DG Flugzeugbau DG-1000 Repair Manual
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Also See for DG-1000:
- Flight manual (130 pages) ,
- Maintenance manual (152 pages) ,
- Flight manual (138 pages)
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FLUGZEUGBAU GMBH
F O R S A I L P L A N E S A N D M O T O R G L I D E R S
T Y P E :
V A R I A N T :
T C D a t a S h e e t N o . : E A S A . A . 0 7 2
I s s u e d :
O w n e r :
S e r . N o . :
R e g i s t r a t i o n :
Copyright DG Flugzeugbau GmbH any copy or publishing prohibited
DG Flugzeugbau
Otto Lilienthalweg 2
76646 Bruchsal
www.dg-flugzeugbau.de
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Telefon (07251) 3020-0
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Table of Contents
Related Manuals for DG Flugzeugbau DG-1000
Summary of Contents for DG Flugzeugbau DG-1000
- Page 1 S e r . N o . : I d e n t - N r : R e g i s t r a t i o n : Copyright DG Flugzeugbau GmbH any copy or publishing prohibited DG Flugzeugbau Otto Lilienthalweg 2...
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Page 2: General
DG-1000M, new standardized format 2.1, 4.1 – 4.3, 5.1, Miscellaneous changes to the contents December 5.3, 6.3 of the latest amendments of the initial 2010 repair manuals Issued December 2010 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited... - Page 3 0.0 December 10 " " " 1.1 December 10 2.1 December 10 3.1 December 10 4.1 December 10 " " 5.1 December 10 " " December 10 " " Issued December 2010 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited...
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Page 4: Table Of Contents
Repairing small dents in a sandwich panel skin (no cracks in the gelcoat) ........................5.2 Outer skin finish..................5.3 Repairing control surfaces ............... 5.3 Engine bay insulation................5.3 Types of materials and overlap dimensions..........6.1 Issued December 2010 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited... -
Page 5: Preface
When doubts arise as to the repairability of damage, the DG Flugzeugbau factory should be contacted for further information. The information in this manual refers only to repairs of minor damage like holes in the underside of the fuselage resulting from a wheel up landing, or damage from hangar accidents etc, see section 2. -
Page 6: Repairs Of Composite Structures, General
Caution: Damaged fittings should not be repaired but must be replaced. Note: Special hints for handling FRP repairs are found in the Petite Plane Patch Primer (Author U. Hänle). Issued December 2010 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited... -
Page 7: Tools And Facilities Required
12 hours afterwards should be maintained at 21°C (70° F). After that the repaired parts are to be tempered. Therefore you may construct a tempering tent, using plastic film or Styrofoam plates. Issued December 2010 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited... -
Page 8: Material List For Frp Repairs
C. Cramer style 14 K (158 g/m²) (as core in the ailerons of the outboard wings and in the trailing edges of the stabilizer and the wings in the aileron region) Issued December 2010 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited... -
Page 9: Carbonfibre Fabric
(available in the USA) Simtec Prestec 2781 Super White Polyester Coating with catalyst D MEKP UN3105 mixing ratio: 100:2, no thinner PUR paint if such paint was optionally applied. Issued December 2010 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited... -
Page 10: Glue For Plexiglas
+ hardener. Application and mixing is the same as for the cotton flocks. 4.13 Sources for material All materials can be obtained from the DG Flugzeugbau Factory. Issued December 2010 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited... -
Page 11: Instructions For Frp Repairs
Heat the area around the hole to approx. 60°C (140°F). Then tap the outer skin with a round headed hammer so that the foam is somewhat compressed. Apply the new cloth. Issued December 2010 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited... -
Page 12: Repair Of Outer And Inner Skin Of A Sandwich Panel
Final sanding with wet sandpaper grade 600 should finish the job. In more severe cases, one coat of gelcoat will remove all trace of the dent. Issued December 2010 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited... -
Page 13: Outer Skin Finish
DG-1000M: „Pyroplast-ST 120 top“. Let dry for another 24 hours at min. 20°C. Only DG-1000M: Apply aluminium tape (Tesametall 4504, 100 mm wide) to cover the repaired area. Issued December 2010 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited... -
Page 14: Types Of Materials And Overlap Dimensions
Inner skin 0,8 1x200g/m² carbonfibre M40J d Ailerons outboard wings Exterior skin 0,8 1x90070l +1x205g/m² carbonfibre d Core 1xDiolen fabric 158g/m²l Inner skin 0,8 1x205g/m² carbonfibre d Issued December 2010 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited... - Page 15 + 1x92145 l up to 600mm above fuselage centre line Fuselage front part from outside to inside 3.35 1x92110 d 1x92145 l 1x92125 d 1x92140 d 1x92145 l 1x92140 d 1x92145 l Issued December 2010 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited...
- Page 16 Caution: There are several other reinforcements in the fuselage-fin intersection and near the top of the fin and at the engine bay components. Issued December 2010 Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited...