Repair to Blade Shells

Damage to outer laminate and core material

1. Remove the topcoat coat around the damage as a first assessment of the damage.
2. Remove the defective laminate and core from the damaged area until you reach healthy laminate and assess the extent of the damage. Check inner laminates are healthy.
3. Measure the area around the repair with required measurements showing preparation for chamfering of laminate layers. Note; the number of layers damaged will determine the number of chamfers out from the main repair area. All overlaps must comply as a minimum with the requirement in the given work instructions.
4. Prepare chamfers for lamination.

The repair of a shell damage that effects both outer laminate and core material should be done in 2 steps with an intermediate cure:

Step 1: New core placement.

After cure, sand or grind the new core to sit flush with existing healthy core.

Step 2: Outer layer repair.

5. The inner laminate area for new core must be sanded and clean from any old core material.
6. Apply a film of laminating resin mixed with fumed silica in the shell cavity where the new core will sit.
7. Apply new core. The new core must fill the gap with a tolerance of no more than 2mm around the edges.
8. Apply peel ply and vacuum materials.
9. Once cured, remove vacuum equipment and sand the core flush with existing healthy core.
10. Check all surfaces are clean, dust free and ready for outer layer laminations.
11. Laminate outer layers. Apply peel ply and vacuum consumables.
12. Allow to fully cure. Use a heating blanket to achieve full cure of laminate. Make sure to heat at required temperature as stated within the safety and technical data sheets.
13. After curing, remove vacuum materials and grind/sand edges of repair to achieve a smooth finish.
14. Fill the repair with filler and sand to regain blade profile.
15. Mask off an area 100mm around the repair and apply paint/topcoat.