f PlK-20 Service manual rpm-” Repair manual
Contents
1. PIK 20 Repair n A 4 REPAIRING OF METAL PARTS The steel parts of the sailplane are made of chrome molybdenum steel SAE 4130 The steel plate has been in a soft condition and the tube normalized If you use an inert gas welding system it is necessary to carry out an nealing afterwards This can be done for instance by warming the wel ding line and surrounding it with a gas flame When you use a normai gas welding system annealing is not needed The wing fitting parts landing gear and flaps airbrakes torgue tube are normalized 100 kp mm If these parts are welded they must be renormalized Paint the repaired area with primer for instance Herberts Standox Reaktions grund The interior surface of the tubes are protected against rust Di nitrol ML NOTE Only a qualified welder may weld airplane parts The push rods are made of aluminum with rod ends The rollers of the push rods leads are made of nylon All the bolts are millimetric high strenght bolts The bolts used in control system are of close tolerance and these are sold by the manufacturer The fastening bolts are coated with zinc for instance Bright Zinc F ZB The fuselage pins and bolts are made of chrome molybdenum steel If a bushing made ofbronze wears it can be changed to a close tolerance bushing AP 110 The rudder cont rol cables are totally enclosed in a nylon tube The cable is 7 x 7 3 32 MIL 1511 and it is approximately 6 40 m long2. EIRIAVION OY Kis llinkatu 8 page 7 PIK 20 Repair manual AILERONS For strenghtening the surfaces in flaps and ailerons the PVC plate used is5 mm Outer surface is of the same kind as the wing but there is no la mination on the inner surface Repairs are similar to the repairs of sandwich plate except that the in ner surface is not made The PVC plate is glued with microballoon resin only at the edge 0071 1i1f1im Ver PVE wor Nye 77 12 PT SOS ON LE h RAG GLUE WITH BALLOON Figure 6 NOTE When repairing the control surfaces it is important to prevent an increase in the weight An increase in weight usually causes the center of gravity to shift This means that the control surfaces should be massbalanced again EIRIAVION OY Kis llinkatu 8 SF 15170 Lahti 17 PIK 20 Repair manual FINISHING Use sandpaper no 100 to roughen and start finishing with sandpaper no 300 Use microballoon resin as filler It is easy to handle and grind When repairing the wing use a metal plate to spread the microballoon This way the solid area supports the work Use water sandpaper no 400 600 to sand the filler Use filler until the weave of the cloth can not be seen after sanding Then the surface of the cloth is ready for painting When the paint has hardened start grinding with wet water sandpaper no 600 and use grinding pastes afterwards If you can still see the weave of the cloth another coat
3. PIK 20 Service manual Item Part Weight Arm Moment Ibs ins Ib ins 1000 pagell 14 PIK 20 Repair manual Turn and bank indicator Model Artificial horizon Model Battery Model 2 i T Accelerometer Model PIK 20 Clock REPAIR MANUAL Model Radio Model Oxygen Equipment Model Water Ballast tanks Model Approved EIRIAVION OY Kis llinkatu 8 SF 15170 Lahti 17 EIRIAVION OY Kis llinkatu 8 SF 15170 Lahti 17 PIK 20 Repair manual FOREWORD The intention of this repair manual is to give basic advice needed for re pairing structural damage to the PIK 20 sailplane made of glass fiber reinforced plastic GFRP Basic information about GFRP is not treated in this manual because the repair worker is assumed to have professio nal knowledge of repairing items of GFRP Repairing sailplanes is not a proper field for practising GFRP laminating Before starting the work study carefully what kinds of material supp lies tools and work methods are reguired You will find the answers in this manual To maintain the excellent performance figures of the sail plane the surface guality should be egual to the original one If there are doubts about repairing structural damage always contact the manufacturer to find out what can and what cannot be done The information given in this booklet applies to minor repairs such as a hole in the bottom fuselage caused by a
4. 92110 LILAS S135 92146 2x IN O 92146 PLYWOOD va Figure 1 First determine how large the damage is by carefully sanding the surface paint up to where the lamination seems to be unbroken Then remove the broken area and make a bevel approximately 60 mm at the edges of the opening Avoid grease Be sure to clean the area with pure acetone Laminate each cloth with approximately 10 mm less overlap than the previous one Laminating this way the last cloth should be 20 mm over the edges The quality and direction of the cloths must always be the sa me as in the original lamination Use an iron roller to eliminate air bubb les in this way the cloths also become better wetted During this period use some film cellophane or usual plastic film to cover the area you are patching and remove the air under the film using a trowel This way you will get a smoother surface and there is less finishing to do Remove the film when the resin has hardened If the hole is big the area should be propped in some way in order to obtain good results when lamina ting This can be done for instance by fastening a thin sheet of plywood with glue on the inner side See Figure 1 The sheet of plywood can be left there because being glued it will not get loose from the lamination If you cannot reach the hole from the inner side make an oval hole and have a prop which can be layed on place through the oval hole Be fore placing the prop set f
5. EIRIAVION OY Kis llinkatu 8 SF 15170 Lahti 17 page 11 PIK 20 Repair manual PIK 20 Repair manual NOTE It is necessary to have two fastening bushings swages at the cable wire ends and their distance from one another must be approximately 8 mm 1 3 in 6 OTHER REPAIRS The repairs of instruments radios and oxygen systems must be perfor med according to instructions of manufacturers or aviation authorities 5 INSPECTION OF WATER TANKS 7 GLASS FIBER CLOTHS USED IN DIFFERENT PLACES The water tanks of the sailplane are made of plastic strenghtened with nylon so they are very strong It is however good to inspect them every year at least Loosen the tanks by sawing loose the fitting which comes out from main rib and take the tank out from the hole in the main rib The easiest way of inspecting the tanks is to look for humid areas or chafed places when tanks are filled with water In case of leakages patches for an air mattress or car wheel are sui table Check durability of the patch before putting the tanks back Start installation by fastening a tube fitting 25 mm GF 21 96 04 with a tube tightener to the tank Then push the tank into wing using a stick approximately 5 m long with a hook which fits the loop of the tank Notice during installation no wrinkles allowed in the tank when it is on the bottom of the wing the seam towards trailing edge When t
6. 7 page17 PIK 20 Repair manual Chopped fibers EC 10 S Manufacturer Gevetex Textilglas GmbH Federal Republic of Germany Release agents Wax QZ 113 Manufacturer CIBA Ag Switzerland Polyvinylalcohol PVA Mould Release Agent No 3 Manufacturer Downland England Protecting ointments for hands Suitable for epoxy resins Arretil Q before lamination Stokolan after washing and lamination Manufacturer Stockhausen Krefeld Acryl plate Finnacryl 3 mm thick Manufacturer Lohjan Kalkkitehdas Oy Finland Repairing material for plexiglass Acryl glue Tenso 7 and hardener Manufacturer ICI England Grinding and polishing material for acryl Perspex Polish No 1 ef No 2A ra x No 3 Manufacturer ICI England EIRIAVION OY Kis llinkatu 8 SF 15170 Lahti 17 page18 wee oP 5 5 ja a i s S SE SE SE S SS J See Se K 5 ok N GE
7. AIRBRAKES AND AILERONS Surface paint 0 90070 45 92145 135 92145 ff sn In addition to this flaps airbrakes have 0 92125 5 mm PVC foam Lynizel 4040 8 RAW MATERIAL LIST FOR PLASTIC STRUCTURES Plastic Resin Riitapox L 02 Hardener Riitapox H 91 SG 91 SG 50 SG Mixture mass parts 34 H 91 100 L 02 33 SG 50 30 SG Manufacturer Bakelite GmbH 5868 Letmathe Gennaerstr 2 4 Federal Republic of Germany Glass fiber cloths Manufacturer Interglas Gmbh Federal Republic of Germany Interglas no weight g m 5 90070 80 92110 116 92125 280 92140 395 92145 215 92146 440 EIRIAVION OY Kis llinkatu 8 lt SF 15170 Lahti 17 page 16 EIRIAVION OY PIK 20 Repair manual Finishing 1 550 Rovings RA 45T 448M 15 Manufacturer Scandinavian Glasfiber Sweden Surface paint Inerta 70 polyurethane surface paint T M shades 101 white 291 yellow 292 red Solvent 9526 Mixture 2 units by volume resin 1 unit by volume hardener Manufacturer Teknos Maalit Oy Finland Core material of sandwich plates Hard PVC foam Conticell 60 60 kg m3 Manufacturer Continental Ag Federal Republic of Germany or Lynizel 4060 60 kg m and 4040 40 kg m Manufacturer Indewek GmbH Federal Republic of Germany Fillers Microballoon Eccospheres Manufacturer Emerson amp Cumings Belgium Kis llinkatu 8 SF 15170 Lahti 1
