickness of the damaged area. If the

remaining thickness is less than 0.053 in. (1,35 mm), this
repair does not apply.
C. Measure the length of the damage area. If the length is greater

than 0.50 in. (12,70 mm), this repair does not apply.
5. Repair of Damaged Graphite Fibers
A. Estimate the weight of the CoMat 08-050 Epoxy Paste Adhesive,

EA9390 needed to cover and patch the damage area. Add 20% more
adhesive to the paste.
B. Mix the CoMat 08-050 Epoxy Paste Adhesive base and catalyst per
the manufacturer’s instructions.
C. Cut 0.031 inches (0,79 mm) long from the edge of the CoMat 01-
165 Graphite Fabric. The fibers of the fabric must be cut into
small pieces. The total weight of the graphite fabric should be
8% - 14% of the total weight of the CoMat 08-050 Epoxy Paste
Adhesive, as measured in Step 5.A.
D. Stir the small pieces of the CoMat 02-165 Graphite fibers into
the catalyzed CoMat 08-050 Epoxy Paste Adhesive until all
fibers are completely coated in adhesive.
E. Fill the damaged area with fiber filled CoMat 08-050 Epoxy
Paste Adhesive and spread to the common surrounding area.
F. Remove the excess epoxy adhesive.
G. Cure the fiber filled CoMat 08-050 Epoxy Paste Adhesive per the

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 044

Page 204
Feb 1/09
H. Use CoMat 05-020 or CoMat 05-081 Waterproof Silicon Carbide

Abrasive Paper to sand the repaired area flush with the
surrounding area.
I. Clean the repaired surface with a CoMat 02-099 Lint Free cloth
moistened with CoMat 01-076 Solvent. Rub the repaired surface
clean and dry before the solvent dries.
6. Prepare CoMat 07-160 Ceramic Coating for Application

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 044

Page 205
Feb 1/09
A. Mix the CoMat 07-160 Ceramic Coating Part A. Use a paint shaker
(22°C).
NOTE: Failure to properly mix Part A will prevent the CoMat 07-
160 Ceramic Coating from properly performing and curing.
NOTE: You may need to shake the CoMat 07-160 Ceramic Coating
part A for longer periods of time to mix completely. All
ceramic particles in Part A must be completely suspended
in the resin mixture before mixing with CoMat 07-161 Part
B.
NOTE: When you shake the CoMat 07-160 Ceramic Coating Part A for
more than 30 minutes at a time, it can become warm causing
reduced pot life. Allow the CoMat 07-160 Ceramic Coating
Part A to cool to ambient temperature before mixing it
with CoMat 07-161 Part B. Before you mix it with CoMat 07-
161 Part B, shake the CoMat 07-160 Ceramic Coating Part A
for another 4 to 6 minutes.
NOTE: For best results, use the coating in quantities of pints

or quarts and to use the unmixed coating within 2 years of
the date of delivery.
NOTE: Do not shake the catalyzed mixture too much. If you shake
the mixed coating too much it can cause heat to build up
and make the resin cure faster than it should.
NOTE: The pot life of mixed CoMat 07-160 Ceramic Coating is

approximately 4 to 6 hours at 72°F (22°C).
NOTE: If it is necessary to thin the mixture before you spray

it, use CoMat 01-438 Solvent or CoMat 01-031 Acetone. Thin
only as needed. Do not thin more than 5% of the total
volume. If you use too much thinner it can damage the
CoMat 07-160 Ceramic Coating and cause it to improperly
bond to the repair surface.
B. Follow the manufactures instructions to mix CoMat 07-160

Ceramic Coating part A with the CoMat 07-161 part B catalyst.
Mix the combined part A and CoMat 07-161 Part B by hand for one
V2500 54-30-00 REPAIR 044

Page 206
Feb 1/09
C. Pour mixed CoMat 07-160 Ceramic Coating into the spray

equipment. Use a standard paint strainer to remove any lumps or
foreign material in the mixed coating.

PPE IS NECESSARY.
AMBIENT TEMPERATURE AND THE REPAIR SURFACE IS ABOVE 40°F
(4.4°C). DO NOT APPLY COMAT 07-160 CERAMIC COATING IF THE
GREATER THAN 85%.

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 044

Page 207
Feb 1/09
A. Spray one layer of CoMat 07-160 Ceramic Coating on a piece of

prepared CoMat 02-321 Aluminum sheet.
NOTE: Use a CoMat 02-088 Nylon Brush or paint roller to apply

the CoMat 07-160 Ceramic Coating. It is best to apply the
CoMat 07-160 Ceramic Coating with a paint spray gun. If
you use a brush or paint roller it will cause inconsistent
results in the thickness of the finished coating.
NOTE: If you use a paint roller to apply the CoMat 07-160

Ceramic Coating, use a short nap roller with a 0.250 in.
(6,35 mm) nap thickness.
NOTE: Use a wet film thickness gauge to measure the depth of the
CoMat 07-160 Ceramic Coating. Make a note of the number of
coats applied to obtain the proper thickness.
B. Apply the coating until a film thickness of 0.006 to 0.008 in.

(0,15 to 0,20 mm) is reached.
NOTE: If the CoMat 07-160 Ceramic Coating is applied too thick,

it will crack when it cures. If it is too thin, the CoMat
07-160 Ceramic Coating will not provide the proper erosion
resistance.
NOTE: The compressed air source for the spray equipment must be
filtered to remove the moisture.
8. Apply the CoMat 07-160 Ceramic Coating to the Repair Area and Entire
Leading Edge

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 044

Page 208
Feb 1/09
CAUTION: APPLY THE COMAT 07-160 CERAMIC COATING ONLY WHEN THE
AMBIENT TEMPERATURE AND THE REPAIR SURFACE IS ABOVE 40×F
(4.4×C). DO NOT APPLY COMAT 07-160 CERAMIC COATING IF THE
GREATER THAN 85%.

A. Use CoMat 02-178 Masking Tape to protect adjacent surfaces from

over spray of CoMat 07-160 Ceramic Coating. Refer to Figure
202.
B. Clean the repair area and entire leading edge with a CoMat 02-
099 Lint Free Cloth moistened with CoMat 01-438 Solvent. Clean
the surfaces before the solvent dries.
C. Apply the CoMat 07-160 Ceramic Coating to the repair area and
entire leading edge. Refer to step 6B to apply the number of
layers needed to get a 0.006 to 0.008 in. (0,15 to 0,20 mm)
thickness.
NOTE: If you apply the CoMat 07-160 Ceramic Coating too thick,
it will crack when it cures. If it is too thin, the CoMat
07-160 Ceramic Coating will not provide the proper erosion
resistance. It is important to get the proper thickness
0.006 to 0.008 in. (0,15 to 0,20 mm) thickness. The
maximum thickness must not be more than 0.009 in. (0,23
mm). If the maximum thickness is more than 0.009 in. (0,23
mm) the cured surface may crack.
NOTE: The compressed air source for spray equipment must be

filtered and be free of any moisture.
V2500 54-30-00 REPAIR 044

Page 209
Feb 1/09
D. Measure the CoMat 07-160 Ceramic Coating thickness in several

places to make sure that the proper thickness has been
obtained. Use a wet film thickness gauge. Repeat step 8C as
necessary until the required thickness is reached. If the
coating is applied too thick, remove the coating while it is
still wet with a CoMat 02-099 Lint Free Cloth moistened with
CoMat 01-438 Solvent and apply the CoMat 07-160 Ceramic Coating
again as described in repeat steps 7C and 7D.
E. Remove the CoMat 02-178 Masking Tape from the edge of the
repair 20 minutes after you apply the final layer of the CoMat
07-160 ceramic coating to allow the edge of the coating to
feather itself onto the surface of the part.
NOTE: Some pinholes may occur in the coating and are acceptable.
If you find a large number of pinholes, it is an
indication that the repair surface was contaminated before
you applied the CoMat 07-160 Ceramic Coating. Remove the
coating in the affected area as described in this step and
apply the CoMat 07-160 Ceramic Coating again.
F. Air-dry the CoMat 07-160 Ceramic Coating for a minimum of 4

hours at the same temperature and humidity that you applied the
coating. Refer to figure 3 for cure times and temperatures. The
coating has a finish that is dry to the touch in 3 hours at 720F
(220C). Make a note of the temperature and relative humidity
after you have applied the final layer of the CoMat 07-160
Ceramic Coating.
G. Cure the CoMat 07-160 Ceramic Coating in a drying room after it

has been air-dried. Fully cure the CoMat 07-160 Ceramic Coating
at a maximum temperature of 120°F (48.8°C) for a minimum of 7
hours. The CoMat 07-160 Ceramic Coating can be cured at room
temperature of 72°F (22°C) for 12 hours. Refer to Figure 203
NOTE: The CoMat 07-160 Ceramic Coating will lose its viscosity
if the temperature is elevated too soon after application.
This will cause the coating to drip and sag off of the
repair area. The CoMat 07-160 Ceramic Coating is very
difficult to remove once it has cured. Make sure the
surface is dry to the touch before you raise the
temperature to cure the coating.
V2500 54-30-00 REPAIR 044

Page 210
Feb 1/09
H. Clean the spray equipment within 15 minutes after you spray the
final layer of the CoMat 07-160 Ceramic Coating. Fully flush
and clean the spray equipment with CoMat 01-438 Solvent or
CoMat 01-031 Acetone.

PPE IS NECESSARY.
DO NOT APPLY ANY SOLVENT TO THE CERAMIC SURFACE. THE NEW
CERAMIC SURFACE IS ABLE TO ACCEPT THE COMAT 07-098 CLEAR
POLYURETHANBE COATING WITHOUT FURTHER PREPARATION.
A. Mix the CoMat 07-098 Clear Polyurethane coating, catalyst, and

reducer according to the manufacturer’s instruction. Let the
mixed CoMat 07-098 Clear Polyurethane coating sit for 15
minutes.
NOTE: For best results, the CoMat 07-098 Clear Polyurethane

components must be mixed and applied when the ambient
temperature is between 60°F and 95°F (15°C to 35°C).
NOTE: The pot life for CoMat 07-098 Clear Polyurethane is 4

hours at 65°F (25°C).
V2500 54-30-00 REPAIR 044

Page 211
Feb 1/09
B. Use a CoMat 02-088 Nylon Brush to apply one layer of the CoMat
07-098 Clear Polyurethane coating onto the cured CoMat 07-160
Ceramic Coating. Brush the CoMat 07-098 Clear Polyurethane a
minimum of 0.25 inch (6,35 mm) over the painted surface of the
part.
NOTE: Do not use spray equipment to apply a CoMat 07-098 Clear

Polyurethane coat.
NOTE: Before you apply the CoMat 07-098 Clear Polyurethane

coating to the repair area, use the sample you made in
step 6 to test the CoMat 07-098 Clear Polyurethane coating
to make sure that it is applied to the CoMat 07-160
Ceramic Coating properly.
C. Before you handle or move the part, air-dry the CoMat 07-098
Clear Polyurethane coating for 15 minutes. Let the CoMat 07-098
Clear Polyurethane coating to cure dry to the touch for 3 hours
at 77°F (25°C). The CoMat 07-098 Clear Polyurethane coating is
fully cured 8 hours after it is applied. You can cure the CoMat
Clear Polyurethane coating in a drying room at 120°F (48°C) for
30 minutes.
D. After the CoMat 07-098 Clear Polyurethane coating is fully

cured, do a visual examination of the CoMat 07-098 Clear
Polyurethane coating. If there are any areas missing in the
CoMat 07-098 Clear Polyurethane coating, reapply CoMat 07-098
Clear Polyurethane coating as required until the CoMat 07-160
Ceramic Coating is completely covered.
NOTE: Full cure of the CoMat 07-098 Clear Polyurethane coating

is not necessary. The uncured coating is structurally and
V2500 54-30-00 REPAIR 044

Page 212
Feb 1/09
10. Repair to the CoMat 07-160 Ceramic Coating After Full Cure

PPE IS NECESSARY.
A. Pinholes in the CoMat 07-160 Ceramic Coating:
1. Use CoMat 05-020 Abrasive Paper to remove contamination and

to make the surface area around the pinholes rough.
2. Use a CoMat 02-099 Lint-free Cloth moistened with CoMat 01-

438 Solvent. Rub the surface clean and dry before the
solvent dries.
3. Apply CoMat 07-160 Ceramic Coating again by following Step

7.
4. Apply CoMat 07-098 Clear Polyurethane by following Step 8.

1. Remove damaged or contaminated CoMat 07-160 Ceramic Coating
entirely with CoMat 05-081 Abrasive Paper as described in
Step 4.
2. Repair damage as described in Step 5.
3. Apply CoMat 07-160 Ceramic Coating as described in Step 6

through Step 8.
4. Apply CoMat 07-098 Clear Polyurethane as described in Step

9.
V2500 54-30-00 REPAIR 044

Page 213
Feb 1/09
A. Do a visual inspection of the repaired area to make sure the

repair was done correctly. If necessary, do the applicable
steps again.
A. Mark “VRS2324” adjacent to the assembly number. Use a CoMat 06-

131 Marking Pen using contrasting color.
V2500 54-30-00 REPAIR 044

Page 214
Feb 1/09
Pre-Cooler Duct - Orientation View

Figure 201
V2500 54-30-00 REPAIR 044

Page 215
Feb 1/09
Pre-Cooler Duct - Application of Erosion-Resistant Coating

Figure 202
V2500 54-30-00 REPAIR 044

Page 216
Feb 1/09
Cure Schedule
A two pass film of six (six) to eight (8) mils (152 - 203 micorns) air dries
to a touch-dry (gel) finish within three (3) hours at 77°F (25°C) and dries
to a 70% cure in twelve (12) hours. Cure times lengthen at lower
temperatures and shorten at higher temperatures. See Cure Profiles in
(Figure 203).
V2500 54-30-00 REPAIR 044

Page 217
Feb 1/09
V2500 54-30-00 REPAIR 044

Page 218
Feb 1/09
REPAIR 045
THRUST REVERSER, C-DUCT TORQUE RING,
METALLIC TWO-PIECE INNER FAIRING REPAIR
(VRS2329)
1. General
A. This repair procedure is used to repair crack damage,

surface damage and dents on the inner fairing of the torque
ring assembly of the fixed structure in the Thrust Reverser.
CAUTION: THIS REPAIR IS APPLICABLE ONLY IF THE INNER FAIRING IS

MECHANICALLY FASTENED TO THE FORWARD FRAME AND AFT FRAME
WITH COUNTERSUNK OR FLUSH HEAD RIVETS.
CONTACT GOODRICH FOR DISPOSITION IF THE INNER FAIRING IS

MECHANICALLY FASTENED TO THE FORWARD FRAME WITH BUTTON OR
DOME HEAD RIVETS.
B. This repair is only applicable to the 2-piece configuration

inner fairing made of aluminum. The inner fairing (Part no.
745-0404)and aft frame (Part no. 745-0405) are two different
parts mechanically fastened.
C. Find out if the damage is located in Area 1 or Area 2 (See

Figure 201, sheet 1)
(1) If the damage is in area 2, this repair is applicable.
(2) If the damage is located in Area 1 (above or below the

actuator), this repair is not applicable.
D. A section from purchased inner fairing assembly is installed

into the cut-out area and secured in place by fabricated
doublers and splices.
E. The forward frame supports the forward edge of the inner

fairing and the aft frame supports the aft edge of the inner
fairing.
F. This type of damage is repaired by cutting out the damage

section.
V2500 54-30-00 REPAIR 045

Page 201
Feb 1/09
CAUTION: DO NOT DAMAGE THE FORWARD AND AFT FRAME OF THE

FAIRING AND DO NOT ENLARGE EXISTING RIVET HOLES.
G. If damage is found on the forward and aft frames, contact

Goodrich Aftermarket Services for further disposition.

B. Consumable materials
(Ref Overhaul Processes and Consumables Index)

CoMat 01-076 Methylethylketone (Substitute to
CoMat 01-438)
CoMat 02-171 Aluminum Sheet, 2024-T3, 0.063 in.
(1.60 mm) thick (Substitute to CoMat 02-360)
CoMat 02-214 Aluminum Sheet, 2024-T3, 0.050 in.
(1,60 mm) thick. (Substitute to CoMat 02-360)
CoMat 02-360 Aluminum Sheet, 2024-0, 0.050 in.
(1,27 mm) thick
CoMat 02-360 Aluminum Sheet, 2024-0, 0.063 in.
(1,60 mm) thick
CoMat 07-028 Chromate Conversion (Alodine 1200)
CoMat 07-106 Chromate Conversion (Substitute to
CoMat 07-028)
CoMat 08-021 EA9394NA Epoxy Paste Adhesive
CoMat 08-033 Sealant, DC 93-006-1
V2500 54-30-00 REPAIR 045

Page 202
Feb 1/09
C. Repair Materials
Part Number/Name Material Description Source

Repair Inner Make from 745-0404-505 Purchased Part
Fairing Skin or -506, Fairing, Inner
Segment Assembly, Left Hand or
Right Hand
Repair Doublers Aluminium sheet, 2024-0 Commercially
(CoMat 02-360) per QQ-A250/4, 0.063 available
in. (1,60 mm) thick.
Heat treat to T62
condition after
forming. Alternate
Material: Aluminium
sheet, 2024-T3, per
QQ-A-250/5, 0.063 in
(1,60 mm) thick.
Repair Splices Aluminium sheet, 2024-0 Commercially
per QQ-A-250/4, 0.063 available
in. (1,60 mm) thick.
Heat treat to T62
condition after
forming. Alternate
Material: Aluminium
sheet, 2024-T3, per
QQ_A-250/5, 0.063 in.
(1,60 mm) thick.
CR3214-5 Blind Rivets Commercially
available
V2500 54-30-00 REPAIR 045

Page 203
Feb 1/09
3. Determine the Length of the Crack
A. Clean the repair area with CoMat 01-438 solvent and wipe dry
with CoMat 02-091 wiping cloth.
B. Look for damage in the forward frame and aft frame (See
Figure 201, sheet 3). If damage is found, this repair is not
applicable. Contact Goodrich Aftermarket Services for further
disposition.
C. Perform Fluorescent Penetrant Inspection (FPI) to find the

extent of crack damage. Refer to SPPM Task 70-23-02-230-501.
Use a CoMat 06-131 marking pen to mark the boundaries of crack
damage.
4. Remove the Damaged Area of Inner Fairing
A. Use CoMat 06-131 marking pen to mark cutting lines on the inner
fairing skin segment to be cut.
B. Mark the cut lines on the inner fairing. Maintain a minimum of

2D+0.060 in. (2D+1,52mm) edge distance between new and existing
fastener location. “D” is the diameter of the
fastener hole.
C. Location of cut lines must be free from interference when the

forward splices, aft splices, and repair doublers are
installed. (See Figure 201, sheet 2).
D. Make sure the cut lines are located to allow (3) rows of
fasteners on each side of the splice. (See figure 201, sheet
2).
V2500 54-30-00 REPAIR 045

Page 204
Feb 1/09
E. Remove the existing fasteners from the forward frame and aft
frame that secure the inner fairing skin segment to be removed.
Do not increase the size of the existing fastener holes.

PPE IS NECESSARY.
F. Cut out the inner fairing skin segment at the cut lines. Do not
damage the forward frame and aft frame.
G. Keep the cut out inner fairing skin segment for use as
template if applicable.
5. Prepare the Repair Material
A. Make the repair inner fairing skin segment from the

purchased inner fairing assembly (745-0404-505 or -506) with
0.38 in. (9,65 mm) radius corners. Use the removed inner
fairing skin segment as template for peripheral outline and
contour.
B. Use CoMat 06-131 marking pen to mark the cut lines.
C. The repair inner fairing skin segment must keep a 2D + 0.060 in.
(2D + 1,52 mm) edge distance between new and existing fastener
holes. (See Figure 201, sheet 2)
D. A maximum gap of 0.050 in. (1,27 mm) must be kept between the
parent inner fairing and repair inner fairing skin
segment.
E. Trim the purchased inner fairing along the drawn cutting lines
to produce the repair inner fairing skin segment.
V2500 54-30-00 REPAIR 045

Page 205
Feb 1/09
F. Make and form forward splices, aft splices, and repair

doublers from 2024-0 aluminum sheet (CoMat 02-360), 0.063 in.
(1,60 mm) thick with 0.38 (9,65 mm) radius corners. Contour and
shape of the forward and aft splices, and repair doublers must
agree with the contour of the repair inner fairing skin segment
with light finger pressure. Aluminum Sheet (CoMAt 02-171),
2024-T3, 0.063 in. (1,60 mm) thick can be use as an
alternative.
G. Contour and shape of the forward splices must agree with the
contour of the forward Frame Flange in contact with the
parent inner fairing with light finger pressure.
H. Contour and shape of the forward splices must agree with the
contour of the aft frame flange in contact with parent inner
fairing with light finger pressure.
I. Width and length of forward splices and aft splices and repair
doublers must be large enough to allow installation of three
(3) rows of fasteners on each side with 2D + 0.060 in. (2D +
1,52 mm) edge distance and 4D-6D spacing between
fasteners on each side of the cutting lines (See Figure 201,
sheet 2)
J. Remove sharp edges on the fabricated parts.
6. Locate Fabricated Parts Into Position

PPE IS NECESSARY.
A. Position in place the forward splices, aft splices, repair

doublers and repair inner fairing skin segment over the
damage area on the parent inner fairing and temporarily secure
in place with temporary clamps and fasteners
(cleckos).
V2500 54-30-00 REPAIR 045

Page 206
Feb 1/09
B. Use the removed damage inner fairing skin segment as a

template to locate existing fastener holes on the forward frame
and aft frame.
C. Use CoMat 06-131 marking pen to mark the location of new and
existing fastener locations on the parent inner fairing.
Maintain an edge distance of 2D + 0.60 in. (2D + 1,52 mm) and 4D
to 6D hole spacing for new fasteners. (See Figure 201, sheet 2)
D. Drill 0.094 in. (2,39mm) pilot holes through the parent inner
fairing and repair doubler, forward splices and aft splices.
Remove burrs.
E. Drill 0.160 - 0.164 in. (4,06 - 4,17 mm) diameter holes through
the parent inner fairing and repair Doubler, forward splices
and aft splices. Remove burrs.
F. Drill 0.094 in. (2,39 mm) pilot holes through the repair inner
fairing skin segment and repair Doubler, forward splices, and
aft splices. Remove burrs.
G. Drill 0.160 - 0.164 in. (4,06 - 4,17 mm) diameter holes through
the repair inner fairing skin segment and repair Doubler.
H. After all holes are drilled and removed cleckos and separate
the repair inner fairing skin segment, forward splices, aft
splices and repair Doubler from the repair area. Remove burrs
if necessary.
I. Countersink fastener holes on the parent inner fairing and

repair inner fairing skin segment to proper diameter and depth
where CR3214-5 fasteners will be installed. Do not “knife edge”
hole.
J. Heat treat aft splices, forward Splice, repair doublers and

repair inner fairing skin segment to T62 condition.
CAUTION: DO NOT HEAT TREAT PARTS MADE FROM 2024-T3 MATERIAL.
NOTE: Do not attempt to heat treat the repair fairing skin

segment that was cut out from the blank inner fairing to
the T62 condition again if it is already heat treated to
this condition.
V2500 54-30-00 REPAIR 045

