Flash bonding: Steps: y y y Removing damage area partially damage- remove only that portion entire core damage-

remove the core down to opposite layer

preparing core replacement: y y y must be fabricated from glass fiber core material if exact thickness is not available, may be cut to size by hand sawing core plug should be flush within range +/- 0.01

potting compound: y y y add micro-ballons to resin mix for 3-5 min add curing agent for 3-5 min apply potting compound to the edge of the core replacement and around the edge of damage area

insertion of core plug: y y y insert the core plug into the repair area remove excessive potting compound with plastic repair allow the core plug to 1 hr at room temp to assure that it is finally in place

Application of glass cloth lamination: y y y y y y y y y y y y y y wipe the surface with clean cloth moistened with MEK, until no trace of foreign particle appearance do not allow MEK to dry clean work area without foreign object 2 sheets of polyethene film 5 larger than damage cut out 2 disks of template of thin metal , 3 larger than damage Place one sheet of polyehtene at damage area Pour adhesive type-38 at film Spread the adhesive over the sheet Place the glass fabric over the adhesive Again place type-38 over the glass fabric Apply 2nd layer cloth Apply t-38 Place 2nd layer polyethene film All air bubbles must be removed

y y y y y y y y

Place these polyethene laminated over lay between two template disk Cut the edge of disk template Remove templates Remove one sheet of polythene film Place the laminated overlay with exposed adhesive on repair surface area Remove remaining sheet of polyethene film Allow 12 hrs to remove final sheet of polyethene at room temperature Clean the surrounding with MEK