8. STRUCTURES 0 4 0 0 WwW EIRIAVION OY Kis llinkatu 8 SF 15170 L hti 17 page iii 2 d Lora n VI L d L L L PIK 20 Repair manual 1 REPAIRING IN GENERAL During rough landings ground loops or when exceeding permitted load factors during flight the largest calculated state of load might be excee ded Damage arising in this way can be difficult to observe but it can cause the structure to become weaker so that the sailplane is durable in normal circumstances but not in situations with increased load After these cases the sailplane must be properly examined because the lami nation may be broken In disintegration of GFRP laminates part of the fibers break and one part becomes loose from the plastic bond The la mination becomes partly or thoroughly white and opague depending on how large the damage is The structure must be repaired because of its incapacity for load in all situations Repair the damaged place by lamina ting the necessary cloths on top of the structure or remove the damaged place and relaminate the whole area These kinds of breaks are also sensitive to humidity because water can permeate into the lamination along the fibers and the bond between plastic and fiber becomes weaker making the lamination less durable NOTE After a rough landing or ground loop the area surrounding the main wing pin must be thoroughly examined for possible damage When starting the repair the guality of cloth use
9. astening pin or iron wire See Figure 1 in the prop so that it can be fastened in place during lamination EIRIAVION OY Kis llinkatu 8 SF 15170 Lahti 17 page 3 PIK 20 Repair manual OUTER SURFACE OF SANDWICH PLATE IS BROKEN Wing Vertical and Horizontal control surfaces There are three cloths in the sandwich plate and for this purpose make a bevel approximately 40 mm Remove broken PVC foam and wash the area with pure acetone Then fill the hole with mixture of microballoon resin When the mixture has hardened sand the area and remove dust and dirt See Figure 2 Cut the pieces of cloth so that the first goes app roximately 40 mm over the edge and the next one always 10 mm less than the previous one You can now laminate the cloth in place When the lamination has hardened the manner of proceeding is the same as in paragraph Broken monocoque structure Figure 2 EIRIAVION OY Kis llinkatu 8 SF 15170 Lahti 17 page 4 EIRIAVION OY PIK 20 Repair manual HOLE IN SANDWICH PLATE Wing Vertical and Horizontal control surfaces When there is a hole in the sandwich plate in such an area where lami nating from the inner side is impossible support the area in some w y First make the hole larger so that edges are solid Remove enough PVC foam so that a strip approximately 20 mm wide is left around the hole See Figure 3 Roughen the strip and make a bevel After this the
10. d the amount and the direction of fibers must all be known To find this out sand the lamina tion with sandpaper or burn some plastic from a little piece which has been removed In this way you can see the cloth directions clearly It is important to remember from which place and direction the pie ce of lamination has been removed Paragraph 7 in this manual treats the structures used in most important surfaces and also the guality of cloth amount and direction of laying EIRIAVION OY Kis llinkatu 8 SF 15170 Lahti 17 page 1 PIK 20 Repair manual TOOLS Accurate balance for preparing the right mixture of resin Jarsand sticks for mixing Brushes for spreading of resin Mohair roller for spreading of resin on large area Iron roller for damping fibers and eliminating air bubbles Scissors for cutting glass fiber cloth Tape Plastic film for high temperature tent Hot air blower hair drier Sandpapers of different degree of fineness Knife Hack saw blades for cutting of reinforced plastic 2 REPAIRING OF REINFORCED PLASTIC LA MINATES Cases of damage that can be self repaired are usually one of the follo wing three Broken monocoque structure Broken surface of sandwich plate Hole in sandwich plate EIRIAVION OY Kis llinkatu 8 SF 15170 Lahti 17 PIK 20 Repair manual BROKEN MONOCOOUE STRUCTURE BHF O