Page 207
Feb 1/09
7. Inspect and Clean the Repair Area
A. Clean the repair parts and repair area with a CoMat 02-099,
lint free cloth moist with CoMat 01-438 Solvent. Wipe the
surfaces dry before the solvent evaporates.
8. Application of Chromate Coating and Primer
A. Apply thin layer of CoMat 07-028 Chromate Conversion coating to

bare surface of all fabricated repair parts. CoMat 07-106 can
be an alternative to CoMat 07-028.
B. Apply one layer of CoMat 07-115 I primer Class M to the entire

surfaces of all fabricated repair parts.
V2500 54-30-00 REPAIR 045

Page 208
Feb 1/09
9. Install the Fabricated Repair Parts
A. Mix CoMat 08-104 EA9394 Epoxy Paste Adhesive.
B. Apply CoMat 08-104 EA9394 Epoxy Paste Adhesive to faying

surfaces of repair parts and the parent inner fairing. CoMat
08-021 is acceptable substitute to CoMat 08-104.
C. Place forward splices, aft splice, repair doublers and repair

inner fairing skin segment into position. Align the fastener of
the repair parts with parent inner fairing. use temporary
fasteners (cleckos) to secure repair parts with parent inner
fairing.
D. Wet install blind rivets with CoMat 08-104 EA9394 Epoxy PAste
Adhesive to secure the repair parts with parent inner fairing.
E. Fill gap between parent inner fairing and repair inner fairing
skin segment with CoMat 08-033 Sealant, DC 93-006-1. Fair flush
repaired area surface. Allow adhesive and sealant to cure per
10. Inspect the Repair
A. Perform visual inspection of the repaired area to make sure

repair was completed per provided procedures.
B. Inspect the repaired area every 6,000 Flight Hours, 4500 Flight
Cycles or 20 months, which ever comes first, from the time the
repair was completed.
C. If damage is found contact Goodrich Aftermarket services for

further disposition.
V2500 54-30-00 REPAIR 045

Page 209
Feb 1/09
A. Identify and record the repair as VRS2329 adjacent to the

Thrust Reverser Part Number. Use CoMAt 06-131, marking pen.
V2500 54-30-00 REPAIR 045

Page 210
Feb 1/09
Location of Damage on Torque Ring Fairing Assy

V2500 54-30-00 REPAIR 045

Page 211
Feb 1/09
Repair Inner Fairing Skin Segment Installation

V2500 54-30-00 REPAIR 045

Page 212
Feb 1/09

V2500 54-30-00 REPAIR 045

Page 213
Feb 1/09

V2500 54-30-00 REPAIR 045

Page 214
Feb 1/09
Typical Profile of Repair Pieces

Figure 202
V2500 54-30-00 REPAIR 045

Page 215
Feb 1/09
V2500 54-30-00 REPAIR 045

Page 216
Feb 1/09
REPAIR 046
TRANSLATING SLEEVE (CONFIGURATION 2), OUTER SKIN, AFT SECTION
METALLIC PATCH REPAIR
(VRS2341)
1. General
A. This repair procedure is used to repair dent damage on the aft

section of the outer skin of the left hand and right hand
Translating Sleeves (See Figure 201).
B. This type of damage is repaired by removing the damaged skin to

expose the honeycomb core. Straighten the honeycomb core cell
and apply adhesive over the damage area and mechanically fasten
a fabricated doubler over the repair area.

mm) in diameter or 19.6 in2. (12267,7 mm2) in area, 3D away from
other damage and 3D away from the edge of panel where D is the
diameter of the damage.
D. This repair is limited to damage location referred as “Repair

Area” in Figure 201, Sheet 2.
E. For damage larger than 5.0 in. (127 mm) in diameter contact
Goodrich for further disposition.
2. Effectivity
This repair is applicable to the components with serial numbers

listed below:
Part No. Serial No.

745-0006 5001 and Subsequent
V2500 54-30-00 REPAIR 046

Page 201
Feb 1/09
A. Standard Tools


Consumable Index)

CoMat 01-438
CoMat 02-214 Aluminium Sheet, 2024-T3, 0.050 in. (1,27 mm)
thick. (Substitute to CoMat 02-360)
CoMat 02-360 Aluminium Sheet, 2024-0, 0.050 in. (1,27 mm)
thick, heat treat to 2024-T42 standard.
CoMat 05-020 Waterproof silicon carbide abrasive paper,
320 Grit
150 Grit
CoMat 07-106 Chromate Conversion Coating, Alodine 1500
CoMat 08-104 Epoxy Paste Adhesive, EA9394
C. Repair Materials
Rivets CR3524-5
V2500 54-30-00 REPAIR 046

Page 202
Feb 1/09
PART IDENT MATERIAL

Acoustic Panel- Perforated Aluminium Sheet Skin (inner)
Aft Section Aluminium Honeycomb Core
Aluminium Sheet Back Skin (outer)
4. Prepare the Damaged Area For Repair, (See Figure 201, Sheet 1 & 2 and
Figure 202)

PPE IS NECESSARY.
A. Clean the damaged area with CoMat 02-099 lint free cloth made
solvent evaporates.
B. Find the size of the dent. Use the tap test method.
C. Mark a border around the damage area. Use CoMat 06-131 marking
pen.
D. Measure the damage area; find out how far the damage is from
other damages and how far from edge of panel.
V2500 54-30-00 REPAIR 046

Page 203
Feb 1/09
E. If damage is larger than 5.0 in. (127 mm) in diameter or 19.6

in2. (12267,7 mm2) in area, less than 3D away from other nearest
damage and less than 3D away from nearest edge of panel contact
Goodrich for further disposition. Where D is the diameter of
the damage.
F. Remove the dent by cutting out the outer skin around the dent
area to expose the honeycomb core. Cut out must be a regular
geometric shape. Corner radius is 0.375 in. (9,5 mm) for
rectangular shapes. Use standard shop cutting equipment.
G. Deburr the edges to remove sharp corners and maintain surface

finish, Ra of 125 in. (3.2 m) or smoother on trimmed edges. Use
Silicone Abrasive Paper-CoMat 05-020 and CoMat 05-081.
H. Perform Eddy Current or Penetrant Inspection per SPPM Task 70-

20-01-200-501 on the trimmed edges to find out if cracks exist.
If cracks are found, consult Goodrich for further disposition.
5. Rework the Damaged Honeycomb Core (See Figure 202)
A. Carefully unbend and straighten the damaged honeycomb core

cells using standard shop tools.
B. Clean the damage area using light air pressure while wiping
clean CoMat 02-099 lint free cloth made moist with CoMat 01-438
solvent. Allow to dry for 30 minutes.
CAUTION: AIR LINE MUST BE DRY AND NO PRESENCE OF OIL. EXCESSIVE AIR
PRESSURE WILL DAMAGE THE HONEYCOMB CORE.
C. Mix CoMat 08-104 Epoxy Paste Adhesive, EA9394 per

D. Apply adhesive. Use a plastic spatula or injection blow gun to

form a partial solid fill on the exposed honeycomb core
avoiding seepage of adhesive through the perforated skin on
opposite side of panel. Fill cells to approximately 1/3 to 1/2
depth. Do not fill core cells completely. See Figure 202, sheet
3 of 3.
E. Cure the adhesive for one hour at 150°F - 160°F (66°C - 72°C).
V2500 54-30-00 REPAIR 046

Page 204
Feb 1/09
F. Sand flush the cured adhesive with the outside mold line of the
repaired area with CoMat 05-020 or CoMat 05-081 Waterproof
silicon carbide abrasive paper.
G. If required, repeat Steps B. through D. until potting is flush

to the outside mold line of outer skin.
H. Wipe the damaged area and the surrounding skin with CoMat
Rub the surface dry before solvent evaporates.
I. Inspect the repaired area for disbond by tap test method.

Consult Goodrich for further disposition if disbond exists.
6. Prepare Repair Material (See Figure 202)
A. Fabricate Repair doubler using CoMat 02-360 Aluminum Sheet,

2024-T42, (2024-T3 alternative) 0.050 in. (1,27 mm) thick
material. Allow two (2) rows of fasteners around the periphery
of damage cut out maintaining 2D edge distance, 2D cut-out edge
distance and 4D to 6D fasteners spacing. Where D is the
diameter of the fastener. (See Figure 202, sheet 1 and 2.)
NOTE: It is acceptable to use one Repair Doubler to cover

multiple dent damage provided the repair size is not
violated. (See Step 1.C.)
B. Use Figure 202 (sheet 1 and 2) as guide to the size, shape and
fastener spacing requirements for the Repair Doubler.
NOTE: The repaired areas must be centered under the Repair

Doubler.
C. Chamfer the edge of the Repair Doubler 0.030 in. (0,76 mm) X 30
degrees.
D. Clean the Repair Doubler with CoMat 02-099 lint free cloth made
moist with CoMat 01-438 solvent. Rub the surfaces dry before
solvent evaporates.
E. Apply one layer of CoMat 07-106 Chromate Conversion Coating,

Alodine 1500 to bare surfaces. Allow to dry per manufacturer’s
instructions.
V2500 54-30-00 REPAIR 046

Page 205
Feb 1/09
7. Install the Repair Doubler (See Figure 202)

PPE IS NECESSARY.
A. Apply a thin coat of CoMat 08-104 Epoxy Paste Adhesive to the

faying surface of the Repair Doubler.
B. Position the Repair Doubler over the reworked damaged area. See
Figure 202 (sheet 1, 2 and 3).
C. Using CoMat 06-131 Marking Pen mark the location of fasteners.

Maintain an edge distance of 2D and 4D to 6D hole spacing of
fasteners. (See Figure 202, sheet 1 and 2.)
D. Drill 0.094 in. (2,39 mm) pilot holes using drilling tools
through the Repair Doubler and outer skin. Do not damage
underlying structures. Remove burrs.
E. Drill 0.160 – 0.164 in. (4,06 – 4,17 mm) diameter holes through
the Repair Doubler and outer skin. Do not damage underlying
structures. Remove burrs.
F. Temporarily secure the Repair Doubler through drilled holes

with temporary fastener (cleckos).
G. Wet install 2 rows of CR3524-5 fasteners with CoMat 08-104

Epoxy Paste Adhesive through the Repair Doubler and the outer
skin.
V2500 54-30-00 REPAIR 046

Page 206
Feb 1/09
H. Cure CoMat 08-104 Epoxy Paste Adhesive per manufacturer’s

instructions.
I. Paint the Repair Doubler and surrounding area to match the

existing paint scheme as required per SRM 54-30-00, REPAIR 023,
Paint Replacement.

procedures in this repair have been accomplished. Do a tap test
to make sure that there is no disbond. If necessary, repeat the
A. Mark VRS2341 adjacent to the repair on the panel edge and next
to the part number on the identification plate. Use CoMat 06-
131, Marking Pen.
V2500 54-30-00 REPAIR 046

Page 207
Feb 1/09
Left and Right Translating Sleeve

V2500 54-30-00 REPAIR 046

Page 208
Feb 1/09
Repair Area
Left Hand Translating Sleeve
V2500 54-30-00 REPAIR 046

Page 209
Feb 1/09
Metallic Patch Repair Multiple Damage

V2500 54-30-00 REPAIR 046

Page 210
Feb 1/09
Metallic Patch Repair Multiple Damage

V2500 54-30-00 REPAIR 046

Page 211
Feb 1/09
Metallic Patch Repair

Figure 202 (sheet 3 of 3)
V2500 54-30-00 REPAIR 046

Page 212
Feb 1/09
REPAIR 047
TRANSLATING SLEEVE LOWER AREA BOTTOM EDGE - NEAR DOUBLE LATCH HEAT
DAMAGE WET LAYUP REPAIR
(VRS2327)
1. General
A. This procedure is use to repair the heat damage and corrosion

on the Translating Sleeve Outer Panel Lower area, near the aft
double latch area.

skin fibers and the installation of a graphite and
fiberglass patch with resin and adhesive.
C. Repair and damage limits is applicable to this repair for the

lower area, bottom edge are as follows:
(1) For all outer panel plies that are missing, disbonded,
gouged or nicked, the maximum length and width of repair
size is: Y = 5.0 in. (127,0 mm) and X = 3.0 in. (76,2 mm).
No two (2) damages or repairs within D = 11.0 in. (279,4
mm). Refer to Figure 202.
D. Recommend incorporation of Service Bulletin 78-0126 and

78-0211.
VRS2327
Heat Lamp (Explosion proof)

Heat Blanket
Temperature Probe
Vacuum Connector
Vacuum Pump
V2500 54-30-00 REPAIR 047

Page 201
Feb 1/09
B. Consumable Materials (Ref Overhaul Processes and

Consumables Index)
CoMat 01-076 Methylethlketone Alternative for

CoMat 01-438
CoMat 02-170A Silicone rubber sheet
CoMat 02-172 Aluminium Alloy plate
CoMat 05-020 Abrasive paper
CoMat 08-050 Resin -Epoxy paste adhesive EA9390
PART IDENT MATERIAL

Composite Outer Skin Graphite Fabric
Panel (CoMat 02-165)
V2500 54-30-00 REPAIR 047

Page 202
Feb 1/09
4. Prepare the Damaged Panel for Repair (See Figure 203)

PPE IS NECESSARY.
A. Clean the surface with solvent (CoMat 01-438) and a lint free
cloth (CoMat 02-099). Wipe and dry the surface before solvent
evaporates.
B. Use a marking pen (CoMat 06-131) to make a rectangular mark

around the damaged area to be removed. Make a mark of the
damaged area to the smallest size that removes all the
damage.
C. Remove all latch hardware. Visually inspect, if the latch

hardware are still serviceable retain for re-fitting on
completion of repair. (See REPAIR 026 for reference)
CAUTION: DO NOT ENLARGE FASTENER HOLES.
D. Make a rectangular cut to remove the damaged skin. Remove all

loose particles, cracks, and separations. Use a minimum radius
of 0.25 in. (6,4 mm) at all inner corners of the
cutout. Taper the sides of the cutout 45° towards the outer
surface of the skin. Smooth the edges of the cutout with
abrasive paper (CoMat 05-020 and 05-081).
V2500 54-30-00 REPAIR 047

Page 203
Feb 1/09
E. Apply teflon tape (CoMat 02-160) to the repair area. Add an

additional 5.5 in. (139,7 mm) all around the repair cutout area
to give an overlap area.
NOTE: The distance between the edge of the sanding ply and the
teflon tape is 0.75 in (19,05 mm). The size of the
border can vary depending on the number of repair plies
used.
CAUTION: DO NOT TAPER OR BREAK THE CARBON FIBERS OF THE TOP SURFACE
OF THE OUTER SKIN PLY.
F. Remove all of the surface finish and lightly make the repair
area rough with waterproof silicon carbide abrasive paper
(CoMat 05-081).
G. Clean the interior and exterior surface with solvent (CoMat 01-
438) and a lint free cloth (CoMat 02-099). Wipe the surface dry
H. Let the repair area dry for one hour at 230°F - 250°F
(110°C - 121°C) with an explosion proof heat lamp.
V2500 54-30-00 REPAIR 047

Page 204
Feb 1/09
5. Prepare the Aluminum Backup Plate (See Figure 204)

PPE IS NECESSARY.
A. Cut a piece of aluminum alloy plate (CoMat 02-172) larger than

the repair cutout to use as a backup plate. Put a sheet of non-
porous parting film (CoMat 02-367) over the backup plate.
B. Attach the backup plate to the underside of the Translating

Sleeve to overlap the repair cutout. Hold the backup plate in
position with teflon tape (CoMat 02-160).
NOTE: The backup plate must have the same contour as the
repair surface. The plate must align the contour of the
surface with light finger pressure.
6. Install the Outer Skin Filler Plies (See Figure 203)
A. Find the number of graphite fabric flies which are needed to

make a filler ply stack the same thickness as the adjacent
skin.

PPE IS NECESSARY
V2500 54-30-00 REPAIR 047

Page 205
Feb 1/09
B. Cut the filler ply from graphite fabric (CoMat 02-165). Cut the
plies 0.50 in (12,7 mm) larger than the cutout all around. Trim
them to the correct size after they are soaked with resin.
(1) Cut ply no. 1 with the warp at 0°.
(2) Cut ply no. 2 with the warp at -45°.
(5) If necessary follow this pattern for additional plies.
C. Mix the EA9390 resin (CoMAt 08-050) in accordance with the

manufactures instructions.
D. Prepare the filler ply stack.
(1) Put the first filler ply on a sheet of non-porous parting

(2) Apply the resin to the ply and cover the ply with another
sheet of the non-porous parting film.
(3) Use a roller to force the resin into the ply thoroughly.
V2500 54-30-00 REPAIR 047

Page 206
Feb 1/09
(6) Lay the second ply over the first ply and smooth the
wrinkles.
(7) Repeat steps (5) and (6) for the remaining filler plies to
make a stack of filler plies.
(8) Cut the edges of the stack of filler plies to the correct
size of the cutout.
E. Install the filler ply stack.
(1) Apply resin to the edges of the cutout.
(2) Make sure the backup plate is properly positioned. Use

clamp or teflon tape as necessary to keep the plate in
place.
(3) Remove the non-porous parting film from bottom side of the
stack.
(4) Put the stack into cutout. Press the stack into position
against the backup plate. Use a roller to remove the
wrinkles.
stack.
7. Make a Vacuum Bag for the Filler Ply Stack (See Figure 204).
NOTE: You can cure the filler ply stack and the repair plies
together if you are sure you can get the correct contour.
Refer to step 10 if filler plies and repair plies are cured
together.
A. Put a minimum of 4 thermocouples around the perimeter of the

filler ply stack. Do not put them on the filler ply stack.
B. Cover the filler ply stack with a sheet of porous parting film
(CoMat 02-334) that is 3.0 in. (76,2 mm) larger all around the
backup plate.
C. Put five plies of fiberglass fabric (CoMat 02-167) over the

porous parting film to serve as bleeder cloth.
V2500 54-30-00 REPAIR 047

Page 207
Feb 1/09
D. Put a sheet of non-porous parting film (CoMat 02-367) over the

bleeded cloth.
E. Put a sheet of silicone rubber (CoMat 02-170A) over the

F. Cover the silicone rubber sheet with the heat blanket.
G. Put 2 plies of breather cloth (CoMat 02-166) over the heat

blanket.
H. Cover the repair area with the nylon bagging film

(CoMat 02-163) that is minimum of 2.00 in. (50,8 mm) larger all
around the repair area. Put the thermocouple and the vacuum
connector under this vacuum bag and seal the edges with sealant
(CoMat 12-024).
I. Attach the vacuum pump hose to the vacuum connector and connect
the heater blanket to an electrical source.
8. Cure the Filler Ply Stack
A. Cure the filler ply stack for 220 minutes at 190°F - 210°F (88°C
- 99°C). Keep a steady vacuum pressure of 22 in. of
B. After the resin has cured, remove the vacuum bag materials from
the filler ply stack.
C. Do a tap test of the repair area. If necessary, repeat the

applicable steps.
9. Smooth the Filler Ply Stack (See Figure 203)

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 047

Page 208
Feb 1/09
A. Make the filler ply stack level with the adjacent skin. Use the
waterproof carbide abrasive paper (CoMat 05-081) to level the
filler ply with the adjacent skin.
B. Shape the forward edge of the ply stack to 4:1 ratio taper. Use
abrasive paper (CoMat 05-020 and 05-081).
C. Clean the surface with solvent (CoMat 01-438) and a lint free
cloth (CoMat 02-091). Wipe the surface dry before the solvent
evaporates.

PPE IS NECESSARY.
A. Cut five repair plies of graphite fabric (CoMat 02-165) and cut
one sanding ply from fiberglass fabric (CoMat 02-167). Cut the
corner of the place 45° by 1.0 in. (25,4 mm).
(1) Cut ply no. 1 with the warp at 0°. Cut the ply 1.00 in.
(25,4 mm) larger all around than the cutout. Trim the
corner 45 degrees x 1.00 in (25,4 mm).
(2) Cut ply no. 2 with the warp at -45°. Cut the ply 0.75 in.
(19,05 mm) larger all around than the first ply. Trim the
corners 45° x 1.00 in. (25,4 mm).
V2500 54-30-00 REPAIR 047

Page 209
Feb 1/09
(19,05 mm) larger all around than the second ply. Trim the
corners 45 ° X 1.00 in. (25,4 mm).
(4) Cut the ply no. 4 with the warp at 0°. Cut the ply 0.75
in. (19,05 mm) larger all around than the third ply. Trim
the corners 45° x 1.00 in. (25,4 mm).
(19,05 mm) larger all around than the fourth ply. Trim the
corners 45° x 1.00 in (25,4 mm).
(6) Cut the sanding ply from the fiberglass fabric (CoMat 02-
167). Cut the ply 0.75 in. (19,05 mm) larger than the
fifth repair ply all around. Trim the corners 45° x 1.00
in. (25,4 mm).
NOTE: Do not cover the teflon tape with the fiberglass sanding
ply.
B. Mix the EA9390 resin (CoMat 08-050) in accordance with the

manufacture’s instructions.
C. Lay the first repair ply on a sheet of non-porous parting film

(CoMat 02-367) and apply the resin to the ply. Cover the ply
with another sheet of the non-porous parting film.
D. Use a roller to force the resin into the ply thoroughly.
V2500 54-30-00 REPAIR 047

Page 210
Feb 1/09
E. Install the first repair ply.

from the repair.
(2) Lay the repair ply on top of the filler ply stack.
(3) Press the ply firmly in position and remove any

wrinkles. Use a roller if necessary.
(4) Remove the top sheet of non-porous parting film from the
repair ply.
F. Repeat steps C, D, and E for the remaining plies and the

NOTE: Make sure the warp of each ply is installed properly and
that the non-porous parting film is removed from each of
the plies.
11. Make a Vacuum Bag for the Repair (See Figure 205)
A. Put a minimum of 4 thermocouples around the perimeter of the

sanding ply. Do not put them on the sanding ply.
B. Cover the repair plies with a sheet of porous parting film

(CoMat 02-334) that is 3.00 in. (76,2 mm) larger all around the
repair.
C. Put five plies of fiberglass fabric (CoMat 02-167) over the

porous parting film to serve as bleeder cloth.
D. Put a sheet of non-porous parting film (CoMat 02-367) over the

bleeder cloth.
E. Put a sheet of silicon rubber (CoMat 02-170A) over the

F. Cover the silicon rubber sheet with the heat blanket.
G. Lay 2 plies of breather cloth (CoMat 02-166) over the heat

blanket.
V2500 54-30-00 REPAIR 047

Page 211
Feb 1/09
H. Cover the repair area with the nylon bagging film (CoMat
02-163) that is a minimum of 2.00 in. (50,8 mm) larger all
around. Put the thermocouples and the vacuum connector under
this vacuum bag and seal the edges with sealant (CoMat
12-024).
NOTE: The breather cloth and vacuum bag must extend forward
over the edge to the underside of the translating sleeve
land.
I. Attach the vacuum pump hose to the vacuum connector and connect
12. Cure the Repair
A. Cure the repair for 220 minutes at 190° - 210°F (88° - 99°C)
while you keep a steady vacuum pressure of 22 inches of
B. After the resin has cured, disconnect the heat blanket and the
pressure source. Remove the bagging materials.
C. Remove the backup plate and teflon mask tape.
13. Smooth the Repair Surface (See Figure 203)

PPE IS NECESSARY.
A. Remove sharp edges. Make the repair surface smooth with the
adjacent surface. Prepare the surface ready to apply the
external paint. Use waterproof silicon carbide abrasive paper
(Comat 05-081).
B. Clean the surface with a lint free cloth (CoMat 02-099) moist
with CoMat 01-438 solvent. Wipe the surface dry before the
solvent evaporates.
V2500 54-30-00 REPAIR 047

Page 212
Feb 1/09
C. Apply primer and a top coat to the repair area in accordance

with standard painting procedures as given in REPAIR 023.
A. Do a tap test of the repair area to make sure all the steps are
done properly. If necessary, repeat the applicable steps.
15. Install the Attaching Hardware
A. Install the attaching fasteners and latch hardware per

engineering drawings. Refer to Table 1 and Figure 203.
B. Drill a 0.38 in. (9,65 mm) diameter drain hole through the
repair plies.
A. Mark the VRS2327 adjacent to the repair area on the panel edge.
Use a CoMat 06-131 marking pen for high color contrast.
FASTENER HOLE DIAMETER in. (mm)

NAS9309ML(5) PRODUCTION 0.160-0.164 (4,064-4,1656)
NAS9309ML(6) PRODUCTION 0.192-0.196 (4,8768-4,9784)
CR3524-5 (Alt for NAS9309ML(5)) 0.160-0.164 (4,064-4,1656)
CR3524-6 (Alt for NAS9309ML(6)) 0.192-0.196 (4,8768-4,9784)
TABLE 1
V2500 54-30-00 REPAIR 047

Page 213
Feb 1/09
Translating Sleeve
Figure 201
V2500 54-30-00 REPAIR 047

Page 214
Feb 1/09
Damage Location
V2500 54-30-00 REPAIR 047

Page 215
Feb 1/09
Damage Location
V2500 54-30-00 REPAIR 047

Page 216
Feb 1/09
Repair Scheme
V2500 54-30-00 REPAIR 047

Page 217
Feb 1/09
Repair Scheme
V2500 54-30-00 REPAIR 047

Page 218
Feb 1/09
Filler Ply Stack Lay-up and Vacuum Bag Installation

Figure 204
V2500 54-30-00 REPAIR 047

Page 219
Feb 1/09
Repair Patch Lay-up and Vacuum Bag Installation

Figure 205
V2500 54-30-00 REPAIR 047

Page 220
Feb 1/09
REPAIR 048
THRUST REVERSER, TRANSLATING SLEEVE MISSING AND/OR
LOOSE RIVETS REPAIR
(VRS2332)
1. General
A. This repair procedure is use to repair the missing or loose

rivets on the V2500-A5 Translating Sleeve of each Thrust
Reverser half, post serial number 5001 only. (See Figure 201
and 202).
B. This type of damage is repaired by removing and replacing the

loose and or missing rivets with oversize rivets.
C. This repair is applicable to the following:
(1) The entire row of rivets on the edge (circumferential) of

the Forward Split Line of the Translating Sleeve, see
Figure 202.
(2) The last nine (9) rivets at the outer panel skin bottom
edge (longitudinal), forward of the Forward Split Line of
the Translating Sleeve, see Figure 203.
(3) Translating Sleeve that have undergone a repair (see Step

4.B. Note) on rivet holes of rivets susceptible to
loosening and or missing on the edge of the Forward Split
Line, see Figure 202.
(4) Translating Sleeve that have undergone a repair (see Step

4.B. Note) on rivet holes of the last (9) rivets
susceptible to loosening and or missing on the outer panel
skin bottom edge and forward of the Forward Split Line,
see Figure 203.
D. Contact Goodrich Aerostructures for further disposition if the

damage falls beyond the Allowable Damage Limits givem in Table
1)
VRS2332
V2500 54-30-00 REPAIR 048

Page 201
Aug 1/09
A. Standard Tool
Standard shop tools

Consumable Index)
CoMat 01-076 Methylethylketone Alternative for

CoMat 01-438
CoMat 08-021 Epoxy Paste Adhesive (EA934NA)
E. Component Materials - none
F. Repair Materials
CR 3555-5 Cherrymax Rivet, Unisink Head, Oversize Dia.

CR 3555-6 Cherrymax Rivet, Unisink Head, Oversize Dia.
NAS9309MP4 Blind Rivet, 100° Flush Shear Head
V2500 54-30-00 REPAIR 048

Page 202
Aug 1/09
4. Prepare and Examine the Damaged Area for Repair (See Figure 203)
A. Clean the surface of the damage area with CoMat 02-099 lint
surface clean and dry before the solvent evaporates.
B. Carefully drill out loose rivet. Do not increase the

diameter of the rivet hole and do not drill through the panel.
NOTE: If the Translating Sleeve being repaired has undergone

a previous temporary repair, remove aluminum filler
AV121N and Hardener HY 951 in the oversized holes.
C. Vacuum the debris from the rivet holes
D. Clean the surface of the damage area with CoMat 02-099 lint
surface clean and dry before the solvent evaporates.
E. Visually inspect the rivet hole with 10X magnification.
F. Measure the size of the rivet holes and record the

measurements.
V2500 54-30-00 REPAIR 048

Page 203
Aug 1/09
5. Install the Repair Rivets
A. Ream clean and round rivet holes per Table 1.
DIAMETER OF REAM CLEAN 100° OVERSIZE

RIVET HOLE AND COUNTERSUNK RIVET TO
MEASUREMENTS ROUND TO: DIAMETER USE:
USE:
0.165-0.173 in. 0.176-0.180 in. 0.208 in CR 3555-5

(4,19 -4,39 mm) (4,47-4,57 mm) (5,28 mm)
0.197-0.201 in. 0.205-0.209 in. 0.255 in CR 3555-6

(5,00-5,10 mm) (5,21-5,31 mm) (6,48 mm)
DIAMETER OF ORIGINAL REPAIRABLE

UNDAMAGED RIVET RIVET SIZE FASTENER
HOLE DIAMETER TO USE: IDENTITY
(FIGURE 203)
0.129-0.132 in. NO REAMING COUNTERSINK NAS9309MP4

(3,27-3,35 mm) REQUIRED EXIST

(4.06-4,65 mm) REQUIRED EXIST

(4,87-4,98 mm) REQUIRED EXIST
TABLE 1
DAMAGE AND UNDAMAGED HOLE MEASUREMENT, REAM CLEAN AND
ROUND TO, RECOMMENDED RIVET
NOTE: If the size of the enlarged or elongated hole is larger

than the hole measurement listed in Table 1, this repair
is not applicable. Contact Goodrich Engineering Repair
Group for further disposition if this is the case.
B. Countersink the hole per Table 1.
V2500 54-30-00 REPAIR 048

Page 204
Aug 1/09
C. Use Table 1 to determine the size of the replacement rivet for

the appropriate rivet hole size.
NOTE: If the rivet hole measurement matches the “Undamaged

Hole Diameter Measurements” in Table 1. installation of
original rivets size corresponding to the rivet
measurement is acceptable.
D. Maintain existing edge distance for all repair rivets.
E. Maintain existing distance between fasteners. Contact Goodrich

for further disposition if 4D - 6D can not be maintained. “D” is
the diameter of the hole.
F. Install applicable repair rivets wet with CoMat 08-021 Epoxy

Paste Adhesive.
G. Remove excess CoMat 08-021 Epoxy Adhesive with CoMat 02-099

Lint Free Cloth wet with CoMat 01-438 Solvent.
H. Cure CoMat 08-021 Epoxy Paste Adhesive, refer to the

A. Perform visual inspection of the completed repair to make sure

all requirements of this repair are done.
A. Identify and record the repair as VRS2332 adjacent to the

Thrust Reverser Part Number. Use CoMat 06-131 marking pen.
V2500 54-30-00 REPAIR 048

Page 205
Aug 1/09
Translating Sleeve
Figure 201
V2500 54-30-00 REPAIR 048

Page 206
Aug 1/09
Translating Sleeve
Figure 202
V2500 54-30-00 REPAIR 048

Page 207
Aug 1/09
Translating Sleeve
Figure 203
V2500 54-30-00 REPAIR 048

Page 208
Aug 1/09
REPAIR 049
THRUST REVERSER, C-DUCT, PRE-COOLER DUCT
LEADING EDGE WET LAY-UP REPAIR
(VRS2331)
1. General
A. This repair procedure is used to repair erosion damage caused

by rain or grit on the leading edge (see Figure 201) of the
composite Pre-cooler Duct.
B. This type of damage is repaired by removing the erosion damage

on the leading edge of the composite Pre-cooler Duct, wet lay-
up of Graphite Fabric and application of Ceramic-Epoxy Coating
and Polyurethane Clear Coat.
C. This repair is applicable for damage located on the edge

highlight of the leading edge. The maximum length of the damage
is 3.50 in. (89 mm). The damage is less or equal to 3 layers of
ply. The damage must be within a distance of 1.50 in. (38 mm)
from mid point ridge of the highlight and 1.5 in. (38 mm) away
from the corner radius. Refer to Figure 201 and Figure 202
(Sheet 2 of 2).
D. This repair is also applicable to Pre-cooler Ducts previously

coated with Ceramic Coating.
A. Standard Tools
Paint brush
Spray tools
Standard shop tools

Consumable Index)
CoMat 01-076 Solvent; Alternate for CoMat 01-438
V2500 54-30-00 REPAIR 049

Page 201
Feb 1/09

CoMat 02-165 Graphite Fabric, AH370-5H
CoMat 02-321 Aluminium sheet
320 Grit
150 Grit
CoMat 08-059 Dry Fabric, Graphite, 3K-135-8H
PART IDENT MATERIAL

Pre-Cooler Duct Composite Material, Graphite Fabric
3. Prepare and Examine the Damaged Area For Repair, (See Figure 202)

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 049

Page 202
Feb 1/09
moist with CoMat 01-076 Solvent. Rub the surface clean and dry
B. Remove the paint, primer and any remaining aerodynamic sealant

from the entire leading edge area by lightly sanding with CoMat
05-081 silicon carbide abrasive paper. Do not abrade into the
Graphite fibers underneath the primer.
NOTE: The CoMat 07-160 Ceramic Coating will not adhere to

surfaces contaminated with Silicone. It is important to
remove all residues of Silicone from the aerodynamic
surfaces.
C. Perform a water break test to the repair areas. A surface is

water break free if a thin unbroken film of water can stay on
the surface for at least 30 seconds. If the water breaks free
from the surface, repeat the sanding and cleaning procedures in
this step until a thin, unbroken film of water can remain on the
surface for at least 30 seconds.
moist with CoMat 01-076 Solvent. Clean the surfaces before the
solvent dries.
E. Determine the damage size by visual, tap test or ultrasonic

inspection method.
F. Use CoMat 02-131 marking pen to mark a regular geometric shape

around the damage area boundary on the damaged laminate. Make
sure that the mark is the smallest area that will remove all
damage.
V2500 54-30-00 REPAIR 049

Page 203
Feb 1/09
G. Determine the number of damaged ply. If the number of damaged

ply exceeds 3 plies this repair is not applicable. Contact
H. Measure the length of the damage area. If the length is greater

than 3.50 in. (89 mm) this repair is not applicable. Contact
I. Mask around an additional 2.5 in. (63,5 mm) perimeter using

wide strips of teflon tape (CoMat 02-007). Additionally, mask
any other areas that can be contaminated by this procedure.
J. Fasteners that are located inside the perimeter of repair area

must be removed.
4. Remove Damaged Laminate
A. Determine the total overlap dimension and start scarfing (taper

sanding) the edges around the damage area. Make sure a taper
ratio of 35:1. Use CoMat 05-081 waterproof silicone carbide
abrasive paper, 150 grit. Refer to Figure 204.
B. Remove material in a regular geometric shape ensuring that a

minimum of 0.50 in. (12,7 mm) corner radii is maintained.
C. Scuff-sand an additional 1.5 in. (38,1 mm) wide border around

the scarf/step area to allow for one (1) overlap ply and one (1)
sanding ply.
D. The skin damage cut-out opening is to be taper sanded. Repair

Filler plies and Repair Doubler plies are to be bonded to the
undamaged laminate.
E. Vacuum the debris and dust from the repair area.
F. Verify and identify existing material warp direction.
V2500 54-30-00 REPAIR 049

Page 204
Feb 1/09
5. Prepare Repair Materials
CAUTION: USE CLEAN, WHITE GLOVES THAT ARE FREE OF LINT TO MOVE OR
TOUCH CLEANED AREAS OR REPLACEMENT PIECES OR CONTAMINATION
WILL OCCUR. COMPOSITE MATERIAL REQUIRES SPECIAL HANDLING
AND REFRIGERATED STORAGE. MANUFACTURER’S INSTRUCTIONS
MUST BE FOLLOWED. VERIFY MATERIAL CONTROLS RECORD AND
STORAGE LIFE CARD (SHELF LIFE).
CAUTION: RECORD ALL REQUIRED DATA OF THE REPAIR PROCESS TO MAKE

SURE THERE IS TRACEABILITY. REJECT ANY DISCREPANT
MATERIAL, AS REPAIR QUALITY AND PERFORMANCE WILL BE
AFFECTED. REFER TO THE APPLICABLE QUALITY DEPARTMENT.
NOTE: IF YOU SEE OR THINK THAT THE REPAIR PARTS HAS LIQUID
CONTAMINATION, REMOVE THE LIQUID BEFORE YOU BEGIN THE
REPAIR TO PREVENT FURTHER DAMAGE AS PER SAE ARP4977 OR
EQUIVALENT.
NOTE: IF THE CUTOUT IS RECTANGULAR, CUT THE CORNERS OF ALL

PLIES 45 DEGREES BY 0.50 IN. (12,7 MM).
A. Generate a patch drawing to include a coordinate system showing

ply orientation and shape.
B. Use one Repair Filler ply for every damaged ply.
NOTE: The highlight of the leading edge is comprised of 7

layers of laminated graphite fabric. Six layers of
graphite fabric at 0.014 in. (0,35 mm) thick per layer
and one layer of graphite tape at 0.004 in. (0,010 mm)
thick.
C. Create templates for each Repair Filler ply, for each Repair
Doubler ply and for Sanding ply. Mark the ply number and the ply
orientation on each template. The ply orientation should be the
same as in the original lay-up. The stacking template is used
to mock-up the actual patch and shall be sized to the proper
dimensions. Refer to Figure 204.
D. Cut the Sanding ply from CoMat 08-059 dry graphite fabric
material using the template as guide. Label the ply with the
ply number in the proper stacking sequence and orientation.
V2500 54-30-00 REPAIR 049

Page 205
Feb 1/09
E. Cut the Repair Doubler plies from CoMat 08-059 dry graphite
fabric material using the template as guide. Label each ply
with the ply number in the proper stacking sequence and
orientation.
F. Cut the Repair Filler plies from CoMat 08-059 dry graphite
fabric material using the template as guide. Label each ply
with the ply number in the proper stacking sequence and
orientation. Plies shall be stored in a clean room environment
until ready for use.
6. Impregnation of the Repair Fillers and Repair Doublers.
A. Cut two pieces of CoMat 02-168 non-porous parting film

approximately 3.00 in. (76,2 mm) larger than each Sanding ply,
Repair Doubler ply and each Repair Filler ply all around.
B. Tape each piece to a smooth surface.
C. Determine the quantity of CoMat 08-050, Epoxy Paste Adhesive.
(1) Determine the weight of the repair material that is to be

impregnated. This can be done by weighing or calculating
the weight based on the total area of repair material and
weight of the fabric.
(2) The target CoMat 08-050 epoxy paste adhesive content for a
typical wet lay-up is 50% by weight. Therefore the weight
of the mixed adhesive should equal the weight of the
fabric. It is recommended that 20% be added to the gross
weight of the mixed adhesive to account for transfer
inefficiencies.
V2500 54-30-00 REPAIR 049

Page 206
Feb 1/09
hardener.
EXAMPLE:
A piece of fabric 20 in. X 10 in. (508,0 mm X 254,0 mm) is

to be impregnated. Since most adhesive manufacturers
specify their products in metric units, metric is used in
this example.
(508,0 x 254,0) × 1 ÷ 106 = 0.129 m2(EQ. 1)
Based on the manufacturer’s data the weight of the example

fabric is 370 g/m2. Therefore the weight of the fabric is:
0.129 m2 × 370 g/m2 = 47,73 g (Eq. 2)
Since the weight of the mixed resin should equal to the

weight of the fabric plus 20%, the required weight of
mixed adhesive is:
47,73 g + (0.20 × 47,73 g) = 57,27 g(Eq. 3)
The manufacturer of the paste adhesive used in this

example specifies a resin/hardener ratio of 100/25 parts
by weight. The component portion is determined by
multiplying the total mixed weight by the ratio of the
component to the total weight of the mixed adhesive
required. The weight for the component portions is as
follows:
Resin: 57,27 g × (100/125) = 45,82 g
Hardener: 57,27 g × (25/125) = 11,45 g
D. Lay each Sanding ply, each Repair Doubler ply and each Repair
Filler ply to the matching CoMat 02-168 non-porous parting
film.
E. Spread the mixed CoMat 08-050 epoxy paste adhesive to

adequately cover the entire Repair Doubler plies and Repair
Filler plies.
V2500 54-30-00 REPAIR 049

Page 207
Feb 1/09
F. Cover each repair fabric ply with the matching CoMat 02-168
G. Press the mixed CoMat 08-050 epoxy paste adhesive through the
repair materials by working over the non-porous parting film
with a roller or squeegee. This process impregnates the repair
fabric with the mixed adhesive and removes entrapped air.
H. Work excess mixed adhesive to the edges of the fabric such that
the repair fabric weave is barely visible.
I. Repeat applicable steps for each fabric ply of the repair.
J. Make a template for each ply using transparent Mylar. Mark the
ply number and the ply orientation on each template. The
orientation should be the same as in the original lay-up. Refer
to Figure 204.
K. Cut the impregnated fabric to the required sizes for each

individual ply using the templates as guide. Refer to Figure
204.
L. Clean the work surface and the cutting tools with

CoMat 01-176 solvent.
M. Apply light coat of CoMat 08-050 epoxy paste adhesive over the
repair area.
N. Remove the non-porous film from one side of the smallest ply of
the repair lay-up. Place the exposed face against the repair
area with the proper orientation and overlap around.
O. Use standard shop tool over CoMat 02-168 non-porous release

film that covers the repair area to smooth and remove wrinkles
and entrapped air. Do not apply excessive pressure. Excessive
pressure will result into deficient resin content.
P. Remove CoMat 02-168 non-porous release film from the ply and
the nest larger ply of the lay-up. Place the next ply on the
repair area with the proper orientation and overlap all around.
Q. Repeat applicable steps for all subsequent plies.
V2500 54-30-00 REPAIR 049

Page 208
Feb 1/09
7. Rebuild Damaged Area
NOTE: Make sure that the damaged area is free of any contaminants
or poor bonding will occur. If required, clean the repair
area with solvent (CoMat 01-438) and lint-free cloth (CoMat
02-099). Wipe the area dry with a clean piece of lint-free
cloth before the solvent evaporates.
NOTE: Make sure the warp direction of the repair and doubler plies
are the same as the existing ply they overlap.
A. Lay all repair plies into position. Verify ply for proper
stacking sequence and orientation.
B. Lay the Sanding ply into position.
C. Place CoMat 02-367 non porous film over the lay-up and use
roller or spatula to squeeze out air bubbles and excess resin.
8. Vacuum Bag the Repair
A. Perform vacuum bagging procedure per SRM 54-02-00, General

Repair No. 4 Composite Repairs Vacuum Bagging Procedures.
9. Cure the Repair
A. Cure the repair area using a heat blanket on each side of the
repair.

OCCURING, DO NOT SET OR ADJUST TEMPERATURE CONTROLLER
SPECIFIED.
NOTE: APPLY ADDITIONAL INSULATION (BREATHER MATERIAL) OVER

VACUUM BAG ASSEMBLY AS REQUIRED TO ASSIST IN OBTAINING THE
DESIRED CURE TEMPERATURE.
B. Heat the repair area at a rate of 1 to 5°F (1 to 4°C) per minute

to bring all thermocouples to 250° +/- 10°F
(121° +/- 5°C).
V2500 54-30-00 REPAIR 049

Page 209
Feb 1/09

TEMPERATURE.
C. Upon the coldest thermocouple reaching the 250° +/- 10°F (121°
+/- 5°C) temperature range, begin a 120-minute soak period.
the cure temperature range is maintained during soak period.
D. After the soak period, cool to approximately 140°F (60°C) at a

rate not to exceed 5°F (3°C) per minute. Upon reaching 140°F
(60°C), remove the vacuum bag and associated equipment and
materials.
10. Re-drill Existing Fastener Holes
A. Re-drill fastener holes that were covered by the repair.

Drilling is performed from the un-repaired side.
B. Use 0.192 in. (4,88 mm) drill bit for the three (3) middle
fastener holes and 0.169 in. (4,29 mm) drill bit for the two (2)
corner fastener holes of the vertical flange.
C. Use a lint free cloth (CoMat 02-099) made moist with solvent
(CoMat 01-438). Wipe the surfaces clean before the solvent
evaporates.
A. Inspect cure chart for time, temperature, temperature rise rate

and vacuum.
B. Inspect the repair area for delamination(s) and surface

irregularity using tap test or ultrasonic inspection method.
Report any damage to Goodrich.
V2500 54-30-00 REPAIR 049

Page 210
Feb 1/09

PPE IS NECESSARY.
C. Use a lint free cloth (CoMat 02-099) made moist with solvent
evaporates.
12. Prepare CoMat 07-160 Ceramic Coating for Application.

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 049

Page 211
Feb 1/09
(22°C).
NOTE: It may be required to shake the CoMat 07-160 Ceramic

Coating part A for longer periods of time in order to
get it to mix completely. All ceramic particles in Part
A must be completely suspended in the resin mixture
before mixing with CoMat 07-161 Part B.
NOTE: When shaking the CoMat 07-160 Ceramic Coating Part A for
more than 30 minutes at a time, it can become warm
causing reduced pot life. Allow the CoMat 07-160
Ceramic Coating Part A to cool to ambient temperature
before mixing it with CoMat 07-161 Part B. Prior to
mixing with CoMat 07-161 Part B, shake the CoMat 07-160
Ceramic Coating Part A for another 4 to 6 minutes.
NOTE: Failure to properly mix Part A will prevent the CoMat

07-160 Ceramic Coating from performing and curing
properly.
NOTE: For best results, it is recommended to use the coating

in quantities of pints or quarts and to use the unmixed
coating within 2 years of the date of delivery.
CAUTION: ALWAYS POUR COMAT 07-160 CERAMIC COATING PART A INTO

COMAT 07-161 PART B. DO NOT MIX BY POURING COMAT 07-161
PART B INTO COMAT 07-160 CERAMIC COATING PART A.
B. Follow the manufactures instructions to mix CoMat 07-160

Ceramic Coating part A with the CoMat 07-161 part B catalyst.
Mix the combined part A and CoMat 07-161 Part B by hand for one
NOTE: Do not shake the catalyzed mixture too much. Shaking the
mixed coating too much can cause heat to build up and
cause an exothermic reaction to occur. This will make
the resin cure faster than it should.
NOTE: The pot life of mixed CoMat 07-160 Ceramic Coating is

V2500 54-30-00 REPAIR 049

Page 212
Feb 1/09
NOTE: If it is necessary to thin the mixture for spraying, use

CoMat 01-438 Solvent or CoMat 01-031 Acetone. Thin only
as needed. Do not thin more than 5% of the total volume.
If too much thinner is used, it can damage the CoMat 07-
160 Ceramic Coating and cause it to improperly bond to
the repair surface.
C. Pour mixed CoMat 07-160 Ceramic Coating into the spray

equipment. Use a standard paint strainer to remove any lumps or
foreign material in the mixed coating.

