ILLUSTRATED FIELD MANUFACTURE ITEMS LIST
This appendix contains complete instructions for manufacturing nondestructive inspection support accessories in
An index order is provided for cross-referencing the number of the item to be manufactured to the figure number
which covers fabrication criteria.
All bulk materials needed for manufacture of an item are listed by part number or specification number.
See Figure C-1.
Test block with aluminum honeycomb (0.75 or 1.0 inch) between 0.020 fiberglass skin
and a 0.063 aluminum skin
Test block with aluminum honeycomb (0.75 or 1.0 inch) between a 0.040 aluminum skin
and a 0.020 skin
All dimensions ,+/-) 1/16 inch. Break all sharp edges and corners.
Scuff sand the adhesive side of the fiberglass panel.
Scotchbrite scuff and alcohol/acetone rinse the adhesive side of the aluminum panels.
Milling or grinding of core cutouts is preferable over crushing techniques. A rotary file or end
mill cutter should produce acceptable results.
Polyolefin disks (inserts) should be flush with core if not slightly recessed.
Mix adhesives per manufacturer's instructions; exercise caution applying around inserts.
Moderate weight should be applied to the panels throughout the cure cycle.
2024-T3 aluminum panels (0.020, 0.040 and 0.063 inch thick) specification QQ-4-250/5
Fiberglass panel 0.020 inch thick, specification MIL-1-24768/27
Aluminum honeycomb core 0.75 or 1.0 inch thick, 1/8 cell size specification MIL-C-7438-G
Polyolefin disks 0.025-0.030 inch thick (High-Density Polyethylene or Polypropylene)
Adhesive EA934 or equivalent