11. he surface if they are deep Fasten the paper on a soft grinding tool which has curved edges Do the grinding by gently rotating with help of the weight of the fingers After this use grinding paste Perspex Po lish no 1 which is also good for starting to repair very small cracks Sp read the paste with a soft piece of cloth or grinding disc if a grinding LE me Figure 9 machine is available Change the cloth every five minutes the paste must not dry on the cloth The grinding pressure must be very light Re move the paste with a clean piece of cotton cloth after this polish with polishing liquid Perspex Polish no 2A Use the same piece of cloth both for spreading and polishing Take care that the piece of cloth is clean from dust and dirt during the work Use Perspex Polish no 3 to remove possible static electricity due to grinding and polishing If neces Sary use water to make the Polish thinner and spread the Polish on the canopy with a soft humid cloth Use a clean soft and dry cloth for rub bing the canopy shiny You can also wash the canopy with a solution consisting of 10 Perspex Polish no 3 and 90 water Afterwards dry the canopy with a soft cloth After washing the static electricity must be removed to avoid dust Use warm water and soap for washing The use of organic solutions as solvents of paint and turpentine is for bidden EIRIAVION OY Kis llinkatu 8 SF 15170 Lahti 17
12. he tank is inside push the tube fitting into the hole in the main rib and lock the tank by gluing the fitting 0 25 GF 21 64 01 to the tube fitting Parts for water tanks are sold by the manufacturer A FUSELAGE Surface paint 92146 KTP 92146 92146 92146 EIRIAVION OY EIRIAVION OY Kis llinkatu 8 Kis llinkatu 8 SF 15170 Lahti 17 page13 SF 15170 Lahti 17 PIK 20 Repair manual B VERTICAL STABILIZER Surface paint 90 92110 90 92125 10mm Hard PVC foam Lynizel 4060 0 92110 C STABILIZER Surface paint 0 90070 0 92125 5 mm Hard PVC foam Lynizel 4060 0 92110 CO dy ec OE d E EE sesen TELP LES D RUDDER Surface paint 0 92110 5 mm PVC foam Lynizel 4040 0 92110 EIRIAVION OY Kis llinkatu 8 SF 15170 Lahti 17 PIK 20 Repair manual E ELEVATOR Surface paint 0 92110 0 92125 5mm PVC foam Lynizel 4040 WING Surface paint 45 90070 45 92145 135 92145 10 mm PVC foam Lynizel 4060 45 92110 EIRIAVION OY Kis llinkatu 8 SF 15170 Lahti 17 oa ee D He SE ve N W e G W 2 DEEH page15 PIK 20 Repair manual G FLAPS
13. landing gear up a handling accident in hangar etc l N Bos ei Kit in OL IE A enen Gene en J Lm a et W n Rz Kgl wm Lol Lol Less Major repairs must not be accomplished before contacting the manu facturer or their representative Typical repairs that must be considered major are 1 Damage to the wing spar 2 Damage to the wing root rib N 3 Damage to the fuselage main bulkheads 4 A hole in the wing trailing edge that damages the rear spar of the wing Damage to vertical stabilizer fuselage fitting and bulkhead 6 Damage to horizontal stabilizer fitting 7 Damage to control surfaces that includes holes cracks or other da mage that reach 20 of the chord into the structure 8 Holes cracks or other damage in the wing that are larger than 15 cm 6 in in diameter or 25 cm 10 in in length Additional information about repairing of laminates is given in FAA Advisory Circular AC 43 13 1A oi EIRIAVION OY E J Kis llinkatu 8 i SF 15170 Lahti 17 page ii PIK 20 Repair manual TABLE OF CONTENTS 1 REPAIRING IN GENERAL Tools 2 REPAIRING OF REINFORCED PLASTIC LAMINATES Broken monocoque structure Broken outer surface of sandwich plate Hole in sandwich plate Ailerons Finishing REPAIRING OF CRACKS IN PLEXIGLASS REPAIRING OF METAL PARTS INSPECTION OF WATER TANKS OTHER REPAIRS GLASS FIBER CLOTHS USED IN DIFFERENT PLACES RAW MATERIAL LIST FOR PLASTIC