PPE IS NECESSARY.
GREATER THAN 85%.
CAUTION: COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE CLEANED
REPAIR SURFACE. THIS PREVENTS CONTAMINATION.
A. Spray one coat of CoMat 07-160 Ceramic Coating to a piece of

prepared CoMat 02-321 Aluminum sheet.
V2500 54-30-00 REPAIR 049

Page 213
Feb 1/09
NOTE: The CoMat 07-160 Ceramic Coating can be applied using a

CoMat 02-088 Nylon Brush or paint roller. The preferred
method to apply the CoMat 07-160 Ceramic Coating is by
spraying it with a paint spray gun. Using a brush or
paint roller will cause inconsistent results in the
thickness of the finished coating.
NOTE: If a paint roller is used to apply the CoMat 07-160

Ceramic Coating, use a short nap roller with a 0.250 in.
(6,35 mm) nap thickness.
07-160 Ceramic Coating. Apply more coats as necessary until a
film thickness of 0.006 to 0.008 in. (0,15 to 0,20 mm) is
reached. Make a note of how many coats were applied to obtain
the proper thickness.
NOTE: If the CoMat 07-160 Ceramic Coating is applied too

thick, it will crack when it cures. If it is too thin,
the CoMat 07-160 Ceramic Coating will not provide the
proper erosion resistance. It is important to obtain
the proper thickness of 0.006 to 0.008 in. (0,15 to 0,20
mm).

filtered to free moisture.
V2500 54-30-00 REPAIR 049

Page 214
Feb 1/09
14. Apply the CoMat 07-160 Ceramic Coating to the Repair Area and Entire
Leading Edge

PPE IS NECESSARY.
AMBIENT TEMPERATURE AND THE REPAIR SURFACE IS ABOVE 40×F
(4.4×C). DO NOT APPLY COMAT 07-160 CERAMIC COATING IF THE
GREATER THAN 85%.

A. Use CoMat 02-178 Masking Tape to protect adjacent surfaces from

over spray of CoMat 07-160 Ceramic Coating. Refer to Figure 202
(sheet 1 of 2).
B. Clean the repair area and entire leading edge with a CoMat 02-
099 Lint Free Cloth made moist with CoMat 01-438 Solvent. Clean
the surfaces before the solvent dries.
C. Apply the CoMat 07-160 Ceramic Coating by spraying it onto the

repair area and entire leading edge. Refer to step 14.B. to
apply the number of coats needed to obtain a 0.006 to 0.008 in.
(0,15 to 0,20 mm) thickness.
V2500 54-30-00 REPAIR 049

Page 215
Feb 1/09
NOTE: If the CoMat 07-160 Ceramic Coating is applied too

thick, it will crack when it cures. If it is too thin,
the CoMat 07-160 Ceramic Coating will not provide the
proper erosion resistance. It is important to obtain
the proper thickness 0.006 to 0.008 in. (0,15 to 0,20
mm) thickness. The maximum thickness must not exceed
0.009 in. (0,23 mm). If the maximum thickness of 0.009
in. (0,23 mm) is exceeded, cracking in the cured surface
may occur.

filtered and be free of any moisture.
D. Measure the CoMat 07-160 Ceramic Coating thickness in several

places to verify that the proper thickness has been obtained.
Use a wet film thickness gauge. Repeat step 15.C. as necessary
until required thickness is reached. If the coating is applied
too thick, remove the coating while it is still wet using CoMat
02-099 Lint Free Cloth moisten with CoMat 01-438 Solvent and
apply the CoMat 07-160 Ceramic Coating again as described in
step 15.C.
E. Remove the CoMat 02-178 Masking Tape from the edge of the
repair 20 minutes after the final spray of the CoMat 07-160
ceramic coating has been applied to allow the edge of the
coating to feather itself onto the surface of the part.
NOTE: Some pinholes may occur in the coating and are

considered acceptable. If you find a large number of
pinholes, it is an indication that the repair surface
was contaminated prior to the application of the CoMat
07-160 Ceramic Coating. Remove the coating in the
affected area as described in this step and apply the
CoMat 07-160 Ceramic Coating again.

hours at the same temperature and humidity that the coating was
applied. Refer to Figure 205 for cure times and temperatures.
The coating has a finish that is dry to the touch in 3 hours at
72°F (22°C). Make a note of the temperature and relative
humidity once the final coat of the CoMat 07-160 Ceramic
Coating has been applied.
V2500 54-30-00 REPAIR 049

Page 216
Feb 1/09

has been air-dried. Fully cure the CoMat 07-160 Ceramic Coating
at a maximum temperature of 120°F (48.8°C) for a minimum of 7
hours. The CoMat 07-160 Ceramic Coating can be cured at room
temperature of 72°F (22°C) for 12 hours. Refer to Figure 205
NOTE: The CoMat 07-160 Ceramic Coating will lose its

application. This will cause the coating to drip and sag
off of the repair area. The CoMat 07-160 Ceramic Coating
is very difficult to remove once it has cured. Make sure
the surface is dry to the touch before elevating the
H. Clean the spray equipment within 15 minutes after spraying the

final coat of the CoMat 07-160 Ceramic Coating. Thoroughly
flush and clean the spray equipment with CoMat 01-0438 Solvent
or CoMat 01-031 Acetone.

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 049

Page 217
Feb 1/09
CERAMIC SURFACE IS ABLE TO ACCEPT THE COMAT 07-098 CLEAR
POLYURETHANBE COATING WITHOUT FURTHER PREPARATION.

reducer according to the manufacturer’s instruction. Set the
mixed CoMat 07-098 Clear Polyurethane coating aside for 15
minutes.
NOTE: For best results, the CoMat 07-098 Clear Polyurethane

components must be mixed and applied when the ambient
temperature is between 60° and 95°F (15° to 35°C).
NOTE: The pot life for CoMat 07-098 Clear Polyurethane is 4

B. Apply one coat of the CoMat 07-098 Clear Polyurethane coating

onto the cured CoMat 07-160 Ceramic Coating. Use a CoMat 02-088
Nylon Brush. Make the CoMat 07-098 Clear Polyurethane overlap
onto the painted surface of the part a minimum of 0.25 inch
(6,35 mm).
NOTE: Do not use spray equipment to apply a CoMat 07-098 Clear

Polyurethane coat.
NOTE: Use the sample created in step 6 to test the CoMat 07-
098 Clear Polyurethane coating prior to applying to the
repair area to make sure that it is applied to the CoMat
07-160 Ceramic Coating properly.
C. Air-dry CoMat 07-098 Clear Polyurethane coating for 15 minutes

before handling or moving the part. Allow the CoMat 07-098
fully cured 8 hours after it is applied. The CoMat Clear
Polyurethane coating can be cured in a drying room at 120°F
(48°C) for 30 minutes.
V2500 54-30-00 REPAIR 049

Page 218
Feb 1/09

cured, do a visual examination of the CoMat 07-098 Clear
Polyurethane coating. If there are any areas missing in the
CoMat 07-098 Clear Polyurethane coating, reapply CoMat 07-098
Clear Polyurethane coating as required until the CoMat 07-160
Ceramic Coating is completely covered.
NOTE: Full cure of the CoMat 07-098 Clear Polyurethane

16. Repair to the CoMat 07-160 Ceramic Coating After Full Cure

PPE IS NECESSARY.
A. Pinholes in the CoMat 07-160 Ceramic Coating:
(1) Use CoMat 05-020 Abrasive Paper to remove contamination

(2) Use a CoMat 02-099 Lint-free Cloth moist with CoMat 01-438
Solvent. Rub the surface clean and dry before the solvent
dries.
(3) Apply CoMat 07-160 Ceramic Coating again by following Step

13 though Step 15.
V2500 54-30-00 REPAIR 049

Page 219
Feb 1/09
(4) Apply CoMat 07-098 Clear Polyurethane by following Step

16.
(1) Remove damaged or contaminated CoMat 07-160 Ceramic

Coating entirely by using CoMat 05-081 Abrasive Paper as
describe in Step 4.
(2) Repair damage as described in Step 5.
(3) Apply CoMat 07-160 Ceramic Coating as described in Step 13

through Step 15.
(4) Apply CoMat 07-098 Clear Polyurethane as described in Step

16.
A. Perform visual inspection of the repaired area to make sure the

repair was completed per provided procedures. If necessary, do
the applicable steps again.
A. Mark “VRS2331” adjacent to the assembly number. Use a CoMat 06-

131 Marking Pen using contrasting color.
V2500 54-30-00 REPAIR 049

Page 220
Feb 1/09
Pre-Cooler Duct – Orientation View

Figure 201
V2500 54-30-00 REPAIR 049

Page 221
Feb 1/09
Pre-Cooler Duct – Leading Edge High Light

V2500 54-30-00 REPAIR 049

Page 222
Feb 1/09
Pre-Cooler Duct – Leading Edge Highlight Ridge Mid Point

V2500 54-30-00 REPAIR 049

Page 223
Feb 1/09
Typical Erosion Damage Removed

Figure 203
V2500 54-30-00 REPAIR 049

Page 224
Feb 1/09
Typical Repair Lay-up

Figure 204
V2500 54-30-00 REPAIR 049

Page 225
Feb 1/09
CURE SCHEDULE
A TWO PASS FILM OF SIX (6) TO EIGHT (8) MILS (152-203 MICRONS) AIR DRIES TO
A TOUCH-DRY (GEL) FINISH WITHIN THREE (3) HOURS AT 72°F (22°C) AND DRIES TO
A 70% CURE IN TWELVE (12) HOURS. CURE TIMES LENGTHEN AT LOWER TEMPERATURES
AND SHORTEN AT HIGHER TEMPERATURES. SEE CURE PROFILES IN A AND B.
Figure 205
Pre-Cooler Duct - Erosion Resistant Coating Cure Cycle
V2500 54-30-00 REPAIR 049

Page 226
Feb 1/09
REPAIR 050
COMPOSITE BLANK CASCADE FULL PENETRATION REPAIR
(VRS2334)
1. General
A. The repair procedure in this repair may be used to repair Full

Penetration damage to Composite Blank Cascade if the damage is
located in the field area that is 3.15 in. (80 mm) away from the
edges. Refer to Figure 201.
B. The damage must be limited to an area of 2.0 in. (50,8 mm)

diameter or less. Refer to Figure 201.
C. This type of damage must be repaired by removal of the damaged

area, replacement of the honeycomb core with foaming adhesive
and the application of graphite fiber patch with resin.
D. Damage larger than the limits of this repair must be referred

to Goodrich.
E. It is recommended to perform VRS2335 if damage is not down to

the underlying skin plies.
70-38-07-380-501 Standard Practices/Processes Manual

(SPPM), Surface Treating
Heat lamp 113° - 131°F (45° - 55°C)

Heat blanket 32° - 248° (0° - 120°C)
Vacuum suction pump 0 - 30 in. (0 - 762 mm) of mercury
Temperature probes 32° - 248° (0° - 120°C)
Steel roller 2.0 in. (50,8 mm) diameter, 2.0 in.
(50,8 mm) long
Suction cleaner
and equipment
V2500 54-30-00 REPAIR 050

Page 201
Feb 1/09
B. Consumable materials (Ref. Overhaul Processes and Consumable

Index)
CoMat 01-076 Methylethylketone (Alt. to CoMat 01-438)

CoMat 02-360 Aluminium Sheet, 2024-0
CoMat 05-021 Waterproof Silicon Carbide Abrasive
Paper, 240 Grit
CoMat 05-074 Abrasive Paper, 180 Grit
Paper, 150 Grit
CoMat 08-051 Sealant Tape
CoMat 08-071 Aluminium Honeycomb Core
CoMat 08-090 Foaming Film Adhesive, MA562
CoMat 08-136 Film Adhesive, FM300-2M
CoMat 08-138 Pre-preg Fabric, Graphite
PART IDENT MATERIAL

Blank Cascade Composite structure: Graphite Skin,
Aluminium Honeycomb Core
4. Examine the Damaged Area (Refer to Figure 201 and 202)
A. The damage must be located more than 3.15 in. (80 mm) from the
edges of the Composite Blank Cascade. The damage must be
confined to an area of 2.0 in. (50,8 mm) diameter or less.
V2500 54-30-00 REPAIR 050

Page 202
Feb 1/09
5. Prepare the Damaged Area for Repair (Refer to Figure 202)

PPE IS NECESSARY.
A. Determine which face of the Blank Cascade has the larger

damage.
B. Clean the damage area with solvent (CoMat 01-438) and lint-free
cloth (CoMat 02-099). Wipe the area dry with a clean piece of
C. On the face where the damage is larger determine the extent of

the damage by performing an ultrasonic inspection or tap test
and visual inspection on the laminate adjacent to the damage.
D. Lay out a regular geometric shape that will contain the repair
area on both surfaces of the Blank Cascade panel. Mark with
marking pen (CoMat 06-131) a 2.5 in. (63,5 mm) perimeter beyond
the maximum edge of damage.
E. Mask around an additional 2.5 in. (63,5 mm) perimeter using


V2500 54-30-00 REPAIR 050

Page 203
Feb 1/09

PPE IS NECESSARY.
CAUTION: DO NOT USE CHEMICAL STRIPPERS FOR FINISH REMOVAL ON

COMPOSITES. DO NOT SAND INTO LAMINATE WHEN REMOVING
FINISH. BLACK RESIDUE INDICATES SANDING INTO LAMINATE AND
GRAPHITE FIBER IS BEING REMOVED. IF THE FIBERS ARE DAMAGED
THEN THE PART CAN BE WEAKER THAN THE INITIAL PART.
F. Vacuum clean the repair area and clean with solvent (CoMat 01-
438) and lint-free cloth (CoMat 02-099). Wipe the area dry with
a clean piece of lint-free cloth before the solvent evaporates.
6. Remove the Damaged Skin and Core (Refer to Figure 202 & 203, Sheet
1).
A. Use a rotary grinder with adjustable depth, turning at 18,000

to 23,000 rpm to remove the section of damaged skin, damaged
core and the damaged skin on the opposite surface. Remove
material in a circle, oval or rectangular pattern ensuring that
a minimum of 0.50 in. (12,7 mm) corner radii is maintained.
V2500 54-30-00 REPAIR 050

Page 204
Feb 1/09
NOTE: The 5-harness graphite fabric ply is 0.014-inches

(0,356 mm) thick. The field area of the outer skin
consists of three (3) 5-harness graphite fabric plies.
The field area of the inner skin consists of three (3)
5-harness graphite fabric plies.
B. The skin damage cut-out opening is to be tapered sanded on both

surfaces. Refer to Figure 203 (Sheet 1 and 2).
7. Prepare the Damaged Area for Repair (Refer to Figure 203 Sheet 2)
A. Both surfaces comprise of three (3) layers of graphite fabric.
B. Determine the total overlap dimension and start scarfing

(taper-sanding) the edges around the cutout opening. Make sure
a taper ratio of 35:1. Use 150 grit waterproof silicon carbide
abrasive paper (CoMat 05-081). Refer to Figure 203 (sheet 1).
C. Use a magnifying glass (8 to 12 power) and a straight edge at

every 2.0 in. (50,8 mm) interval to verify the correct slope.
D. Scuff-sand an additional 1.25 in (31,8 mm) wide border around

the scarf/step area to allow for one (1) overlap ply and one
sanding ply.
E. Vacuum all debris and dust from repair area.
F. Clean the repair area with solvent (CoMat 01-438) and lint-free
G. Visually inspect the scarf sanding to make sure that the proper
scarf slope and straightness are maintained.
H. Verify and identify existing material warp direction. Refer to

Figure 202.
8. Fabricate Caul Plate and Shims (See Figure 204)
A. Fabricate two (2) caul plates from aluminum alloy sheet (CoMat
02-360) approximately 0.063 to 0.100 in.
(1,6 to 2,54 mm) thick.
V2500 54-30-00 REPAIR 050

Page 205
Feb 1/09
B. Form the caul plates to match the contour of the exterior and
interior surfaces of the panel. Make sure the caul plates
overlaps the cut out by a minimum of 2 in. (50,8 mm) in every
direction. The caul plates must fit in position with light
finger pressure.
C. Use one of the caul plates on the surface with smaller damage.
D. Fabricate shims to match the size of the core cut and step
sanded profile from 0.005 in. (0,127 mm) to 0.015 in. (0,381
mm) thick aluminum sheet (CoMat 02-360).
E. Remove the sharp edges of the caul plate and shims. Use
waterproof silicon carbide abrasive paper grit size 150 (CoMat
05-081).
F. Clean the caul plate and shims with solvent (CoMat 01-438) and
lint-free cloth (CoMat 02-099). Wipe dry with a clean piece of
G. Perform Moisture Removal Process per SRM 54-02-00, REPAIR 002.
9. Fabricate the Honeycomb Repair Plug (Refer to Figure 204)

PPE IS NECESSARY.
A. Cut the honeycomb core repair plug with standard shop cutting
tool.
(1) Wear lint-free gloves (CoMat 02-097) and cut the aluminum
honeycomb core (CoMat 08-071) so that it is a good fit in
the repair hole.
(2) Make sure that the ribbon direction of the honeycomb core
repair plug is in the same ribbon direction as that of the
undamaged honeycomb.
V2500 54-30-00 REPAIR 050

Page 206
Feb 1/09
10. Prepare the Skin Patch Repair Materials (Refer to Figure 205)
RECORD ALL REQUIRED DATA OF THE REPAIR PROCESS TO MAKE SURE

THERE IS TRACEABILITY. REJECT ANY DISCREPANT MATERIAL, AS
REPAIR QUALITY AND PERFORMANCE WILL BE AFFECTED. REFER TO
THE APPLICABLE QUALITY DEPARTMENT.
NOTE: If you see or think that the repair parts have liquid
contamination, remove the liquid before you begin the
repair to prevent further damage as per SAE ARP4977 or
equivalent.
NOTE: If the cutout is rectangular, cut the corners of all

plies 45 degrees by 0.50 in. (12,7 mm). See Figure 203,
Sheet 2 of 2.

ply orientation and shape. Refer to Figure 202 for existing ply
orientation.
B. Create templates for each Repair Filler ply and for each Repair
Doubler ply and for each Sanding ply. The stacking template is
used to mock-up the actual patch and shall be sized to the
proper dimensions.
NOTE: Use two (2) plies of pre-preg graphite fabric (CoMat 08-
138) material to replace one (1) ply of the existing
surface material. Repair filler plies should be laid-up
the same orientation as that of the original lay-up
orientation.
NOTE: Two (2) repair doubler plies shall be oriented in the 0°

direction.
V2500 54-30-00 REPAIR 050

Page 207
Feb 1/09
A. Cut the Repair Doubler plies from pre-preg graphite fabric

(CoMat 08-138) material using the template as guide. Leave the
pre-preg material on the backing film. Label each ply with the
Plies must be stored in a clean room environment until ready
for use.
B. Cut the Repair Filler plies from pre-preg graphite fabric

for use.
C. Cut the Sanding plies from pre-preg graphite fabric (CoMat 08-
138) material using the template as guide. Make the sanding
plies 0.50 in. (12,7 mm) minimum larger all around the top
Repair Doubler ply. Leave the pre-preg material on the backing
film. Label each ply with the ply number in the proper stacking
sequence and orientation. Plies must be stored in a clean room
environment until ready for use.
D. Cut two layer of FM300-2M Film Adhesive (CoMat 08-136) for a

bond line ply between the top and bottom of the Repair Core Plug
and the Repair Filler plies.
E. Cut out Foaming Film Adhesive (CoMat 08-090) to wrap around the
Repair Core Plug periphery.
11. Rebuild the Damage Area (Refer to Figure 204)
A. Cover the caul plate and shims with a non-porous parting film
(CoMat 02-367) to prevent the repair from bonding to the caul
plate.
B. Position one of the caul plates and shims under the surface of
the damage area. Use Teflon tape (CoMat 02-007) to hold the
caul plate in position.
NOTE: Make sure that the damaged area is free of any

contaminants or poor bonding will occur. If required,
solvent clean area using isopropyl alcohol, or other
structural bonding approved solvent and clean lint free
V2500 54-30-00 REPAIR 050

Page 208
Feb 1/09
cloth until no trace of contaminant remains. Allow to

air dry.
C. Wrap Foaming Film Adhesive (CoMat 08-090) around the periphery

of the Repair Core Plug. Insert the Repair Core Plug and Foam
Adhesive. The Foam Adhesive may have to be pushed in place
between the cell walls as necessary to fill gaps. Make sure the
Repair Core Plug fits and the cell ribbon direction matches.
D. Place the shims and caul plates in place to enclose the core/
foam adhesive in the cut out.
E. Use Teflon tape (CoMat 02-007) to maintain the position of the

caul plates and shims.
F. Place non-porous parting film (CoMat 02-367) over repair area.
G. Place three (3) thermocouples adjacent to repair area. Secure

with Teflon tape (CoMat 02-007).
H. Place mechanical pressure or dead weight over repair to prevent

Foam Adhesive from expanding out of the core splice area.
I. Heat the repair area at a rate of 1 to 5°F (1 to 4°C) per minute

to bring all thermocouples to 250° +/- 10°F (121° +/- 5°C). Use
a heat lamp or heat blanket.
J. Upon the coldest thermocouple reaching the desired temperature,

begin 60-minute cure time.
K. Remove (CoMat 02-367), caul plates and shims. Sand excess Foam
Adhesive from the inner and outer surfaces maintaining the
tapered feature of the cut-out.
L. Clean the repair area with solvent (CoMat 01-438) and lint free
V2500 54-30-00 REPAIR 050

Page 209
Feb 1/09
12. Install Repair Material (Refer to Figure 205)
A. Apply a layer of FM300-2M Film Adhesive (CoMat 08-136) for the

bond line between the top of the Repair Core Plug and the Repair
Filler plies.
B. Lay the Repair Fillers and Repair Doublers into position.

Verify ply for proper stacking sequence and ply orientation.
C. Lay the Sanding ply (CoMat 08-138) into position.
D. Repeat Step 12.A to Step 12.C for the opposite side.
A. Perform vacuum bagging procedure per SRM 54-02-00, Repair No.

4, General-Composite Repairs Vacuum Bagging Procedures.
14. Cure the Repair

SPECIFIED.

