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DG Flugzeugbau GmbH
Otto-Lilienthal-Weg 2 / Am Flugplatz • • • • D-76646 Bruchsal • • • • Germany
Postbox 1480, D-76604 Bruchsal • • • • Germany
Tel. 07251 3020-100 • • • • Telefax 07251 3020-200 • • • • eMail: dg@dg-flugzeugbau.de
Spare part and material sales: Tel. 07251 3020-270 • • • • lager@dg-flugzeugbau.de
www.dg-flugzeugbau.de
R E P A I R M A N U A L
f o r t h e
M O T O R G L I D E R
DG – 400
German Data Sheet No. 826
Issued: November 1982
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Summary of Contents for DG Flugzeugbau DG-400
- Page 1 DG Flugzeugbau GmbH Otto-Lilienthal-Weg 2 / Am Flugplatz • • • • D-76646 Bruchsal • • • • Germany Postbox 1480, D-76604 Bruchsal • • • • Germany Tel. 07251 3020-100 • • • • Telefax 07251 3020-200 • • • • eMail: dg@dg-flugzeugbau.de Spare part and material sales: Tel.
- Page 2 Repair manual DG-400 No. Page Description Date Signature Material list for FRP repairs May 83 10,11, Jan. 84 5, 9, 4/6 english dimensions July 84 TN 826 / 10 additional resin sytem Jan. 85 9, 11 english dimensions May 85...
- Page 3 Repair manual DG-400 content page issued List of contents Febr. 87 1. Preface Jan. 84 2. Definition of minor damage ʺ ʺ 3. Tools and facilities required ʺ ʺ 4. Material list for F R P repairs Febr. 87 Material list for F R P repairs ʺ...
- Page 4 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.
- Page 5 Repair manual DG-400 2. Definition of minor damage Only the below listed damage can be considered as minor damage repaired by oneself. 1. Any damage limited to gelcoat or filler. 2. Holes in the fuselage underside where the average diameter does not...
- Page 6 Repair manual DG-400 3. Tools and facilities required Tools - Accurate scale for the correct mixing of resin and hardener - Containers and wood mixing sticks - Brushes (short hair) to apply the resin - Metal roller to press down the glass cloth and to force the air out to reduce...
- Page 7 Repair manual DG-400 . Material list for FRP repairs Fuselage, (apart from engine compartment) and horizontal stabilizer resin systems resin - Shell Glycidäther 162 with hardener - BASF Laromin C 260 mixing ratio 100:38 by weight 2: 1 by volume...
- Page 8 Repair manual DG-400 4. Carbon fibre fabric Wing outer skin and wing flaps Interglas 03040 or 02924 or Sigri 8042 or 8003 (Twill or linen 200 g/m²) Aileron and engine compartment Interglas 03056 or03092 or Sigri 8043 or 8049 (Twill or linen 240 g/m²)
- Page 9 Microballoon BJO - 0930 can be used mixed with the resin-hardener. Application and mixing is the same as for the cotton flocks. Sources for material All materials can be obtained from the DG Flugzeugbau Factory. Issued: August 1992 TN 826 / 26...
- Page 10 Repair manual DG-400 Instructions for FRP repairs Only materials listed in sect. 3 should be used. Only damage defined in sect. 2 should be repaired. Repair method for fibre reinforced plastics (see sect. 2 and 3) 5.3.1 Cut out damaged area, roughen the surrounding area for the overlap required see (sect.
- Page 11 Repair manual DG-400 5.3.4 Repairing the outer skin of a foam sandwich panel Cut out the damaged area, remove the gelcoat over the overlap area +10 mm (0.4 in.) around the damaged area. Fill the damaged foam area with resin thickened with microballoons (microballoon-resin), let harden. Sand down.
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Page 12: Outer Skin Finish
Repair manual DG-400 5.4 Repairing small dents in a foam sandwich panel skin (no cracks in the gelcoat) Small dents can usually be removed by heating up to 60° to 70° C (140° - 158°F). Use a hot air blower to heat the area of the dent. The crushed foam will then spring back to its original form, so that the dent will hardly be seen. - Page 13 Repair manual DG-400 6. Types of fabric and overlap dimensions The following overlap dimensions are to be maintained. Part overlap fabric type, etc. (cm) (in.) (see sect. 4 too) Wing skin outside 1 x 01832# or 90070# glassfibre outside + 1 x 200 g/m² carbonfire#...
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