14. man ner of proceeding is the same as in the paragraph Broken monocoque structure A thin sheet of plywood can be used for supporting After this you can laminate 45 92125 on the support and on the inner solid cloth Let it harden If the hole is small 100 mm the manner of procee ding is the same as in the paragraph Broken outer surface of sandwich plate When the hole is larger make a PVC plate to fit the curvature of the hole PLY W 000 Figure 3 Fill the pores of PVC foam with microballoon resin and glue it immedia tely on top of the inner cloth Put a load on the piece to make it stick better in lamination Kis llinkatu 8 SF 15170 Lahti 17 page5 PIK 20 Repair manual When the glue has hardened sand the area smooth and make a bevel the same way as in the paragraph Broken outer surface of sandwich plate Fill the pores of PVC plate and laminate the cloths immediately When the hole is larger first glue the inner laminate to the PVC plate To begin the manner of proceeding is the same as in the previous case Fill the pores of the PVC plate with microballoon resin and fit the plate to suit the hole then laminate the cloth of inner surface 45 92125 im mediately to PVC plate When this has hardened glue a sheet of ply wood as a prop and draw a nail or iron wire through the plate and ply wood Then glue the PVC plate on the area with microballoon resin see Figure 4 Remember
15. of paint is needed For waxing the sailplane a normal car wax is good enough not however one con taining silicone NOTE For painting the exterior surface use only INERTA 70 two component paint The hardener is an aliphatic isocyanate thus the binder is fully resistant to ultra violet light Also the pigmenta tion is fully resistant to light The following coloration standard measured with a Hunterlab D 25 D colordifference meter may be used Color CIE chromaticity co ordinates x and y Luminance factor Y TM 101 white x 0 336 y 0 366 Y 90 8 TM yellow x 0 501 y 0 485 Y 659 TM 292 red x 0 627 y 0 324 Y 99 Green x 0 343 y 0 461 Y 28 75 3 REPAIRING OF CRACKS IN PLEXIGLASS Before starting the work prevent the progression of the crack by stop drilling 2 mm hole the ends of the crack Then open the crack and fill it with acryl glue starting from the bottom of the V See Figure 9 Use Tensol no 7 for gluing Fill the crack layer by layer and let the layers har den in between to prevent air bubbles because the glue shrinks while hardening When the crack has been filled and the glue is hard grind the EIRIAVION OY Kis llinkatu 8 SF 15170 Lahti 17 page9 PIK 20 Repair manual patch smooth first with fine water sandpaper and afterwards with grin ding pastes and liguids so that the bond line becomes transparent To begin use water sandpaper no 600 for eliminating scratches and defects of t
16. to wash the area with acetone and to roughen it before gluing Use a load or iron wire to accomplish pressing Do notuse too much load because then the inner laminate can get loose from PVC plate GLUE WITH BALLOONY INNER LAMINATE Figure 4 The third way to patch a hole in sandwich plate is to first prepare the patch and bond line together Remove all broken parts of the hole and leave no inner laminate as edge Shape the PVC plate to the hole and glue the previously prepared piece of cloth laminate to the PVC plate EIRIAVION OY Kis llinkatu 8 SF 15170 Lahti 17 page 6 SF 15170 Lahti 17 PIK 20 Repair manual The piece of laminate consists of two cloths 45 92146 135 92145 which overlap the edge by approximately 40 mm See Figure 5 Perform the lamination of the cloth on a table on top of plastic film or 2 3 layers of wax and one layer of PVA After gluing cut the pieces of laminate to a suitable size a GE WIRE BALLOON JEP UB 92 146 N 135 92146 Figure 5 Roughen and wash the bond lines Then glue the patch with microbal loon resin Make an oval for reaching the hole from the inner side Use iron wire to accomplish pressing When the resin has hardened continue the work as usual NOTE Especialiy when you are gluing blindly use microballoon resin so that air is eliminated from the bond line For this purpose make the bond line approximately 40 mm wide
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