TEMPERATURE.
A. Cure the repair area per SRM 54-02-00, REPAIR 010 (VRS2378),
General- Pre-Impregnated Material Handling and Curing.
NOTE: Apply additional insulation (breather material) over

vacuum bag assembly as required to assist in obtaining
the desired cure temperature.

and vacuum.
B. Inspect the repair area for disbond(s), delamination(s) and

surface irregularity using tap test or ultrasonic inspection
method. Report any damage to Goodrich Technical Services.
V2500 54-30-00 REPAIR 050

Page 210
Feb 1/09

PPE IS NECESSARY.
A. Make the repair area smooth. Use 180 to 320 grit abrasive paper
(CoMat 05-074, CoMat 05-129). Remove any sharp edges. Make the
repair surface smooth with the adjacent surface. Do not sand
into the fiber of the outer-most ply.
B. Use a lint free cloth (CoMat 02-099) made moist with solvent
evaporates.
A. Identify and record the repair as VRS2334 adjacent to the Blank

Cascade Part Number. Use CoMat 06-131 Marking Pen.
V2500 54-30-00 REPAIR 050

Page 211
Feb 1/09
Figure 200
Cascades Installation
V2500 54-30-00 REPAIR 050

Page 212
Feb 1/09
Figure 201
Composite Blank Cascades
V2500 54-30-00 REPAIR 050

Page 213
Feb 1/09
Figure 202
Typical Full Penetration Damage
V2500 54-30-00 REPAIR 050

Page 214
Feb 1/09

Typical Full Penetration Damage Removed
V2500 54-30-00 REPAIR 050

Page 215
Feb 1/09

Typical Full Penetration Damage Removed
(Looking Down or Looking Up)
V2500 54-30-00 REPAIR 050

Page 216
Feb 1/09
Figure 204
Core Plug Installation
V2500 54-30-00 REPAIR 050

Page 217
Feb 1/09
Figure 205
Repair Material Installation (SCARF METHOD)
V2500 54-30-00 REPAIR 050

Page 218
Feb 1/09
REPAIR 051
THRUST REVERSER, C-DUCT, TORQUE RING TIE-IN BRACKET
CRACK REPAIR
(VRS2328)
1. General
A. This repair procedure is used to repair crack damage on the

tie-in brackets of the torque ring installation of the fixed
structure in the thrust reverser.
B. There are two tie-in brackets of each Thrust Reverser half, one
on the upper and one on the lower.
C. The existing tie-in brackets are made from 2024-To Aluminum

Alloy material heat treated to 2024-T62 after forming and is
0.080 inch (2,03 mm) thick.
D. This type of damaged is repaired by stop drilling the crack and

installing a steel doubler over the damaged area using existing
rivet holes.
E. This repair is applicable to the following:
(1) Crack damage of any length.
(2) If previous repair to the tie-in brackets has been

performed using Aluminum doubler.

V2500 54-30-00 REPAIR 051

Page 201
Feb 1/09
B. Consumable materials (Reference Overhaul processes am

Consumable Index)

CoMat 05-020 Waterproof Sil Carbide Abrasive Paper,
320Grit
CoMat 05-081 Waterproof Sil Carbide Abrasive Paper,
150Grit
CoMat 07-028 Chromate Conversion Coating (Alodine 1200)
CoMat 07-140 Epoxy Primer (10-P4-2)
CoMat 08-121 EA934NA Epoxy Paste Adhesive
C. Repair Materials
Repair Doubler 17-4PH Stainless Steel, per AMS5604, H900

condition, Thickness = 0.063 in. (1,60 mm)
Rivets CR3524-6
3. Inspect the Tie-in Bracket
A. Remove the block seal from the repair area to expose the damage
on the tie-in bracket located on upper end of the torque ring.
See IPC 78-32-46, 84A-020 for the LH and
78-32-76, 82A-030 for the RH.
B. Remove the plug seal from the repair area to expose the damage
on the tie-in bracket located on lower end of the torque ring.
See IPC 78-32-46, 84A-030 for the LH and
78-32-76, 82A-050 for the RH.
C. If the tie-in bracket has been repaired using an Aluminum

doubler proceed to Step No. 4.
D. If the tie-in bracket has been repaired using a steel doubler

this repair is not applicable. Re-install the block seal and
the plug seal that were removed in Step No. 3. No further work
is required.
V2500 54-30-00 REPAIR 051

Page 202
Feb 1/09
E. Perform Fluorescent Penetrant Inspection (FPI) on the

damaged area per Goodrich SPPM Task 70-23-02-230-501 medium
sensitivity water washable fluorescent penetrant crack
inspection.
F. Find end of crack.
G. Proceed to step no. 5.
4. Remove the Aluminum Doubler
A. Remove the blind fasteners from the aluminum doubler and tie-in
bracket. Do not increase the size of the diameter of the
fastener holes.
NOTE: Do not remove hi-loks pins from bracket. Refer to

Figure 201 (Sheet 2).
B. Using standard shop practices remove the aluminum doubler from

the tie-in bracket being repaired.
C. Remove sealant or adhesive from the tie-in bracket repair area.
D. Inspect the tie-in bracket using Fleeciest Penetrant Inspection

(FPI) and if additional crack is found, stop drill at the end of
new crack using no. 20 drill bit.
E. Proceed to step no. 6.
V2500 54-30-00 REPAIR 051

Page 203
Feb 1/09
5. Remove the Damaged Area for Repair
A. Stop drill crack using no. 20 drill bit. Refer to Figure 201.
B. Remove blind fasteners from the tie-in bracket being repaired.

Do not increase the diameter of the fastener holes.
NOTE: Do not remove hi-lok pins from bracket. Refer to figure

201 (Sheet 2).
6. Fabricate the Repair Doubler
A. Using the peripheral outline and contour of the existing tie-in

bracket or the removed aluminum doubler as template, fabricate
the repair doubler from 17-4PH Stainless Steel sheet, per
AMS5604, H900 condition, thickness = 0.063 in. (1,60 mm). Refer
to Figure 201 and Figure 202.
B. Repair doubler shall have 0.125 to 0.187 in.

(3,18 to 4,75 mm) outer corner radius and 0.250 to 0.375 in.
(6,35 to 9,53 mm) inner corner radius. Refer to Figure 202.
C. Remove sharp edges from repair doubler.
7. Locate and Drill Holes on Repair Doubler
A. Mark hole pattern of blind fastener holes from the existing

tie-in bracket (Figure 201) or from the removed aluminum
doubler and transfer hole pattern to the repair doubler (Figure
1) using CoMat 06-131, marking pen.

PPE IS NECESSARY
B. Drill pilot holes on the repair doubler using drilling tools.

Remove burrs.
C. Drill 0.192 - 0.196 in. (4,88 - 4,98 mm) diameter holes on the
repair doubler using drilling tools. Remove burrs.
V2500 54-30-00 REPAIR 051

Page 204
Feb 1/09
D. Countersink holes to 0.295 to 0.303 in. (7,49 to 7,70 mm)

diameter using drilling tools. Remove burrs.
8. Inspect and Clean the Repair Area
A. Perform visual inspection to the repair doubler and existing

tie in bracket being repaired to make sure there is no damage.
B. Clean the repair doubler and repair area with a CoMat 02-099,
lint free cloth moist with Comat 01-438, solvent. Wipe the
9. Application of Chromate Coating and Primer
A. Apply one layer of CoMat 07-028, chromate conversion coating to

bare surfaces of the tie-in bracket being repaired. Allow to
dry per manufacturer’s instructions.
B. Apply one layer CoMat 07-140, Epoxy Primer to the repair

doubler. Allow to dry per manufacturer’s instructions.
V2500 54-30-00 REPAIR 051

Page 205
Feb 1/09
10. Install the Repair Doubler
A. Apply CoMat 08-021, EA934NA Epoxy Paste Adhesive to bonding

surfaces of the repair doubler and the existing tie in bracket.
B. Position repair doubler on top of tie-in bracket ensuring

fastener holes are aligned.
C. Wet install rivets CR3524-6 with CoMat 08-021, EA934NA Epoxy

Paste Adhesive, or CoMat 08-104, EA9394 Epoxy Paste
Adhesive.
D. Cure CoMat 08-021, EA934NA Epoxy Paste Adhesive, or CoMat 08-

104, EA9394 Epoxy Paste Adhesive per manufacturer’s
instructions.
E. Reinstall the block seal and the plug that were removed in step
3. If necessary, install new Block Seal and Plug.
A. Perform a visual inspection of the completed repair to make

sure all the requirements of this repair are done.
A. Mark the VRS2328 adjacent to the repair on the panel edge. Use
CoMat 06-131, marking pen.
V2500 54-30-00 REPAIR 051

Page 206
Feb 1/09
Location of Thrust Reverser, C-duct, Torque Ring, Tie-in Bracket

(View Looking Fwd)
V2500 54-30-00 REPAIR 051

Page 207
Feb 1/09
Tie-in Bracket
V2500 54-30-00 REPAIR 051

Page 208
Feb 1/09
Repair Doubler for Tie-in Bracket

Figure 202
V2500 54-30-00 REPAIR 051

Page 209
Feb 1/09
V2500 54-30-00 REPAIR 051

Page 210
Feb 1/09
REPAIR 052
COMPOSITE BLANK CASCADE PARTIAL PENETRATION REPAIR
(VRS2335)
1. General
A. This procedure may be used to repair Partial Penetration damage

to Composite Blank Cascade if the damage is located in the
field area that is 3.15 in. (80 mm) away from the edges. Refer
to Figure 201.
B. The damage must be limited to an area of 2.0 in. (50,8 mm)

diameter or less. Refer to Figure 201.
C. This repair can be performed on partial penetration damage to

either the inner or the outer skin of the blank cascade.
D. This type of damage must be repaired by removal of the damage

area, replacement of the honeycomb core with foaming adhesive
and the application of a graphic fiber patch with resin.
E. Damage larger than the limits of this repair must be referred

to Goodrich.
F. It is recommended to perform VRS2334 if damage is not down to

the underlying skin plies.
70-38-07-380-501 Standard Practices/Processes Manual

(SPPM), Surface Treating
Heat lamp 113° - 131°F (45° - 55°C)

Heat blanket 32° - 248°F (0° - 120°C)
Vacuum suction pump 0 - 30 in. (0 - 762 mm) of mercury
Temperature probes 32° - 248°F (0° - 120°C)
Steel roller 2.0 in. (50,8 mm) diameter, 2.0 in.
(50,8 mm) long
V2500 54-30-00 REPAIR 052

Page 201
Feb 1/09
Suction cleaner
and equipment

Index)
CoMat 01-076 Methylethylketone (Alt. to CoMat 01-438)

Paper, 240 Grit
Paper, 150 Grit
CoMat 08-051 Sealant Tape
CoMat 08-071 Aluminum Honeycomb Core
CoMat 08-090 Foaming Film Adhesive, MA562
CoMat 08-136 Film Adhesive, FM300-2M
CoMat 08-138 Pre-preg Fabric, Graphite
PART IDENT MATERIAL

Blank Cascade Composite structure: Graphite Skin,
Aluminum Honeycomb Core
V2500 54-30-00 REPAIR 052

Page 202
Feb 1/09
4. Examine the Damaged Area (Refer to Figure 201 and 202)
A. The damage must be located more than 3.15 in. (80 mm) from the
edges of the composite blank cascade. The damage must be
confined to an area of 2.0 in. (50,8 mm) diameter or less.
B. There must be no evidence of damage on the underlying skin

surface.
5. Prepare the Damaged Area for Repair (Refer to Figure 201 and 202)

PPE IS NECESSARY.
A. Clean the damage area with solvent (CoMat 01-438) and lint-free
B. Determine the extent of the damage by performing an ultrasonic

inspection or tap test and visual inspection on the laminate
adjacent to the damage.
C. Lay out a regular geometric shape that will contain the repair
area on both surfaces of the blank cascade panel. Mark with
marking pen (CoMat 06-131) a 2.5 in. (63,5 mm) perimeter beyond
the maximum edge for damage.
V2500 54-30-00 REPAIR 052

Page 203
Feb 1/09
D. Mask around an additional 2.5 in. (63,5 mm) perimeter using

CAUTION: DO NOT USE CHEMICAL STRIPPERS FOR FINISH REMOVAL ON

COMPOSITES. DO NOT SAND INTO LAMINATE WHEN REMOVING
FINISH. BLACK RESIDUE INDICATES SANDING INTO LAMINATE AND
GRAPHITE FIBER IS BEING REMOVED. IF THE FIBERS ARE DAMAGED
THEN THE PART CAN BE WEAKER THAN THE INITIAL PART.
E. Vacuum clean the repair area and clean with solvent (CoMat 01-
438) and lint-free cloth (CoMat 02-099). Wipe the area dry with
a clean piece of lint-free cloth before the solvent evaporates.
6. Remove the Damaged Skin and Core (Refer to Figure 202 and 203,
Sheet 1).

PPE IS NECESSARY.
A. Use a rotary grinder with adjustable depth, running at 18,000

to 23,000 rpm to remove the section of damaged skin and damaged
core. Remove material in a circle, oval or rectangular pattern
ensuring that a minimum of 0.50 in.
(12,7 mm) corner radii is maintained.
NOTE: The 5-harness graphite fabric ply is 0.014-inches

(0,356 mm) thick. The field area of the outer skin
consists of three (3) 5-harness graphite fabric plies.
The field area of the inner skin consists of three (3)
5-harness graphite fabric plies.
B. The skin damage cut-out opening is to be taper-sanded. Refer to

Figure 203 (Sheet 1 and 2).
V2500 54-30-00 REPAIR 052

Page 204
Feb 1/09
7. Prepare the Damaged Area for Repair (Refer to Figure 203,

Sheet 1 and 2)

PPE IS NECESSARY.
A. The skin surface of the blank cascade is comprised of three (3)

layers of graphite fabric.
B. Determine the total overlap dimension and start scarfing

(taper-sanding) the edges around the cutout opening. Make sure
a taper ratio of 35:1. Use 150 grit waterproof silicon carbide
abrasive paper (CoMat 05-081). Refer to Figure 203 (Sheet 1 and
2).
C. Use a magnifying glass (8 to 12 power) and a straight edge at

every 2.0 in. (50,8 mm) interval to verify the correct slope.
D. Scuff-sand an additional 1.25 in (31,8 mm) wide border around

the scarf/step area to allow for one (1) overlap ply and one
sanding ply.
E. Vacuum all debris and dust from repair area.
F. Clean the repair area with solvent (CoMat 01-438) and lint free
V2500 54-30-00 REPAIR 052

Page 205
Feb 1/09
G. Visually inspect the scarf sanding to make sure that the proper
scarf slope and straightness are maintained.
H. Verify and identify existing material warp direction. Refer to

Figure 202.
8. Fabricate the Honeycomb Repair Plug (See Figure 204)

PPE IS NECESSARY.
A. Cut the honeycomb core repair plug with standard shop cutting
tool.
(1) Wear lint-free gloves (CoMat 02-097) and cut the aluminum
honeycomb core (CoMat 08-071) so that it is a good fit in
the repair hole.
(2) Make sure that the ribbon direction of the honeycomb core
repair plug is in the same ribbon direction as that of the
undamaged honeycomb.
9. Prepare the Skin Patch Repair Materials (Refer to Figure 204)
V2500 54-30-00 REPAIR 052

Page 206
Feb 1/09
RECORD ALL REQUIRED DATA OF THE REPAIR PROCESS TO MAKE SURE

THERE IS TRACEABILITY. REJECT ANY DISCREPANT MATERIAL, AS
REPAIR QUALITY AND PERFORMANCE WILL BE AFFECTED. REFER TO
THE APPLICABLE QUALITY DEPARTMENT.

ply orientation and shape. Refer to Figure 202, 203 (Sheet 2)
and 204 for existing ply orientation and arrangement.
NOTE: If you see or think that the repair parts have liquid
contamination, remove the liquid before you begin the
repair to prevent further damage as per SAE ARP4977 or
equivalent.
NOTE: If the cutout is rectangular, cut the corners of all

plies 45 degrees by 0.50 in. (12,7 mm). See Figure 203,
Sheet 2 of 2.
B. Fabricate templates for each filler, doubler, and sanding

repair plies. The stacking template is used to mock-up the
actual patch and shall be sized to the proper dimensions.
NOTE: Use two (2) plies of pre-preg graphite fabric (CoMat 08-
138) material to replace one (1) ply of the existing
surface material. Repair filler plies should be layed-
up the same orientation as that of the original lay-up
orientation.
NOTE: Two (2) repair doubler plies shall be oriented in the 0°

direction.
C. Cut the repair doubler plies from pre-preg graphite fabric

for use.
V2500 54-30-00 REPAIR 052

Page 207
Feb 1/09
D. Cut the repair filler plies from pre-preg graphite fabric

for use.
E. Cut the sanding plies from pre-preg graphite fabric (CoMat 08-
138) material using the template as guide. Make the sanding
plies 0.50 in. (12,7 mm) minimum larger all around the top
Repair Doubler ply. Leave the pre-preg material on the backing
film. Label each ply with the ply number in the proper stacking
sequence and orientation. Plies must be stored in a clean room
environment until ready for use.
F. Cut two layer of FM300-2M film adhesive (CoMat 08-136) for a

bond line ply between the top of the repair core plug and the
repair filler plies and bond line between the bottom of the
repair core plug and the undamaged skin.
G. Cut a layer of FM300-2M Film Adhesive (Comat 08-136) as a

sanding ply for the exterior surface. Make the adhesive layer
0.50 in. (12,7 mm) minimum larger all around the top repair
doubler ply.
H. Cut out foaming film adhesive (CoMat 08-090) to wrap around the
repair core plug periphery.
V2500 54-30-00 REPAIR 052

Page 208
Feb 1/09
10. Rebuild the Damaged Area (Refer to Figure 204)
A. Apply a layer of FM300-2M film adhesive (CoMat 08-136) for the

bond line between the inside face sheet of the undamaged side
and the Repair Core Plug.
B. Wrap foaming film adhesive (CoMat 08-090) around the periphery

of the repair core plug. Insert the repair core plug and foam
adhesive. The foam adhesive may have to be pushed in place
between the cell walls as necessary to fill gaps. Make sure the
repair core plug fits and the cell ribbon direction matches.
C. Apply a layer of FM300-2M Film Adhesive (CoMat 08-136) for the

bond line between the Repair Core Plug and the Repair Filler
plies.
D. Lay the repair fillers and repair doublers into position.

Verify ply for proper stacking sequence and ply orientation.
E. Lay the Sanding ply into position.
F. Place three (3) thermocouples adjacent to repair area. Secure

with Teflon tape as required (CoMat 02-007).
V2500 54-30-00 REPAIR 052

Page 209
Feb 1/09
A. Perform vacuum bagging procedure per SRM 54-02-00, REPAIR 004

(VRS2370), General-Composite Repairs Vacuum Bagging Procedures.
NOTE: Make sure the damaged area is free of any contaminants

or poor bonding will occur. If required, solvent clean
area using isopropyl alcohol, or other structural
bonding approved solvent and clean lint free cloth
until no trace of contaminant remains. Allow to air dry.
12. Cure the Repair

SPECIFIED.

TEMPERATURE.
A. Cure the repair area per SRM 54-02-00, REPAIR 010 (VRS2378),
General- Pre-Impregnated Material Handling and Curing.
NOTE: Apply additional insulation (breather material) over

vacuum bag assembly as required to assist in obtaining
the desired cure temperature.

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 052

Page 210
Feb 1/09

and vacuum.
B. Inspect the repair area for disbond(s), delamination(s) and

surface irregularity using tap test or ultrasonic inspection
method. Report any damage to Goodrich Technical Services.
C. Make the repair area smooth. Use 180 to 320 grit abrasive paper
(CoMat 05-074, CoMat 05-129). Remove any sharp edges. Make the
repair surface smooth with the adjacent surface. Do not sand
into the fiber of the outer-most ply.
D. Use a lint free cloth (CoMat 02-099) made moist with solvent
evaporates.
A. Identify and record the repair as VRS2335 adjacent to the Blank

Cascade Part Number. Use CoMat 06-131 Marking Pen.
V2500 54-30-00 REPAIR 052

Page 211
Feb 1/09
Cascades Installation
Figure 200
V2500 54-30-00 REPAIR 052

Page 212
Feb 1/09
Composite Blank Cascades

Figure 201
V2500 54-30-00 REPAIR 052

Page 213
Feb 1/09
Typical Partial Penetration Damage and

Typical Skin Lay-up and Ply Orientation
Figure 202
V2500 54-30-00 REPAIR 052

Page 214
Feb 1/09
Typical Partial Penetration Damage Removed

V2500 54-30-00 REPAIR 052

Page 215
Feb 1/09
Typical Partial Penetration Damage Removed

(Looking Down or Looking Up)
V2500 54-30-00 REPAIR 052

Page 216
Feb 1/09
Repair Material Installation

(Applicable to Damaged Inner and Outer Skin)
(SCARF METHOD)
Figure 204
V2500 54-30-00 REPAIR 052

Page 217
Feb 1/09
V2500 54-30-00 REPAIR 052

Page 218
Feb 1/09
REPAIR 053
THRUST REVERSER, TRANSLATING SLEEVE, FORWARD EDGE EROSION REPAIR
(VRS2343/VRS2344)
1. General
A. This procedure is used to repair erosion damage on the forward

edge of the outer barrel of the Translating Sleeve. Refer to
Figure 201.
B. The repair is done by removal of the erosion damage on the

forward edge of the outer barrel and application of potting
compound.
C. This repair includes the steps for the subsequent application

of the Ceram-Kote. The application of Ceram-Kote is not
required and is not part of the basic repair. The application
is an added step to provide increased durability and resistance
to erosion.
NOTE: Application of Ceramic-Epoxy Coating (Ceram-Kote) is

recommended in this repair, but usage of this product
maybe subject to local government restrictions.
D. This repair is applicable when the erosion damage is within

1.00 in. (25 mm) of the forward edge and not more than 30 in.
(762 mm) long on the circumference. The erosion damage must be
limited to the first two (2) plies deep of eroded outer skin.
NOTE: The translating sleeve forward edge comprises 6 plies:

4-off outer skin-graphite fabric plies, 2-off inner
skin-glass fabric piles.
E. This repair is applicable to translating sleeves that were

previously repaired or coated with ceramic coating
F. Perform repair in a controlled environment.
V2500 54-30-00 REPAIR 053

Page 201
Feb 1/09
A. VRS2343 for Left Hand Translating Sleeve repair
B. VRS2344 for Right Hand Translating Sleeve repair.
A. Standard Tools
Paint brush
Spray tools
Standard shop tools
External heat source, explosion proof
Paint shaker

Consumable Index)
CoMat 01-076 Methylethylketone (Substitute to CoMat 01-438)
CoMat 02-088 Nylon Brush
V2500 54-30-00 REPAIR 053

Page 202
Feb 1/09
PART IDENT MATERIAL

Translating Sleeve- Composite MAterial- Graphite Fabric,
Outer Panel Aluminum Honeycomb Core, Graphite Tape
and Glass Fabric
F. Repair Parts - none
4. Prepare and Examine the Damaged Area for Repair. (See Figure 202)

PPE IS NECESSARY.
CONTAMINATION.
moist with CoMat 01-076 Solvent. Rub the surface clean before
the solvent dries.
V2500 54-30-00 REPAIR 053

Page 203
Feb 1/09
B. Remove the paint, primer and repair materials if previously

repaired. Lightly sand with CoMat 05-081 silicon carbide
abrasive paper to get the initial basic lay-up. Do not abrade
into the graphite fibers below the primer.
NOTE: 1. The CoMat 07-160 Ceramic Coating will not adhere to

surfaces contaminated with silicone. It is important
to remove all residues of silicone from the
aerodynamic surfaces.
2. If there is damage to the Graphite Fibers then repair

the damage as described in Step 5.
C. Do a water break test to the repair areas. Apply water to the

surface to see if the surface is water break free. The surface
is water break free if a thin broken film of water can stay on
the surface for 30 seconds. Do the sanding and cleaning
procedures in this step until a thin unbroken film of water can
stay on the surface for a minimum 30 seconds.
D. Clean the repair area with CoMat 02-099 lint free cloth made
moist with CoMat 01-076 Solvent. Clean the surfaces before the
solvent dries.
E. Asses the damaged area. If the erosion damage is through the

3rd ply of the outer skin panel, this repair is not applicable.
Contact Goodrich for further disposition.
F. Measure the length of the damage area. If the width is more than
1.0 in. (25 mm) or the length is longer than 30 in. (762 mm) on
the circumference, this repair is not applicable. Contact
G. Measure the remaining thickness of the damaged area. If the

remaining thickness is less than 0.038 in. (0,97 mm), this
repair does not apply.
V2500 54-30-00 REPAIR 053

Page 204
Feb 1/09
5. Repair of Damaged Graphite Fibers

PPE IS NECESSARY.
A. Estimate the quantity in the weight of CoMat 08-050 Epoxy Paste

Adhesive, EA9390 to patch the damaged area. Add 20% more of the
estimated quantity.
B. Cut, mill or chop 0.031 inch (0,79 mm) long graphite fibers
from the edges of CoMat 01-165 Graphite Fabric. The total
weight of graphite fibers used should be 8%- 14% of the total
weight CoMat 08-050 Epoxy Paste Adhesive, as measured in Step
5.A.
C. Mix CoMat 08-050 Epoxy Paste Adhesive base and catalyst per
D. Mix CoMat 02-165 Graphite fibers into the catalyzed CoMat 08-
050 Epoxy Paste Adhesive until all fibers are fully coated in
adhesive.
E. Apply fiber filled CoMat 08-050 Epoxy Paste Adhesive to fill

damaged area. Overfill to common surrounding area.
F. Remove excess epoxy adhesive by sweeping the area with

appropriate shop aid to minimize sanding.
V2500 54-30-00 REPAIR 053

Page 205
Feb 1/09
G. Cure fiber filled CoMat 08-050 Epoxy Paste adhesive. Refer

H. Sand the repaired area flush to the surrounding area. Use CoMat
05-020 or CoMat 05-081 Waterproof Silicon Carbide Abrasive
Paper.
I. Clean the surface with a Co-Mat 02-099 lint free cloth made
moist with CoMat 01-076 Solvent. Rub the surface clean the
solvent dries.
6. Prepare CoMat 07-160 Ceramic Coating for Application
NOTE: Steps 6 through 8 is optional, subject to local government

restrictions. Refer to General 1.C.

