Outer Skin Finish; Repairing Control Surfaces; Engine Bay Insulation - DG Flugzeugbau DG-1000 Repair Manual

5.7 Outer skin finish

Repairs should be such that the area is exactly level or only slightly higher
than the surrounding skin surfaces. Sand the hardened repair surface with
dry grade 80 sandpaper. Fill with Polyesterfiller, let dry and sand with dry
sandpaper. When the surface is smooth, sand the repair area and at least 5
cm (2 in.) of the surrounding gelcoat with wet sandpaper grade 400. Spray
the repair area with UP gelcoat.
After the gelcoat has hardened, sand with grade 400, 600 and 800 and
eventually 1000 wet sandpaper until the surface is smooth.
Note: In case of Polyurethane painting, the PU paint will be sprayed onto the
UP gelcoat surface after sanding with grade 600. When hardened continue
sanding with grade 800 and 1000.
Polish with a power buffer (electric drill or similar with cloth polishing
wheel). Apply a block of wax onto the rotating polishing wheel and then
polish the repaired area. Do not polish in only one direction, and do not
polish one spot for too long so that overheating occurs, see sect. "general
maintenance" in the maintenance manual.

5.8 Repairing control surfaces

After the repair the mass balance must be checked again with the values
given in the maintenance manual. Should the maximum values be
exceeded, then the parts have to be replaced.

5.9 Engine bay insulation

Damaged fire resistant paint must be removed and repaired:
2 coats of „Pyroplast ST 100" must be applied. The paint must dry for 24
hours at min. 20°C after each coat has been applied.
Then apply one coat of top coat:
DG-1000T: „Icosit PUR Color" (Mixing ratio 92:8 by weight).
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
Repair manual DG-1000
5.3