PPE IS NECESSARY.
(22°C).
V2500 54-30-00 REPAIR 053

Page 206
Feb 1/09
NOTE: 1. Shake the CoMat 07-160 Ceramic Coating part A until

fully mixed. All ceramic particles in Part A must be
fully suspended in the resin mixture. Mix with CoMat
07-161 part B.
2. When the CoMat 07-160 Ceramic Coating Part A is

shake for more than 30 minutes at a time, it can
become warm and can cause decreased pot life. Let
the CoMat 07-160 Ceramic Coating Part A to cool to
the ambient temperature before mixing it with CoMat
07-161 Part B. Before you mix with CoMat 07-161 Part
B, shake the CoMat 07-160 Ceramic Coating Part A
again for 4 to 6 minutes.
3. Mix the part A properly to let the CoMat 07-160

Ceramic Coating to perform and cure correctly.
4. It is recommended to use the coating in quantities

of pints or quarts. Use the unmixed coating in 2
years of the date of delivery for best results.
5. Avoid shaking the catalyzed mixture. Shaking can

cause heat to build-up promoting exothermic reaction
to occur reducing pot life.
6. The pot life of mixed CoMat 07-160 Ceramic Coating is

7. Use CoMat 01-438 solvent or CoMat 01-031 acetone if

you must thin the mixture for spraying. Thin only as
necessary. Do not thin more than 5% of the total
volume. If too much thinner is used, it can damaged
the CoMat 07-160 Ceramic Coating and cause it to
improperly bond to the repair surface.
B. Follow the manufacturer’s instruction to mix CoMat 07-160

Ceramic Coating part A with the CoMat 07-161 Part B catalyst.
Mix all part A and the CoMat 07-161 Part B catalyst. Mix all
part A and the CoMat 07-161 Part B manually for one minute.
Mechanically shake the mixture for two to four minutes at 72° F
(22°C).
V2500 54-30-00 REPAIR 053

Page 207
Feb 1/09
C. Put mixed CoMat 07-160 Ceramic Coating into the spray

equipment. Use a standard paint strainer to remove any pieces
or particles in the mixed coating.


PPE IS NECESSARY.
GREATER THAN 85%.
NOTE: Use CoMat 02-097 lint free gloves when you touch the
cleaned repair surface to prevent the contamination.
V2500 54-30-00 REPAIR 053

Page 208
Feb 1/09
A. Spray one coat of CoMat 07-160 Ceramic Coating to a piece of

prepared CoMat 02-321 Aluminum Sheet.
NOTE: 1. Use CoMat 02-088 Nylon Brush or paint roller to apply

CoMat 07-160 Ceramic Coating. The recommended
procedure to apply the CoMat 07-160 Ceramic Coating
is by spraying it with a paint spray gun. Using a
brush or paint roller causes different results in
the thickness of the completed coating.
2. If a paint roller is used to apply the CoMat 07-160

Ceramic Coating, use a short nap roller with a 0.250
in. (6,35 mm) nap thickness.
07-160 Ceramic Coating. Apply more coats as necessary until a
film thickness of 0.006 to 0.008 in. (0,15 to 0,20 mm)is
reached. Record how many coats were applied to get the proper
thickness.
NOTE: 1. If the CoMat 07-160 Ceramic Coating is applied too

thin, the CoMat 07-160 Ceramic Coating will not
give the correct erosion resistance. It is important
to get the correct thickness of 0.006 to 0.008 in.
(0,15 to 0,20 mm).
2. The compressed air source for spray equipment must be

filtered to free moisture.
8. Apply the CoMat 07-160 Ceramic Coating to the Repair Area and
Entire Leading Edge.

NOTE: If the steps 6 through 8 is not done, Steps 9 through 10 is

not necessary.
V2500 54-30-00 REPAIR 053

Page 209
Feb 1/09

PPE IS NECESSARY.
REPAIR SURFACE IS WET OR IF THE RELATIVE HUMIDITY IS MORE
THAN 85%.

A. Apply CoMat 02-178 Masking Tape 1.5 in. (38 mm) away from all
forward edge. This prevents adjacent surfaces from over spray
of CoMat 07-160 Ceramic Coating.
B. Clean the repair area and all forward edge with a CoMat
Clean the surfaces before the solvent dries.
C. Apply the CoMat 07-160 Ceramic Coating by spraying it on the

repair area and all forward edge. Refer to step 7 B to apply the
number of coats necessary to get a 0.006 to 0.008 in. (0,15 to
0,20 mm) thickness.
V2500 54-30-00 REPAIR 053

Page 210
Feb 1/09
NOTE: 1. If the CoMat 07-160 Ceramic Coating is applied too

thin, the CoMat 07-160 Ceramic Coating will not give
the correct erosion resistance. It is important to
get the correct thickness of 0.006 to 0.008 in.
(0,15 to 0,20 mm). The maximum thickness must not
exceed 0.009 in. (0,23 mm). If the maximum thickness
is exceeded, crack in the cured surface can occur.
2. The compressed air source for spray equipment must be

filtered and be free of any moisture and oil.
D. Make sure the correct thickness of the CoMat 07-160 Ceramic

Coating thickness is achieved. Use a wet film thickness gauge.
Do the step 8C as necessary until necessary thickness is
reached. If the coating is applied too thick, remove the
coating while it is still wet. Use CoMat 02-099 lint free cloth
moisten with CoMat 01-438 solvent. Apply the CoMat
07-160 ceramic coating as described in step C. Repeat this step
until necessary coating thickness is achieved.
E. Remove the CoMat 02-178 masking tape 20 minutes after

the last spray of the CoMat 07-160 Ceramic Coating. This will
allow the edge of the coating to feather itself on the
surface of the part.
NOTE: Some pinholes can occur in the coating and are

considered acceptable. A large number of pinholes are
indication that the repair surface was contaminated
before the application of the CoMat 07-160 Ceramic
Coating. Remove the coating in the affected area as
describe in this step and apply the CoMat 07-160 ceramic
Coating again.

hours at the same time temperature and humidity that the
coating was applied. Refer to Figure 203 for cure times and
temperatures. The coating has a finish that is dry to the touch
in 3 hours at 72°F (22°). Record the temperature and relative
humidity when the last coat of the CoMat 07-160 Ceramic Coating
has been applied.
V2500 54-30-00 REPAIR 053

Page 211
Feb 1/09

has been air dried. Fully cure the CoMat 07-160 Ceramic Coating
at a maximum temperature at 120°F (48.8°C) for a minimum of 7
hours. The CoMat 07-160 Ceramic Coating can be cured at the
room temperature of 72°C (22°C) for 12 hours. Refer to Figure
203 for applicable temperatures and cure times.
NOTE: The CoMat 07-160 Ceramic Coating will lose its

application. This will cause the coating to drip and sag
off the repair area. The CoMat 07-160 Ceramic Coating is
very difficult to remove once it has cured. Make sure
the surface is dry to the tough before elevating the
H. Clean the spray equipment in 15 min. after spraying the last

coat of the CoMat 07-160 Ceramic Coating. Fully flush and clean
the spray equipment with CoMat 01-438 Solvent or CoMat 01-0312
acetone.
NOTE: Not applicable if steps 6 thru 8 are not performed.

PPE IS NECESSARY.
V2500 54-30-00 REPAIR 053

Page 212
Feb 1/09
CERAMIC SURFACE CAN ACCEPT THE COMAT 07-098 CLEAR
POLYURETHANE COATING WITHOUT FURTHER PREPARATION.
07-160 CERAMIC COATING. THIS PREVENT CONTAMINATION.

reducer. Refer to the manufacturer’s instruction. Set the mixed
CoMat 07-098 Clear Polyurethane coating aside for 15 minutes.
NOTE: 1. For best results, the CoMat 07-098 Clear

Polyurethane components must be mixed and applied
when the ambient temperature is between 60°F and
95°F (15°C to 35°C).
2. The pot life for CoMat 07-098 Clear Polyurethane is 4

B. Apply one coat of the CoMat Clear Polyurethane coating on CoMat

07-160 Ceramic Coating. Use a CoMat 02-088 Nylon Brush. Make
the CoMat 07-098 Clear Polyurethane overlap on the painted
surface of the part a minimum of 0.25 inch (6,35 mm).
NOTE: 1. Do not use spray equipment to apply a CoMat 07-098

Clear Polyurethane.
2. Use the sample created in step 7 to test the CoMat

07-098 Clear Polyurethane coating prior to applying
to the repair area to make sure that it coats the
CoMat 07-160 Ceramic Coating properly.
C. Air dry CoMat 07-098 Clear Polyurethane coating for 15 minutes

before handling or moving the part. Allow the CoMat 07-098
fully cured 8 hours after it is applied. The CoMat 07-098 Clear
Polyurethane coating can be cured in a drying room at 120°F
(48°C) for 30 minutes.
V2500 54-30-00 REPAIR 053

Page 213
Feb 1/09

cured, do a visual examination. If there are any areas missing
in the CoMat 07-098 Clear Polyurethane coating
re-apply CoMat 07-098 CoMat 07-098 Clear Polyurethane coating
as necessary until the CoMat 07-160 Ceramic Coating is fully
covered.
NOTE: Full cure of the CoMat 07-098 Clear Polyurethane

structurally and functionally acceptable
10. Repair to the CoMat 07-160 Ceramic Coating After the Full Care
NOTE: Not applicable if steps 6 thru 8 are not performed.

PPE IS NECESSARY.
A. Pinholes in the CoMat 07-160 Ceramic Coating.
(1) Use CoMat 05-020 Abrasive Paper to remove contamination

(2) Clean the surface with CoMat 02-099 lint free cloth made
moist with CoMat 01-076 solvent. Rub the surface clean
(3) Apply CoMat 07-160 Ceramic Coating as described in Step 6

through Step 8.
V2500 54-30-00 REPAIR 053

Page 214
Feb 1/09

9.
B. Large area repairs
(1) Remove damaged or contaminated CoMat 07-160 Ceramic

Coating entirely by using CoMat 05-081. Abrasive Paper as
describe in Step 4.
(2) Repair damage as described in Step 5.

9.
A. Do the visual inspection of the repaired area to make sure the

repair was completed in reference to this procedure. If
A. Mark “VRS2343” adjacent to the assembly number if the repair

was performed on the Left Hand Translating Sleeve. Mark
“VRS2344” adjacent to the assembly number if the repair was
performed on the Right Hand Translating Sleeve. Use a CoMat 06-
131 Marking Pen preferably contrasting color.
V2500 54-30-00 REPAIR 053

Page 215
Feb 1/09
Orientation View
Figure 201
V2500 54-30-00 REPAIR 053

Page 216
Feb 1/09
Damage Location
V2500 54-30-00 REPAIR 053

Page 217
Feb 1/09
Damage Location
Figure 202 (Sheet 2of 2)
V2500 54-30-00 REPAIR 053

Page 218
Feb 1/09
CURE SCHEDULE
A TWO PASS FILM OF SIX (6) TO EIGHT (8) MILS (152-203 MICRONS) AIR DRIES TO
A TOUCH-DRY (GEL) FINISH WITHIN THREE (3) HOURS AT 72°F (22°C) AND DRIES TO
A 70% CURE IN TWELVE (12) HOURS. CURE TIMES LENGTHEN AT LOWER TEMPERATURES
AND SHORTEN AT HIGHER TEMPERATURES. SEE CURE PROFILES IN A AND B.
Figure 203
Erosion Resistant Coating Cure Cycle
V2500 54-30-00 REPAIR 053

Page 219
Feb 1/09
V2500 54-30-00 REPAIR 053

Page 220
Feb 1/09
STRUCTURE IDENTIFICATION - MIXED EXHAUST SYSTEM
1. General
A. The mixed exhaust system is made up of the common nozzle

exhaust collector and the engine exhaust cone.
B. The common nozzle exhaust collector accepts the hot and cold
stream gas outflows. These outflows then go out to the
atmosphere through the common nozzle. The nozzle forms a
convergent duct which increases the speed of the mixed gases to
give forward thrust.
C. The engine exhaust cone forms the inner contour of the common
nozzle exhaust collector. It is made of welded titanium alloy
skin, an attachment ring and a closure cone.
D. The mixed exhaust system accepts two gas streams. The first is
the cold stream, which is fan bypass air. The second is the hot
gas stream, which comes from the turbine gas generator.
E. The cold stream exhaust is part of the thrust reverser system.

When the thrust reverser operates, the cold stream and hot
stream outflows are separated and go in different directions.
2. Description
A. Common Nozzle Exhaust Collector
(1) The common nozzle exhaust collector is made up of an inner

duct with four radial struts. These struts support an
outer duct. The unit is installed on the outer rear flange
of the engine turbine case.
(2) The inner duct forms a ring around the core engine outlet
nozzle. The front flange of the duct is used to install
the exhaust collector on the outer rear turbine case
flange.
V2500 54-40-00 Page 1

Feb 1/09
(3) Four support struts, positioned radially around the inner

duct, hold the exhaust collector outer duct assembly. Two
side struts are positioned horizontally, and are riveted,
one on each side, to the inner duct. Each of the struts is
attached to the outer duct by two bolts and captive nuts.
(4) The lower center strut aligns with the vertical

centerline. It is riveted to the inner duct. The strut is
attached to the outer duct by eight bolts with captive
self-locking nuts.
(5) At the t op center position, an upper strut assembly

stradles the inner duct across the vertical centerine. It
is riveted to the inner duct and to the outer duct.
(6) Two fire seals are riveted to the front flanges of the
upper strut assembly. These provide a fireproof and a
pressure bulkhead which stops fan stream pressure leakage
into Zone 3.
(7) The collector outer duct is made up of a conical duct to

which a sheet metal forward fairing is riveted. The
leading edge of the fairing is against the rear of the
cold stream thrust reverser case. The translating cowl
trailing edge overlaps the outer duct leading edge.
(8) A common nozzle fairing is attached to the rear of the

upper support strut and to the inside of the outer duct
along its upper edge. The fairing tapers to a pen nib
profile at its trailing edge. This gives a streamlined
profile for the cold stream air which enters the
collector.
(9) Interface seals provide sealing between the exhaust

collector, thrust reverser and aircraft pylon.
V2500 54-40-00 Page 2

Feb 1/09
1 SEE DETAIL I
2 A
SEE DETAIL V
4
5
SEE DETAIL II
SEE DETAIL III

13512A
Common Nozzle Assembly and Exhaust Cone

V2500 54-40-00 Page 3

Feb 1/09
10 8
DETAIL I
12
11
DETAIL II
13513A

V2500 54-40-00 Page 4

Feb 1/09
13
14
SEE DETAIL IV
15
DETAIL III
16
19
17
18
DETAIL IV
13514A

Figure 1 (Sheet 3 and 5)
V2500 54-40-00 Page 5

Feb 1/09
SEE
20 DETAIL VI
22
DETAIL V
23
21
20
DETAIL VI
TYPICAL
13 PLACES
13515A

V2500 54-40-00 Page 6

Feb 1/09

V2500 54-40-00 Page 7

Feb 1/09

(INCH)
1 OUTER SKIN 0.018 TI-6AL-4V TITANIUM SHEET,
AMS4911
2 INNER SKIN 0.020 TI-6AL-4V TITANIUM SHEET,
AMS4911
3 FIRE SHIELD 0.063 TI-6AL-4V TITANIUM SHEET
AMS4911, ANNEALED
4 FAIRING 2024-0 ALUMINUM ALLOY EXTRU-
SION, QQ-A-200/3
5 CONE 0.040 TI-6AL-2SN-4ZR-2M0 TITANIUM,
AMS4919, DUPLEX ANNEALED
6 SHELF 0.125 TI-6AL-4V TITANIUM SHEET,
AMS4911
7 SKIN 0.050 TI-6AL-4V TITANIUM SHEET,
AMS4911
8 BULKHEAD 0.071 TI-6AL-4V TITANIUM SHEET,
AMS4911
9 INTERCOSTAL 0.071 TI-6AL-4V TITANIUM SHEET,
AMS4911
10 BULKHEAD 0.071 TI-6AL-4V TITANIUM SHEET,
AMS4911
11 FITTING 17-4 PH CASTING, AMS5432
12 SKIN 220-T8511 ALUMINUM ALLOY
EXTRUSION, AMS4162
13 FAIRING 0.040 2024-0 ALUMINIUM SHEET, QQ-A-
250/4
14 SKIN 0.050 TI-6AL-4V TITANIUM SHEET,
AMS4911

V2500 54-40-00 Page 8

Feb 1/09

(INCH)
15 CLOSURE 0.063 TI-6AL-4V TITANIUM SHEET,
AMS4911, ANNEALED
16 STIFFENER 0.063 TI-6AL-4V TITANIUM SHEET,
AMS4911
17 CHANNEL 0.063 TI-6AL-4V TITANIUM SHEET,
AMS4911
18 CHANNEL 0.063 TI-6AL-4V TITANIUM SHEET,
AMS4911
19 ANGLE 0.063 TI-6AL-4V TITANIUM SHEET,
AMS4911
20 RING TI-6AL-2SN-4ZR-2M0 TITANIUM
BAR, AMS4975
21 SKIN 0.040 TI-6AL-2SN-4ZR-2M0 TITANIUM
SHEET, AMS4919 DUPLEX ANNEALED
22 CONE 0.090 TI-6AL-2SN-4ZR-2M0 TITANIUM
SHEET, AMS4919
23 CUP 0.063 TI-6AL-2SN-4ZR-2M0 TITANIUM
SHEET, AMS4919 DUPLEX ANNEALED
24 OUTER SKIN 0.063 2219-0 ALUMINUM SHEET CLAD,
HEAT TREAT 2, AMS4096
25 STRAP 0.063 2219-0 ALUMINUM SHEET CLAD,
HEAT TREAT 2, AMS4096
26 SPLICE 0.063 2219-0 ALUMINUM SHEET CLAD,
HEAT TREAT 2, AMS 4096
27 INNER EXIT, 0.050 CP-TI TYPE 1, COMP B AMS 4901
NOZZLE SERIAL
NO. 1 TO 250

V2500 54-40-00 Page 9

Feb 1/09

(INCH)
28 RING WELDED 1.00 2219-0 ALUMINUM PLATE, HEAT
SERIAL NO. 251 TREAT 2, QQ-A-250/30
AND ON, 5001
AND ON
29 RING, REAR 2219 T352 AL FORGING, AMS4313
EXIT NOZZLE, TYPE 2
SERIAL NO. 1
TO 250

V2500 54-40-00 Page 10

Feb 1/09
COMMON NOZZLE ASSEMBLY (CNA) AND EXHAUST CONE-

ALLOWABLE DAMAGE
1. Introduction
This section contains the allowable damage limits for the sheet metal
structural components of the V2500 Common Nozzle Assembly (CNA) and
exhaust cone. Any damage which is found to be more than the allowable
damage limits should be repaired in accordance with the procedures
found in 54-40-00, Repairs, Page Block 201.
2. Zones
The CNA and the exhaust cone are divided into zones. The zones which
are affected by the different types of allowable damage are
identified in Figure 101 and Table 101.
The information in this section is given in two paragraphs. Paragraph

A gives general information about allowable damage, structure
material, and damage types. Paragraph B gives the allowable damage
limits for the CNA and the Exhaust Cone.
A. General

may be returned to service without repair. Damage
permitted by these data will have no significant effect on
the strength or fatigue life of the structure, which will
still be able to fulfill its design function. The types of
allowable damage permitted are defined and brief
descriptions are given of the cleanup procedures needed to
either prevent damage propagation or improve the
aerodynamic smoothness of the damaged part.
V2500 54-40-00 Page 101

Feb 1/09
(2) Material Types - The basic material used in the

construction of the CNA and the exhaust cone are titanium
and aluminum sheet.
(3) Damage - All damage limits assume that exposed edges do

not extend above the skin contour. Any such damage should
be reworked to remove or feather the extensions. Allowable
damage is classified as either unlimited usage or time
limited.
(a) Unlimited usage damage is defined as minor damage

which does not affect the structural integrity or
functional capability of the component and which needs
no repairs over the aircraft design life.

design life of the component. Therefore, damage must
be permanently repaired no later than the next
maintenance “C” check. The location and size of the
“A” check to make sure that the damage has not grown
beyond the time limited damage allowances.
(4) Damage types - the types of allowable damage permitted on

the thrust reverser components are define below. They
apply only to the parent material and do not include
damage to surface finishes such as paint.
(a) Abrasion - An abrasion is a damage area of any size

which results in a cross sectional area change because
the area was scuffed, rubbed, scraped, or had other
surface erosion. An abrasion usually appears rough and
irregular.

results in a cross sectional area change. It is
usually caused by contact with a relatively sharp
object which produces a continuous, sharp or smooth
channel-like groove in the material.
V2500 54-40-00 Page 102

Feb 1/09

Consider a series of nick in a line to be a gouge.

(e) Crack - A crack is a partial fracture or complete

break in the material and produces a most significant
cross sectional area change. It usually appears as an
irregular line.

(g) Hole - A hole is a complete penetration of the

material.
B. Common Nozzle Assembly (CNA) and Exhaust Cone Structure -

Allowable damage (See Table 101)
The allowable damage zones for the CNA and exhaust cone
structure are:
CN1 - Titanium attach ring.

CN2 - Titanium skin and inner anulus
- Titanium lower strut skin
- Titanium upper strut and fairing skins
- Titanium inner skin of the outer duct assembly
- Titanium outer skin of the outer duct assembly
- Titanium inner skin of the exit nozzle
CN3 - Aluminum (extruded) side struts
CN4 - Aluminum outer skin of exit nozzle
CN5 - Titanium exhaust cone
V2500 54-40-00 Page 103

Feb 1/09
TITANIUM
EXHAUST PLUG
ALUMINUM SKIN (Outer) ZONE CN4
ZONE CN5
TITANIUM SKIN (Inner) ZONE CN2
EXHAUST NOZZLE
ALUMINUM TITANIUM FRAME/SKIN

EXTRUDED UPPER STRUT AND FAIRING
SIDE STRUT ZONE CN2
ZONE CN3 TITANIUM SKIN
OUTER DUCT ASSY
ZONE CN4
TITANIUM FRAME
ZONE CN1 TITANIUM SKIN
INNER ANNULUS
ZONE CN2
TITANIUM SKIN
INNER ANNULUS
ZONE CN2
ALUMINUM
TITANIUM SKIN EXTRUDED
LOWER STRUT SIDE STRUT
ZONE CN2 ZONE CN3
ZONE CN4
ZONE CN2
ZONE CN2
ZONE CN2
ZONE CN1
ZONE CN3
ENG CL
CONECL
ZONE CN5
ZONE CN2
ZONE CN2
ZONE CN2
ZONE CN4 13552A
Common Nozzle Assembly and Exhaust Cone Zones

Figure 103
V2500 54-40-00 Page 104

Feb 1/09
Dent CN2 No face sheet thinning. 2.0 inch Operator
CN4 Crush core acceptable. (50.8 mm) max option -
CN5 No two within 3.0 length prevent
inches (76.2 mm). Min. growth
1.5 inch (38.1 mm) from 0.12 inch (3.05
honeycomb core edge. mm) max. depth.
1.0 inch
(25.4 mm) max.
radius
0.25 inch
(6.35 mm) min.
radius.
Gouge CN1 Surface penetration 1.5 inch Airplane
CN2 only, with radiused (38.1 mm) max. “A”
CN3 width. No core crush length. check
CN4 permitted. No two
CN5 within 3.0 inches 0.1 inch
(76.2 mm). Min. 1.5 (2.54 mm) max
inch (38.1 mm) from width.
honeycomb core edge
0.01 inch
(0.254 mm) max.
depth.
0.05 inch
(1.27 mm) min.
radius.
Unlimited use
Common Nozzle and Exhaust Cone Zones

V2500 54-40-00 Page 105

Feb 1/09
Nick CN1 No two within 2.0 0.75 inch Operator
CN2 inches (50.8 mm). (19.05 mm) max. option -
CN3 Min. 1.5 inch length. Prevent
CN4 (38.1 mm) from growth
CN5 honeycomb core edge. 0.1 inch
(2.54 mm) max.
width.
0.01 inch
(0.254 mm) max.
depth.
Unlimited use
Scratch CN1 Surface penetration 1.5 inch Airplane
CN2 only. No two within (38.1 mm) max. “A” check
CN3 2.0 inches (50.8 mm) length.
CN4 Min. 1.5 inch
CN5 (38.1 mm) from honey- 0.05 inch
comb core edge. (1.27 mm) max.
width.
0.005 inch
(0.0254 mm) max.
depth.
Unlimited use.

V2500 54-40-00 Page 106

Feb 1/09
Disbond CN2 Separated from other 1.75 inch Airplane
voids by fully brazed (44.5 mm) max. “A” check
panel four times the width
void diameter. Voids
on opposite face Unlimited use
sheets not opposed or
overlapped. Max. of
two voids in one ft²
(0.09 m²) of panel.
Min. 1.5 inch (38.1
mm) from honeycomb
core edge.

V2500 54-40-00 Page 107

Feb 1/09
V2500 54-40-00 Page 108

Feb 1/09
GENERAL REPAIR
1. General
given.

DISCARD CHEMICALS.


adhesive mixture.

Page 201
Feb 1/09


mixture is approximately seven hours. Heat
cure time.
B. EA956 Adhesive

DISCARD CHEMICALS.

adhesive mixture.


mixture is approximately 30 minutes. Heat
cure time.

Page 202
Feb 1/09
C. EA934NA Adhesive

DISCARD CHEMICALS.

adhesive mixture.


mixture is approximately 40 minutes at 77ºF
(25ºC). Heat accelerates both the adhesive mixture
gel time and cure time.
D. EA9390 Resin

DISCARD CHEMICALS.

Page 203
Feb 1/09

adhesive mixture.

NOTE: The useful life of a 8.82 ounce (250 gram) mixture

is approximately 120 minutes. Heat accelerates
both the resin mixture gel time and cure time.

Page 204
Feb 1/09

P.O. Box 312
Base Part A
Catalyst L3
Polyvinyl
Chloride
Resin System, Epoxy EA9390 Dexter Hysol Aerospace, Inc.
Base Part A
Catalyst Part B
Ketone

Table 201

Page 205
Feb 1/09

Page 206
Feb 1/09
COMMON NOZZLE ASSEMBLY - LIST OF APPROVED REPAIRS

Limits before you do repairs to acoustic areas of the Common
Nozzle Assembly.

001 COMMON NOZZLE ASSEMBLY PEN NIB FAIRING CRACK REPAIR
(VRS2277) (REF 78-11-11 COMMON NOZZLE ASSEMBLY)
002 COMMON NOZZLE ASSEMBLY EXIT NOZZLE OUTER SKIN -
(VRS2290) EXTERNAL PATCH REPAIR (REF 78-11-11 COMMON NOZZLE
ASSEMBLY)
003 COMMON NOZZLE ASSEMBLY EXIT NOZZLE RIVET REPLACEMENT
(VRS2293) REPAIR (REF 78-11-11 COMMON NOZZLE ASSEMBLY)
004 COMMON NOZZLE ASSEMBLY EXIT NOZZLE OUTER SKIN
(VRS2292) REPLACEMENT REPAIR (REF 78-11-11 COMMON NOZZLE ASSEMBLY)
005 COMMON NOZZLE ASSEMBLY REPLACE THE RIVETS ON THE PEN NIB
(VRS2282) FAIRING (REF 78-11-11 COMMON NOZZLE ASSEMBLY)
006 COMMON NOZZLE ASSEMBLY PEN NIB FAIRING TAIL PIECE
(VRS2299) REPLACEMENT REPAIR (REF 78-11-11 COMMON NOZZLE ASSEMBLY)
007 COMMON NOZZLE ASSEMBLY VECTORED EXIT NOZZLE OUTER SKIN
(VRS2366) FLUSH PATCH REPAIR (REF 78-11-11 COMMON NOZZLE ASSEMBLY)
008 COMMON NOZZLE ASSEMBLY NON-VECTORED EXIT NOZZLE OUTER
(VRS2291) SKIN FLUSH PATCH REPAIR (REF 78-11-11 COMMON NOZZLE
ASSEMBLY)
009 COMMON NOZZLE ASSEMBLY AFT RING BLEND REPAIR
010 COMMON NOZZLE ASSEMBLY RUBBING BLOCK REPAIR
011 OUTER BARREL, OUTER SKIN, METALLIC PATCH REPAIR

Page 201
Feb 1/09

Page 202
Feb 1/09
REPAIR 001
PEN NIB FAIRING CRACK REPAIR
COMMON NOZZLE ASSEMBLY
(VRS2277)
1. General
A. This repair procedure is for the repair of cracks on the Pen Nib
Fairing Skin Panels.
B. This type of damage may be repaired by removal of the damaged

area of Pen Nib Fairing Panel and installation of a titanium
patch with sealant and rivets.
C. The illustrations show repair of cracks located near the pen

nib fairing frame. The repairs are also applicable to other
ares of the pen nib fairing side skins, not including the upper
area of the side skin (Reference Figure 202). If there is
damage that requires repair in the upper area of the skin
(Reference Figure 202), all of the side skin must be replaced
(Ref. SB 78-0129 and CMM 78-11-11 REPAIR 022 VRS2356).
D. This repair can be used on the forward edge and edge of the
skin. Two rows of rivets on three sides of the damage is
required. Mark a cutout for repairs on the forward edge and aft
edge of the skin (Reference Figure 202).
E. This repair is applicable only for side skins that include SB

78-0129. If the Pen Nib Fairing Strap (745-1160) in SB 78-0129
has not been installed and the skin is cracked, this repair is
not applicable. To repair a Pen Nib Fairing side skin that does
not include SB 78-0129, refer to SB 78-0129 and CMM 78-11-11
F. The practices and processes referred to in the procedure by the

TASK number are in the SPPM.
G. The maximum repair area permitted is 36 square in. (914,4

square mm). The maximum length of a crack to be repaired is 6
in. (152,4 mm).
VRS2277
V2500 54-40-00 REPAIR 001

Page 201
Feb 1/09
A. Standard Tools
Drill and Drilling tools

Hole finder
Nylon brush
Rivet installation tools
Standard shop tools
Temporary fasteners

Consumable Index)

CoMat 02-320 Titanium sheet, Ti-6Al-Sn-4Zr-2Mo, .063 in.
CoMat 07-115 I Primer class M (Converter)
CoMat 07-126 Water soluble primer (alternative for CoMat 08-
093)
CoMat 07-127 Water soluble primer (Alternative for CoMat 07-
115)
CoMat 07-128 Water soluble primer (Alternative for CoMat 07-
116)
CoMat 08-032 Primer
CoMat 08-078 Adhesive (Alternative for CoMat 08-021)
CoMat 08-093 I Primer class M (Base)
NOTE: Use alternate materials only when the specified

materials are not available.
V2500 54-40-00 REPAIR 001

Page 202
Feb 1/09
E. Repair Parts

NAS1399C5-3 Rivet, Alternative A/R
NAS1739C5-3 Rivet, Oversized A/R
NAS1398C5-4 Rivet, Alternative A/R
NAS1398C5-5 Rivet/alternative A/R
NAS1097U5 Rivet
NOTE: All rivets are commercially available.
NOTE: Use the alternate or oversized rivets only when

necessary.
PART IDENT MATERIAL

Pen Nib Fairing, Titanium sheet
Assembly
V2500 54-40-00 REPAIR 001

Page 203
Feb 1/09

PPE IS NECESSARY.
CONTAMINATION.
A. Clean the repair area wit CoMat 02-099 lint free cloth made
moist with Comat 01-438 solvent. Rub the surfaces dry before
the solvent evaporates.
B. Do a fluorescent penetrant inspection of the cracked area.

Refer to SPPM TASK 70-23-02-230-501. Make a mark at each crack
end.
C. Use drills and drilling equipment to stop the crack. Drill A

hole between 0.123 in. and 0.150 in. (3,175 and 3,810 mm)
diameter at each end of the crack.
D. Make a mark in the damaged area for the cutout. Make marks a
minimum of 0.250 in. (6,350 mm) past stop drill holes. Make
mark of contour area that will be covered by the patch. make
marks for repair rivet locations (Reference Figure 201).
NOTE: Figure 201 and 202 contain instructions for repair of

damage in the vicinity of the frame.
V2500 54-40-00 REPAIR 001

Page 204
Feb 1/09
NOTE: These instructions are also applicable to other ares of

the Pen Nib Fairing Skin. Refer to Paragraph 1.C and
Figure 201 for exceptions.
NOTE: The length and width of the cutout can be up to 3 in.

(76,2 mm). At least 2 rows of rivets must be installed
all around the damage area.
NOTE: If these conditions cannot be met, the entire skin

segment must be replaced.
E. If necessary, use drills and drilling tools to remove rivets

that are in the marked area. Do not cause damage to the rivet
holes. Remove the burrs.
NOTE: Do not remove all the fasteners that attach the 745-
1160 strap to the structure at the same time.
NOTE: If all the fasteners that attach the 745-1160 strap to

the structure have to be removed to perform the repair,
use at least two temporary fasteners at all times to
prevent the 745-1160 strap from falling.
F. Use a router and routing tools to cut out the damage as marked.
Do not cause damage to the structure below when you rout.
G. Use CoMat 05-128 aluminum oxide abrasive paper to remove the

sharp edges from the drilled holes and edges of the routed
cutout.
V2500 54-40-00 REPAIR 001

Page 205
Feb 1/09
5. Make the Repair Patch (See Figure 201)

PPE IS NECESSARY.
CAUTION: DO NOT SOLVENT CLEAN THE FASTENERS. FASTENERS CAN BE

A. Make a patch from the CoMat 02-230 titanium sheet to agree with
the area marked on the skin for the patch. (Reference paragraph
4.D). Remove burrs.
B. Make the patch the same shape as the contour of the Pen Nib
Skin. The patch must be shaped until it can be held correctly in
place with light finger pressure.
C. Make a mark for each rivet hole on the patch (Reference Figure
201).
NOTE: If the repair patch covers the fasteners identified by

Flag Note 1 (Ref Fig 201 and 202) the fasteners may be
removed but not replaced. Do not make a mark or drill a
hole for this fastener. See Flag Note 1 for details.
V2500 54-40-00 REPAIR 001

Page 206
Feb 1/09
D. Use drills and drilling tools to drill rivet holes into the
patch. Refer to Table 1 for hole diameters. Drill holes in the
patch to align with the holes in the structure. Use temporary
fasteners as needed. Drill new holes as marked. Remove burrs.
E. Use CoMat 05-128 aluminum oxide abrasive paper to make the

edges of the repair area and the patch smooth.
CONTAMINATION.
F. Remove unwanted grinding and sanding material from the repair

area. Clean the repair area and repair patch with a CoMat 02-
099 lint free cloth made moist with CoMat 01-438 solvent. Rub
6. Install the Repair Patch
CONTAMINATION.
V2500 54-40-00 REPAIR 001

Page 207
Feb 1/09
A. Refer to the manufacture’s instructions to mix the

CoMat 08-093 I primer class M (Base), CoMat 07-115 I primer
Class M (Converter) and CoMat 07-116 thinner. Do not use primer
mixture for 30 minutes.
NOTE: The CoMat 08-093 I primer (base) must be used with the CoMat
07-115 I primer (converter) and CoMat 07-116 thinner.
NOTE: The alternate CoMat 07-126 water soluble primer must be used
with alternate CoMat 07-127 water soluble primer and
alternate CoMat 07-128 thinner.
NOTE: Do not mix the two primer systems.
B. Use the manufacturer’s instructions to prepare the

CoMat 08-032 primer. Apply a thin layer of primer to the mating
surfaces of the repair patch and the skin.
C. Let the CoMat 08-032 primer dry at room temperature for one
hour. If the primer causes a chalky surface to show, remove the
chalky surface with a clean CoMat 02-099 lint free cloth.
D. Use drill and drilling equipment to make a countersink filler

from a NSA1097U5 rivet.
E. Use the manufacturer’s instructions to prepare the

CoMat 08-093 sealant. Apply sealant to countersinks in areas
that will be below the patch. put the countersink fillers in
place.
F. Apply a thin layer of CoMat 08-033 sealant to mating surface of

the patch only.
V2500 54-40-00 REPAIR 001

Page 208
Feb 1/09
G. Put the repair patch in position. Use temporary fasteners as

necessary. Wet install the rivets with CoMat 08-093, 07-115 and
07-116 primer mixture.
NOTE: Before you install the fasteners use a depth gage in

each hole to make sure that the correct grip length
fastener will be installed in each hole.
H. Remove unwanted primer and sealant with a CoMat 02-099 lint

free cloth made moist with CoMat 01-438 solvent. Do not let the
solvent go into the joint. Rub the surfaces dry before the
solvent evaporates.
I. Air dry the repair for eight hours at room temperature, not
below 59°F (15°C).
NOTE: It is not necessary to let the primer and sealant fully

cure during repair. The uncured primer and sealant are
structurally and functional acceptable.
A. Examine the completed repair to make sure all requirements of

this repair are done.

V2500 54-40-00 REPAIR 001

Page 209
Feb 1/09
FASTENER HOLE DIAMETER

CR2664-5 0.160 to 0.164 in.
NAS1399C5 (4,06 TO 4,17 MM)
NAS1739C5 0.176 to 0.180 in.
(4,47 to 4,57 MM)
HOLE DIAMETERS
TABLE 1
1. DO NOT REMOVE THE FASTENERS AT THIS LOCATION UNLESS IT IS

DAMAGED. IF YOU REMOVE THE FASTENERS, DO NOT INSTALL A NEW
FASTENER IN THE HOLE. REMOVE THE SHARO EDGES, CLEAN AND TREAT
THE HOLE WITH THE APPLICABLE STEPS THEN FILL THE HOLE WITH
COMAT 08-033 SEALANT. DO NOT DRILL A HOLE AT THIS LOCATION ON
THE REPAIR PATCH. (IT COVERS OVER THIS FASTENER). THIS WILL
BECOME A TRAPPED FASTENER IF IT IS NOT DAMAGED AND THE DOUBLER
COVERS IT.
2. INSTALL AT LEAST TWO ROWS OF FASTENERS BEYOND THE DAMAGE CUT

OUT.
V2500 54-40-00 REPAIR 001

Page 210
Feb 1/09
Pen Nib Fairing Crack Repair

Figure 201
V2500 54-40-00 REPAIR 001

Page 211
Feb 1/09
Pen Nib Fairing Crack Repair

Figure 202
V2500 54-40-00 REPAIR 001

Page 212
Feb 1/09
REPAIR 002
EXIT NOZZLE OUTER SKIN-EXTERNAL PATCH REPAIR
(VRS2290)
1. General
A. The common nozzle assemblies are divided into two groups, non-
vectored and vectored (Figure 78-11-11-990-039-001):
(1) Non-vectored nozzle assembly exit nozzles have a constant

length from top to bottom, are made of
0.050 in. (1,27 mm) thick outer skin, an inner skin, and
an extruded ring at the aft edge.
(2) Vectored nozzle assembly exit nozzles are made of a 0.063

in. (1,60 mm) thick outer skin and have a forged nozzle.
B. This type of damage can be repair by the installation of an

external patch on the damage area. If the damage is a crack, you
must cut out the damage part of the skin. The cutout area of the
damage must not exceed 4 in. (104,6 mm) in length or height.
Minimum distance between isolated damage is 4X the cutout

length. Maximum number of damage incidents allowed for each
outer skin segment is two.
The patch thickness, the rivets and the procedure for

installation of the rivets are different for the vectored and
the non-vectored assemblies. Find the type of configuration of
the damage assembly before you start the repair.
C. The practices and processes referred to in the procedure by the

TASK numbers are in the SPPM.
VRS2290
V2500 54-40-00 REPAIR 002

Page 201
Feb 1/09
A. Standard Tools
Drill and Drilling tools

Grinding and grinding tools
Hole finders
Rivet tools

Consumable Index)

CoMat 01-457
CoMat 02-178 Masking Tape
CoMat 02-216 Aluminum Alloy Sheet, 2219-T81, .050 in.
(alternative for CoMat 02-219)
CoMat 05-126 Scotchbrite
CoMat 07-028 Chromate Conversion Coating (alternative for
CoMat 07-106)
CoMat 07-106 Chromate Conversion Coating 1000 for
Aluminum
CoMat 07-126 Water Soluble Primer (alternative for
CoMat 08-093)
CoMat 07-115)
CoMat 07-116)
CoMat 08-078 Adhesive; alternative for CoMat 08-021
V2500 54-40-00 REPAIR 002

Page 202
Feb 1/09
PART IDENT MATERIAL

Outer skin, exit Non-vectored nozzles:
nozzle 0.050 in. (1,27 mm) thick
2219-T81 clad aluminium
alloy
Vectored nozzles:
0.063 in. (1,60 mm) thick
2219-T62 clad aluminium
alloy
F. Repair Parts
PART NO. PART IDENT

NON-VECTORED ASSEMBLY
CR3524-5-3 Rivet (standard)
NAS9309M-5-3 Rivet (alternative standard)
CR3556-5-3 Rivet (oversized)
CR3556P5-3 Rivet (alternative oversized)

NAS9308M4-2 Rivet (alternative standard)
NAS9311M4-2 Rivet (alternative oversized)

MS20426AD4 Rivet (standard)
MS20426DD4 Rivet (alternative standard)
V2500 54-40-00 REPAIR 002

Page 203
Feb 1/09
PART NO. PART IDENT

NAS1241AD4 Rivet (oversized)
NAS1241DD4 Rivet (alternative oversized)
740-1104-501 Skin, outer
VECTORED ASSEMBLY
MS20470T5 Rivet (standard)


NAS9307M5 Rivet (alternative standard)

740-1131-1 Skin, outer, LH

740-1131-2 Skin, outer, RH
V2500 54-40-00 REPAIR 002

Page 204
Feb 1/09
2. Alternative materials for 740-1104-501:
(a) 2219-T81 aluminum alloy sheet (CoMat 02-216)

0.050 in. (1,27 mm) thick
3. Alternative materials for 740-1131-1 and

740-1131-2:
(a) 2219-T62 aluminum alloy sheet (CoMat 02-219)

0.063 in. (1,60 mm) thick
(b) 2219-T81 aluminum alloy sheet (CoMat 02-245)

0.063 in. (1,60 mm) thick
4. Use the alternative rivets if the specified rivets

are not available.
5. Use the oversize rivets when it is necessary. Use the

alternative oversize rivets when the recommended
oversize rivets are not available.
6. In the non-vectored exit nozzles, the outer skin is

made of three 740-1104-501 assemblies. In the
vectored exit nozzles, the outer skin is made of
left and right halves, 740-1131-1 and 740-1131-2.
7. The thickness of the vectored nozzle is not constant

along the aft edge circumference. You must find the
thickness along the length of the patch to get the
correct grip length rivets.
8. On the vectored nozzle assembly, use only protruding

head rivets for this repair. Do not use countersink
rivets. Use countersink fillers as required for
original rivet locations.
V2500 54-40-00 REPAIR 002

Page 205
Feb 1/09
4. Prepare the Damaged Area for Repair

PPE IS NECESSARY.
CONTAMINATION.
A. Use a CoMat 02-099 lint free cloth made moist with

CoMat 01-438 solvent. Rub the surfaces clean before the solvent
becomes dry.
B. Do a fluorescent penetrant inspection to check for cracks.

Refer to SPPM TASK 70-23-02-230-501. Make a mark at each crack
end.
CAUTION: THE EXIT NOZZLE IN VECTORED ASSEMBLIES IS A FORGED

PART WHICH HAS RADICALLY LOCATED RISERS THAT ARE
CLOSE TO THE OUTER SKIN. WHEN YOU DRILL THROUGH THE
OUTER SKIN, YOU MUST USE A DRILL STOP TO PREVENT
DAMAGE TO THE RISERS.
C. Use a CoMat 06-131 marking pen to mark the cutout area. For the
shape and location of the cutout, refer to the applicable
figure.
NOTE: One cutout can be used for damage in two or more

adjacent areas.
V2500 54-40-00 REPAIR 002

Page 206
Feb 1/09
D. Use a CoMat 06-131 marking pen to make a mark for the patch. For
the shape and location of the patch, refer to the applicable
figure.
NOTE: One patch can be used to repair the damage in two or more
adjacent areas.
CAUTION: THE EXIT NOZZLE IN VECTORED ASSEMBLIES IS A FORGED PART

WHICH HAS RADICALLY LOCATED RISERS THAT ARE CLOSE TO THE
OUTER SKIN. WHEN YOU DRILL THROUGH THE OUTER SKIN, YOU
MUST USE A DRILL STOP TO PREVENT DAMAGE TO THE RISERS.
E. Use drills and drilling tools to remove the rivets in the

marked area. Remove at least 2 rivets on both sides of cut out
area. Drill the manufactured head side of the rivets. Do not
make the rivet holes larger. Remove the burrs.
NOTE: 1. In the non-vectored assemblies, the rivet holes along

the aft edge of the exit nozzle assembly are vertical
to the internal surface.
2. In the vectored assemblies, the rivet holes are

vertical to the external surface.
CAUTION: DO NOT DAMAGE OR CUT THE ADJACENT STRUCTURE.
F. Use routers and routing tools. Remove the damaged area. Keep a
minimum 0.50 in. (12,7 mm) radius in corners of cut out. Remove
the burrs.
G. Examine the repair area. Visually examine the repair area to

make sure that all the damage is removed.
H. Use CoMat 05-074 aluminum oxide abrasive paper to remove the

sharp edges.
I. Use dry compressed air or a vacuum to remove unwanted material.

Use a CoMat 02-099 lint free cloth made moist with CoMat 01-438
solvent. Rub the surfaces clean before the solvent becomes dry.
V2500 54-40-00 REPAIR 002

Page 207
Feb 1/09
5. Make the External Patch

PPE IS NECESSARY.
A. Make a patch from the applicable repair aluminum sheet. Chamfer

the edges 0.03 in. X 45º (0,8 mm x 45º) all around. remove the
burrs.
NOTE: As an alternative, you can make the patch from a spare

outer skin (Part Number 740-1104-501 for
non-vectored, 740-1131-1 or 740-1131-2 for vectored).
B. Make filler from the applicable repair aluminum sheet. Filler

is only required if the cutout is over the FWD attach strap or
over the AFT ring. It must be made to fill the area over the FWD
attach strap or AFT ring. The space between the edges of the
cutout and the filler must not be more than 0.50 in. all around.
Keep a minimum edge distance of 2D on rivet locations in
fillers. Make the edges smooth.
NOTE: As an alternative, you can make the filter from a spare

outer skin (Part Number 740-1104-501 for
non-vectored, 740-1131-1 or 740-1131-2 for vectored).
C. Shape the patch to align with the contour of the outer skin in
the repair area. The repair patch must fit the contour of the
outer skin with light finger pressure.
V2500 54-40-00 REPAIR 002

Page 208
Feb 1/09
D. Use a hole finder to make a mark for the rivet holes on the
patch and filler, if used. Refer to the applicable figure for
the recommended distance between the rivets.
NOTE: An alternative procedure can be used to put the rivet

hole pattern on the patch.
CAUTION: THE EXIT NOZZLE IN VECTORED ASSEMBLIES IS A FORGED PART

WHICH HAS RADICALLY LOCATED RISERS THAT ARE CLOSE TO
THE OUTER SKIN. WHEN YOU DRILL THROUGH THE OUTER SKIN,
YOU MUST USE A DRILL STOP TO PREVENT DAMAGE TO THE
RISERS.
E. Use drills and drilling equipment to drill applicable diameter

holes at the marked locations on the patch (and filler, if
used) and on the outer skin. Match drill holes in existing
locations, where applicable. Use temporary fasteners as
required to keep the holes aligned. When you match drill to the
existing holes along the aft edge, drill as follows: Drill non-
vectored assemblies perpendicular to the inner side. Drill
vectored assemblies perpendicular to the outer side. Refer to
Figure 78-11-11-990-039-006 for rivet hole sizes. Remove the
burrs.
F. Use drills and drilling tools. Countersink the holes on the

external surface of the patch. Refer to
Figure 78-11-11-990-039-006 for countersink diameters. Remove
the burrs.
NOTE: If you used protruding head rivets, do not countersink

the holes.
G. Repair the damaged rivet holes. Use drills and drilling tools.
Make the damaged rivet holes larger for use with applicable
oversize rivets. Remove the burrs.
H. Use CoMat 05-074 aluminum oxide abrasive paper to remove all

sharp edges from the repair area.
V2500 54-40-00 REPAIR 002

Page 209
Feb 1/09
6. Install the Patch, (See Figure 201 and Figure 202)
CONTAMINATION.
2. DO NOT SOLVENT CLEAN THE RIVETS. SOME RIVETS CAN BE

LUBRICATED. THE LUBRICANT MUST NOT BE REMOVED.
A. Use a CoMat 02-099 lint-free cloth made moist with

CoMat 01-438 solvent. Rub the surfaces clean before the solvent
becomes dry.
B. Do a water break free test of the bare surfaces in the repair

area.
C. Use a CoMat 02-099 lint-free cloth mae moist with

CoMat 01-438 solvent to clean the test area. Rub the surfaces
D. Use a nylon brush or a CoMat 02-099 lint-free cloth. Apply the

CoMat 07-106 chromate conversion coating to the repair
surfaces. Do not let the solution become dry on the surfaces.
Keep the surfaces wet with clean solution for two to five
minutes.
E. Flush the surfaces fully with demineralized water. Air dry for
30 minutes. The surfaces must be without color.
NOTE: It is acceptable to use the alternative CoMat 07-028

chromate conversion coating on the repair surfaces but
because the alternative CoMat 07-028 chromate
conversion coating is not colorless it will give the
surfaces a golden color. Its use is not recommended.
V2500 54-40-00 REPAIR 002

Page 210
Feb 1/09
F. Use the manufacturer’s instructions to mix the CoMat 08-093 I

primer class M, the CoMat 07-115 I primer class M, and the CoMat
07-116 thinner. Do not use the mixture for 30 minutes.
NOTE: 1. The CoMat 08-093 primer must be used with the CoMat
07-115 primer and the CoMat 07-116 thinner.
2. The alternative CoMat 07-126 water soluble primer

must be used with the CoMat 07-127 water soluble
primer and the CoMat 07-128 thinner.
3. Do not mix the two primer systems.
G. Apply the primer mixture to the applicable repair surfaces.
H. Use an explosion proof heat lamp. Cure the primer for one hour
to between 190º and 210ºF (88º and 99ºC)
7. Install the External Patch

NECESSARY.
CONTAMINATION.
V2500 54-40-00 REPAIR 002

Page 211
Feb 1/09
A. Prepare the adhesive. Use the manufacturer’s instructions to

mix the CoMat 08-078 adhesive.
B. Use rivet tools. Apply a thin layer of the CoMat 08-078

adhesive to the mating surfaces of the patch, to the filler (if
necessary), and to the mating surface of the outer skin. Put
the repair parts in position and align the rivet holes. Use
temporary fasteners to keep the holes aligned. Wet install the
rivets with the adhesives.
NOTE: 1. If the patch covers existing countersinks, apply a

thin layer of the adhesive to the countersink. Make
a metallic countersink filler from an applicable
dimension flush head rivet. Install the countersink
filler in the countersink before you install the
patch. To make a countersink filler, drill the
applicable diameter hole through the rivet head and
cut off the shank. The hole must be in line with the
rivet hole. Cut as necessary.
2. For the non-vectored assemblies, install the rivets

along the aft edge of the outer skin with the
manufactured head on the internal surface.
3. For the vectored assemblies, install the rivets

with the manufactured head on the external surface.
4. The upset head must be milled flush from 0.000 to

+0.005 in. (0,0 to +0,13 mm). Do not damage the
parent material.
5. Fill missing areas along the edges with CoMat 08-

078 adhesive mixture before you install the patch.
(See the applicable figure).
6. The primer mixture can be used as an alternative to

wet install the rivets.
C. Use a CoMat 02-099 lint free cloth made moist with

CoMat 01-438 solvent. Do not get solvent in the joints.
V2500 54-40-00 REPAIR 002

Page 212
Feb 1/09
D. Use an explosion proof heat lamp. Cure the adhesive for one
hour to between 190º and 210ºF (88º and 99ºC).
NOTE: It is not necessary to let the adhesive fully cure

under repair conditions. The uncured adhesive is
A. Examine the completed repair to make sure that the requirements

of this repair are done.
A. Make a mark VRS2290 adjacent to the assembly number. Use CoMat

06-131 marking pen of a color that contrast.
V2500 54-40-00 REPAIR 002

Page 213
Feb 1/09
Common Nozzle Assembly - Exit Nozzle Outer Skin External Patch Repair
Figure 201
V2500 54-40-00 REPAIR 002

Page 214
Feb 1/09
Figure 202
V2500 54-40-00 REPAIR 002

Page 215
Feb 1/09
Common Nozzle Assembly - Exit Nozzle Outer Skin External patch Repair
Figure 203
V2500 54-40-00 REPAIR 002

Page 216
Feb 1/09
Figure 204
V2500 54-40-00 REPAIR 002

Page 217
Feb 1/09
Figure 205
V2500 54-40-00 REPAIR 002

Page 218
Feb 1/09
FASTENER HOLE DIAMETER COUNTERSINK DIAMETER

CR3524-4 0.129 TO 0.132 100º
NAS9309M4 (3.28 TO 3.35 mm) 0.189 TO 0.195 in.
(4.80 TO 4.95 mm)
CR3552-4 0.143 TO 0.146 in. 100º
NAS9311MM4 (3.63 TO 3.70 mm) 0.221 TO 0.229 in.
(5.61 TO 5.81 mm)
CR3524-5 0.160 TO 0.164 in. 100º
NAS9309M5 (4.06 TO 4.17 mm) 0.239 TO 0.247 in.
(6.07 TO 6.27 mm)
CR3553-5 0.176 TO 0.180 in. N/A
NAS9310M5 (4.46 TO 4.57 mm)
CR3556-5 0.176 TO 0.180 in. 120º
CR3556P-5 (4.47 TO 4.57 mm) 0.310 TO 0.318 in.
(7.8 TO 8.07 mm)
MS20426AD4 0.129 TO 0.132 in. 100º
MS20426DD4 (3.28 TO 3.35 mm) 0.221 TO 0.229 in.
(5.61 TO 5.81 mm)
NAS1097U5 0.160 TO 0.164 in. 100º
NAS9314T5 (4.06 TO 4.17 mm) 0.239 TO 0.247 in.
(6.07 TO 6.27 mm)
MS20470T5 0.160 TO 0.164 in. N/A
(4.06 TO 4.17 mm)
NAS1241AD4 0.176 TO 0.180 in. N/A
NAS1241DD4 (4.47 TO 4.57 mm)
NOTE: 1. ALL FIGURE/ITEM NUMBERS REFER TO THE IPL 78-11-11,

UNLESS IDENTIFED DIFFERENTLY.
2. NOT TO SCALE
3. A FILLER IS ONLY REQUIRED IF THE CUTOUT IS OVER THE FWD
ATTACH STRAP OR OVER THE AFT RING. IT CAN BE MADE TO
FILL THE AREA OVER THE FWD ATTACH STRAP OR AFT RING.
MAINTAIN MINIMUM EDGE DISTANCE OF 2D ON FILLERS.
Exit Nozzle Skin Replacement Repair, Common Nozzle Assembly

Figure 206
V2500 54-40-00 REPAIR 002

Page 219
Feb 1/09
V2500 54-40-00 REPAIR 002

Page 220
Feb 1/09
REPAIR 003
EXIT NOZZLE ASSEMBLY
EXIT NOZZLE RIVET REPLACEMENT REPAIR
(VRS2293)
1. General
A. The common nozzle assemblies are divided into two groups. In

the assemblies with a non-vectored nozzle assembly, the exit
nozzle has a constant length from top to bottom. The exit
nozzle is made of a 0.050 in. (1,27 mm) thick outer skin, an
internal skin, and an extruded ring at the aft edge. In the
common nozzle assemblies with a vectored nozzle assembly, the
exit nozzle is longer at the top and shorter at the bottom. This
exit nozzle is made of a 0.063 in. (1,60 mm) thick external skin
and a forged nozzle.
B. Rivets with “*” shall be used only on the forward edge of the
outer skin segment of the Exit Nozzle. Refer to Figure 204.

Hand punch
Hole finder
Nylon brush
Palette knife
Riveting Equipment
V2500 54-40-00 REPAIR 003

Page 201
Feb 1/09

Consumable Index)
CoMat 01-076 Methylethylketone; Alternate for

CoMat 01-438
CoMat 05-074 Aluminium oxide abrasive paper
CoMat 05-126 Scotchbrite
CoMat 06-028 Chromate conversion coating (Alternative for
CoMat 07-106)
CoMat 07-106 Chromate conversion coating 1000 for alumin-
ium
CoMat 07-126 Water soluble primer; Alternative for
CoMat 08-093
CoMat 07-115
CoMat 07-116
CoMat 08-032 Primer
V2500 54-40-00 REPAIR 003

Page 202
Feb 1/09
Repair Parts
PART NO. PART IDENT

Non-Vectored Assembly
NAS9311M-5-3 Rivet (alternative oversized)

CR3556P5-2 Rivet (alternative oversized)
CR3524-6-2 * Rivet Standard
CR3524P-6-2 * Rivet (alternative standard)
NAS9309M-6-2 * Rivet (alternative standard)


MS20426AD4 Rivet (standard)

MS20426DD4 Rivet (alternative standard)
NAS1241AD4 Rivet (oversized)
NAS1241DD4 Rivet (alternative oversized)
V2500 54-40-00 REPAIR 003

Page 203
Feb 1/09
PART NO. PART IDENT

Vectored Assembly
CR3556P-5-3 Rivet (alternative oversized)
CR3524-6-3 * Rivet (standard)
NAS9309M-6-3 * Rivet (alternative standard)
CR3524P-6-3 * Rivet (alternative standard)
NAS1097U5-5 Rivet (standard)

NAS9314T5-5 Rivet (alternative standard)

CR3556P-5-3 Rivet (alternative oversized)

NOTE: 1. Use alternative rivets only when the specified rivets

are not available.
2. Use the oversized rivets only when necessary. Use the

alternative oversized rivets only when the specified
oversize rivets are not available.
3. Whenever a larger rivet than the original is to be

used. the distance from the edge of the part to the
center of the hole must be no less than 2D. Where “D”
is the diameter of the rivet hole.
4. Fasteners with “*” at the end of part number shall be

used, if applicable, only to replace loose or missing
rivet and damaged hole on the forward edge of the outer
skin segment of the Exit Nozzle. Refer to Figure 204.
V2500 54-40-00 REPAIR 003

Page 204
Feb 1/09
4. Prepare the Damaged Area for Repair

PPE IS NECESSARY.
CONTAMINATION.
A. Use a CoMat 02-099 lint free cloth made moist with CoMat
01-438 solvent. Rub the surfaces clean before the solvent
becomes dry.
CAUTION: DO NOT REMOVE A LARGE NUMBER OF DAMAGED RIVETS OR LOOSE AT

ONE TIME. THE REMOVAL OF A LARGE NUMBER OF RIVETS CAN
CHANGE THE ALIGNMENT OF THE ASSEMBLY.
B. Use drills and drilling tools. Remove the damaged or loose

rivets. Drill the rivets from the manufacturer head side.
Remove the burrs.
NOTE: 1. For non-vectored assemblies, the rivet holes along

the aft edge of the exit nozzle assembly are
perpendicular to the inner surface.
2. For vectored assemblies, the rivet holes along the

aft edge of the exit nozzle assembly are
perpendicular to the outer surface.
V2500 54-40-00 REPAIR 003

Page 205
Feb 1/09
C. Use the drills and drilling tools. If necessary, make the

damaged rivet holes larger for use with the applicable oversize
diameter rivets. Refer to Table 1 for hole sizes. remove the
burrs.
NOTE: Whenever a larger rivet than the original is to be used,

the distance from the edge of the part to the center of
the hole must be no less than 2D. Where “D” is the
diameter of the rivet hole.
D. Countersunk the holes. Use the drills and drilling tools. If

the rivet holes were made larger, countersink the holes as
necessary. Refer to Table 1 for the countersink diameters.
Remove the burrs.
E. Examine the repair area to make sure that all the damaged or
loose rivets have been removed. Make sure that the remaining
structure is not damaged.
F. Remove all sharp edges. Use CoMat 05-074 aluminum oxide

abrasive paper to remove all sharp edges.
V2500 54-40-00 REPAIR 003

Page 206
Feb 1/09
5. Prepare the Repair Area for Rivet Installation

EMPLOYER ON WHICH PPE IS NECESSARY
CAUTION: 1. DO NOT SOLVENT CLEAN THE FASTENERS. SOME FASTENERS

CAN BE LUBRICATED. THE LUBRICANT MUST NOT BE REMOVED.
2. USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH THE
CONTAMINATION.
A. Remove the grinding and drilling material from the repair

area. Clean the repair area with a CoMat 02-099 lint free cloth
B. Do a water break test on the bare surfaces of the repair area.

refer to section 54-02-00.
moist with CoMat 01-438 solvent. Rub the surfaces clean before
D. Use a nylon brush or CoMat 02-099 lint free cloth. Apply the
CoMat 07-106 chromate conversion coating to the cleaned, bare
aluminum surfaces. Do not let the solution becomes dry on the
surfaces. Keep the surfaces wet with a clean solution for 2 to
5 minutes.
V2500 54-40-00 REPAIR 003

Page 207
Feb 1/09
E. Flush the surfaces. Flush the surfaces fully with demineralized

water. Air dry for 30 minutes. The surfaces must be without
color.
NOTE: It is acceptable to use the alternative CoMat 07-028

chromate conversion coating on the internal and
external surfaces. But because the alternative CoMat
07-028 chromate conversion coating is not colorless it
will give the surface a golden color. Its use on the
external surface is not recommended.
F. It is acceptable to use the alternative CoMat 07-028 chromate

conversion coating on the internal and external surfaces. But
because the alternative CoMat 07-028/ chromate conversion
coating is not colorless it will give the surface a golden
color. It’s use on the external surface is not recommended.
6. Install the Patch, (See Figure 201 and Figure 202)

CAUTION: 1. DO NOT SOLVENT CLEAN THE FASTENERS. SOME FASTENERS

CAN BE LUBRICATED. THE LUBRICANT MUST BE REMOVED.
2. USE COMAT 02-097 LINT FREE GLOVES WHEN YOU TOUCH

THE CLEANED OR PREPARED SURFACES. THIS PREVENTS
CONTAMINATION.
V2500 54-40-00 REPAIR 003

Page 208
Feb 1/09
A. Use the manufacturer’s instructions to prepare the CoMat

08-078 adhesive.
B. As an alternative for the CoMat 08-078 adhesive, refer to

manufactures’s instructions to mix the CoMat 08-093 I primer
class M and the CoMat 07-116 thinner. Do not use the primer
mixture for 30 minutes.
NOTE: 1. The CoMat 08-093 I primer class must be used with

the CoMat 07-115 I primer class M and the CoMat
07-116 thinner.
2. The alternative CoMat 07-126 water soluble primer

must be used with alternative CoMat 07-127 water
soluble primer and the alternative CoMat 07-128
water soluble thinner.
3. Do not mix the two primers.
C. Install the rivets. Use rivet tools. Align the rivet holes. Use
temporary fasteners to keep the rivet holes aligned. Wet
install the fasteners with CoMat 08-078 adhesive.
NOTE: 1. For non-vectored assemblies, install the rivets

along the aft edge of the outer skin with the

Goodrich SRM

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Goodrich SRM

Uploaded by

Copyright:

Available Formats

850 LAGOON DRIVE

CHULA VISTA CALIFORNIA 91910-2098 TEL: (619) 691-4111•TELEX:69-5038

SUBJECT: V2500 Nacelle Structural Repair Manual Publication Reference:

The subject manual revision is being transmitted.

Questions or comments concerning this publication should be

Printing and distribution and requirement changes should be directed to

TO: V2500 Structural Repair Manual Distribution

CONCERNING: Revision 1, Dated Aug. 1, 2009

MANUAL UPDATE INSTRUCTIONS

An * (asterisk) in front of an entry on the List of Effective Pages show

An (N) in front of an entry on the List of Effective Pages show a new

An (D) in front of an entry on the List of Effective Pages show a

Chapter/Section/Subject Page Number Description of Change

Title -- Revised text.

Record of Revisions 1 - 2 Revised text.

List of Effective Pages 1 - 30 Revised text.

Structure Identification 1-94 Revise Illustration.

Allowable Damage 101-154 Correct Figure reference

V2500 54- TRANSMITTAL LETTER

Chapter/Section/Subject Page Number Description of Change

Repair 31 201-209 Added alternate CoMat,

Repair 32 201-228 Revised to correct

Repair 33 201-232 Revised to correct

Repair 48 201-208 Revised to address

V2500 54- TRANSMITTAL LETTER

THE CONTENTS OF THIS STRUCTURAL REPAIR

FAA APPROVAL NOTICE

Goodrich Aerostructures Proprietary Information

Caution Regarding Use of Materials:

Revision 1: Aug 1/09

THIS PAGE INTENTIONALLY LEFT BLANK

REVISION REVISION REVISION

V2500 54- RECORD OF REVISIONS

THIS PAGE INTENTIONALLY LEFT BLANK

V2500 54- RECORD OF REVISIONS

RECORD OF TEMPORARY REVISIONS

ISSUE DATE ISSUE DATE

RETAIN THIS RECORD IN THE FRONT OF MANUAL. UPON RECEIPT OF REVISION,

V2500 54- TEMPORARY REVISIONS

THIS PAGE INTENTIONALLY LEFT BLANK

V2500 54- TEMPORARY REVISIONS

SERVICE BULLETIN LIST

SERVICE DATE BULLETIN

V2500 54- SERVICE BULLETIN LIST

THIS PAGE INTENTIONALLY LEFT BLANK

V2500 54- SERVICE BULLETIN LIST

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

Title Page *1 Aug 1/09 Table of 1 Feb 1/09

* Indicates revised page

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

* Indicates revised page

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

* Indicates revised page

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

* Indicates revised page

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

* Indicates revised page

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE